EL 501 OSP 5020 Electrical Maintenance RevD

5000/5020 CONTROL LATHE / MACHINING CENTER ELECTRICAL MAINTENANCE TRAINING MANUAL

EL 501 REV. D

Intro

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 : 3.2 CEU 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

Basic Electrical Maintenance for Okuma Lathes, Machining Centers, and Grinders with the OSP 5000/5020/500 series control.

Course Outline MONDAY

SECTION

1.

Instructor and Class Introductions

2.

Okuma History

3.

Terminology

4.

Safety

One

5.

Okuma Documentation

Two

6.

Machine Definition A) Introduction to CNC

Three

7.

Machine Operation A) CNC Operation Panel and Functions. B) Machine operation panel and Functions.

Four

8.

Schematics Nine A) How to Read Okuma Prints a) Symbols (old and new)OSP 5020 Construction

TUESDAY

SECTION

1.

OSP 5020 Construction A) Power Supplies B) Printed Circuit Board Functions C) Servo Systems a) Axis Drives b) Spindle Drives D) Feedback Systems

Five

2.

Diagnostics A) Using Actual Position Pages B) Using Block Data Pages C) Using Check Data Pages

Six

WEDNESDAY 1. 2.

Diagnostics continued D) Alarms Parameters A) Setting Stroke End Limits B) Setting Zero Offsets

Seven

THURSDAY 1.

Software A) Data Management Card B) Software Transfer Procedures a) Backing up parameters b) Initializing a B diskette c) Loading software

2.

Hands-On

FRIDAY 1.

Hands-On A) Troubleshooting

Eight

.

Terminology

The following terms or acronyms pertain to some of the terminology used at Okuma. Some of the terminology is used throughout the industry while some pertain only to Okuma machines. AB0 AC1 ACC/DEC ACP AD Address Address bus APT AD-APT ALU ASCII ATC APC BB0 BB1 BDU Bit BLD BLIID Bus Byte CAD CAM CAP CCP CCOP CIM

Rev. 1-16-01

Axis board Axis card Acceleration/Deceleration Animation CRT Processor board Analog to Digital A location of a specific cell in a computers memory. The wires in a computer that carry signals used to locate a given memory address. Automatic Programmed Tools Adaption of APT Arithmetic/Logic Unit American Standard Code for Information Interchange Automatic Tool Changer Automatic Pallet Changer Bubble memory section (control software on 5000/5020 series) Bubble memory section (part programs on 5000/5020 series) Brushless Drive Unit (1st generation Axis drive) The smallest unit of information in a computer. Brushless Drive Unit (2nd generation Axis drive) Brushless Drive Unit (3rd generation Axis drive) Set of wires carrying signals around a computer. A conductor or set of conductors that transmit information between parts of a computer. Eight bits Computer Aided Design Computer Aided Manufacturing Computer Aided Program Communication Control Processor board Communication Control Optical card Computer Integrated Manufacturing Okuma America Corporation 1

Terminology

Clock CMOS CNC CPU CRP CRT DA Data bus DBR DCPS DDB DMA DMAC DNC DRAM EC/EO ECP EIA EEPROM EPROM FCOM FDC FDD Fiber Optics FIPC2 FOPT Flash Memory FMS FUB-DR FUB-P4M4

A device usually based on a quartz crystal that gives off regular pulses used to coordinate a computers operations. Complementary metal-oxide semiconductor Computerized Numerical Control Central Processing Unit CRT Processor board Cathode-Ray Tube Digital to Analog The wires in a computer that carry data to and from memory locations. Dynamic Braking Resistor Drive Control Power Supply Digital Data Bus Direct Memory Access Direct Memory Access Controller Distributed Numerical Control Dynamic Random Access Memory I/O board on Okuma Lathes and Grinders Electrical Control Processor board I/O control board on Okuma M/Cs Electronics Industries Association Electrically Erasable Programmable Read Only Memory Erasable Programmable Read Only Memory Fieldnet Common terminal card Floppy Disk Controller board Floppy Disk Drive unit The technology of encoding data or pulses of laser light beamed through thin strands of glass. Field Input Photocoupler card Fieldnet Output Power Transistor card Flash memory is a combination of EPROM and EEPROM technology. A non-volatile storage device. Flexible Machining Systems Fieldnet Unit Board-Driver/Receiver board Fieldnet Unit Board-Photocoupler(4 bytes)MOS-FET(4bytes) Okuma America Corporation 2

Rev. 1-16-01

Terminology

FUB-P4R2 GHP GLP IC ID IF IGBT IGF IJP IOCM IOCS ISO ISO 24 Vdc LAP LDU Long Word MAP MB MC MD0: MD1: MOP-Tool MPR NC NIPS OCON OD ODIF OPUS OSP Parallel PCB PG PH Rev. 1-16-01

Photocoupler(4 bytes)Relay outputs(2 bytes) Graphics High Power (CPU power supply on 5000*-G) Graphics Low Power (CPU power supply on 5000*-G) Integrated Circuit Inside Diameter Interface Insulated Gate Bipolar Transistor Interactive Graphics Function Injection Processor board Instantaneous over-current in motor Instantaneous over-current in servo International Standards Organization Isolated 24 volts dc Lathe Automatic Programming Linear Drive Unit 32 bits, 4 bytes, 2 words Machine Automatic Programming Main board Main Card Directory in CMOS (Memory Disk) for parameter backup files Directory in CMOS (Memory Disk) for part programs Monitored Overload Protection Multi-Pole Resolver Numerical Control Numerical Instruction Per Second RCON with Acc/Dec activated Outside diameter RDIFF with Acc/Dec activated Okuma Processing Unit and System Okuma Sampling Path Several bits (8,16, or 32) of information processed at a time. Printed circuit board Pulse Generator Pulse Handle Okuma America Corporation 3

Terminology

PIP PPS PTR PWM RAM RAPA RCON RDIFF RLP RHP RPP RSAPA SAOP SCSI SDU SEL SERCOS Serial SPC SSR S.T.M. SVP TB0 TCC TCU TFP VAC Word

Peripheral Interface Program Pulse Phase Shift Paper Tape Reader Pulse Width Modulation Random Access Memory Actual Position of Axis data (data from A. P. Encoder) Calculated (Commanded) axis position data The difference between RAPA and RCON(following error or lag) Rack Low Power (CPU power supply on 5020) Rack High Power (Opus power supply on 5020) RS232C/Printer/Puncher board Axis position when Touchsetter is detected Sub Amp Operation Serial Communication System Interface Spindle Drive Unit Stroke End Limit Serial Realtime Communication System One bit of information is processed at a time. Servo Processor Card Solid State Relay Spindle, Tool, M Codes Servo Processor board Timing Board Turret Control Card Turret Control Unit Timing Fieldnet Processor board Spindle Drive on Okumas Vector Controlled AC Motor Control 16 bits, half a long word, 2 bytes

Okuma America Corporation 4

Rev. 1-16-01

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OSP 5000/5020 CONTROL SAFETY ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501

.

SAFETY SAFETY PRECAUTIONS Okuma machines are fully equipped with various safety devices to prevent operators and the machine itself from accidents. However, operators are urged to operate the machine with safety in mind. Strict observance of all safety guidelines indicated in the documentation provided with the machine is essential. The following are some points to observe when working with any machine tool. CHECK THE FOLLOWING BEFORE TURNING ON POWER 1) Close the doors of the electric control cabinet and the operation panel. 2) Never place obstacles around the machine. 3) Turn on power to the machine in the following sequence: Depress the Emergency stop button. Turn on the Main power disconnect. CONTROL ON button on the operation panel. (POWER ON button on the control cabinet on machining centers.) 4) Once the control boots up, release E-stop and press the Control On button. PRECAUTIONS TO OBSERVE WHEN USING A CHUCK 1) Before starting the spindle or cutting operations, close the front door. 2) Strictly observe the allowable spindle speed for the chuck installed. Never exceed the maximum allowable spindle speed. 3) When a chuck or fixture unique to the users applications 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 by inputting the spindle speed with G50. To ensure safety in operation, input this spindle speed limiting command in the program (G50S****). 5) If the spindle is operated at a speed close to the allowable maximum speed: Avoid imbalance in the workpiece clamped in the chuck. Apply the maximum allowable pressure to grip the workpiece since increased centrifugal force reduces the chucks gripping force. The maximum allowable spindle speed and applicable pressure for the chuck are indicated on the name plate attached to the front door as well as on the chuck body. The maximum allowable speed and the applicable pressure ensure a chucking force larger than one-third the original chuck gripping force with the standard soft-top jaw set in line with the chuck bodys outer periphery. 6) When special jaws larger than standard soft-top jaws are used: Lower the spindle speed because the chucks gripping force is reduced due to increased centrifugal force and lowered efficiency. If the jaw clamping nut (jaw nut) is outside the chucks outer periphery, only one clamping bolt holds the jaws in place, causing very dangerous conditions. Jaw nuts must always be located within the chuck bodys outer periphery. Machine the jaws to the shape of the workpiece.

Rev. 8-21-01

Okuma America Corporation 1-1

SAFETY 7) Tighten the bolts on the chuck body, jaws, and block securely. Clamping force should be greater than 40 to 50 kg. CHECKUP AROUND THE MACHINE 1) 2) 3) 4)

Before starting daily operations, always check the lubrication oil levels. Always use the specified brand or grade of lubrication oil. For cutting fluid (coolant), use Okumas recommendation whenever possible. Change and replenish lubrication oil for each reservoir at the predetermined schedule as explained in the operation & maintenance manual. 5) Clean the filters periodically according to the schedule explained in the operation & maintenance manual. 6) Check the pressure gauges of the air and hydraulic lines to make sure they all read the correct values as specified in the operation & maintenance manual. 7) For any work required inside the machine door, turn off power and ensure safety beforehand. For work done at the back of the machine that requires the operator to enter the machine operating zone, do not forget to turn off power before attempting any work. PRECAUTIONS FOR MACHINE OPERATIONS 1) Always follow the instructions given in the operation manuals. 2) Never run the machine without protective covers and doors, such as the front door and chuck cover. 3) Close the front door first before starting 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 making sure that the program is completely free of bugs, cut a workpiece in the single block mode operation. Only after making sure that the workpiece can be cut without problems in the single block mode operation should the automatic mode operation be started. 5) Before attempting the following, always make sure that untended operation can be accomplished safely: Spindle rotation Turret indexing Axes movements 6) While the spindle is revolving, never touch chips or the workpiece. 7) Never try to stop a revolving object with hands or tools. 8) Confirm the jaw installation conditions, hydraulic pressure, and allowable maximum speed for the power chuck. 9) Check the installed conditions and arrangement of the tools. 10) Confirm the tool and zero offset settings. 11) Set the spindle speed and feedrate override dials to 100 %. 12) Before feeding the turret, confirm the soft-limit settings and the emergency limit switch settings for both X and Z axes. 13) Confirm the position where the turret index or rotation is allowed. 14) Confirm the tailstock position. 15) Make sure that cutting is conducted within the allowable transmission power and torque ranges. 16) Clamp the workpiece in the chuck or fixture securely. 17) Check the cutting fluid nozzle positions. Set them at positions to supply cutting fluid correctly to the cutting point.


Rev. 8-21-01

SAFETY

SETUP 1) Always make sure that the setup is complete. 2) After changing the setup, operate the machine step by step to make sure the cutting can be conducted without problems. 3) Before replacing the chuck and/or chuck jaws, make sure that the new set fit the job intended. 4) When two or more workers work as a group, establish the necessary safety signs, for example, when lifting or setting heavy objects confirm with other workers whether or not its okay to start the next process. 5) When handling heavy objects use a crane or equivalent tool. 6) When attempting unfamiliar setups check the setup again before going on to the next step. WORKPIECE LOADING and UNLOADING 1) Load and unload workpieces securely. 2) Retract the turret before loading and unloading a workpiece to a position where the cutting tools on the turret will not injure the operators hands. 3) Before attempting to load or unload a workpiece, make sure the spindle has come to a complete stop. 4) Before running a new program, first rotate only the spindle to make sure the workpiece is securely clamped in the chuck. 5) To machine irregularly shaped workpieces, make sure the workpiece is clamped in the chuck securely without imbalance. 6) When handling heavy 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 spindle or tool while the spindle is rotating. 2) Never touch the spindle or tool while the spindle is being oriented, or while it is changing speed range. The spindle might rotate suddenly. 3) Never start spindle rotations with a tool or any other object mounted in the spindle in such a way that it could easily come loose. 4) Always wait until the spindle has come to a dead stop before attempting to remove chips from the tool. 5) Never begin operations without first checking that the workpiece has been securely mounted on the table. 6) Never start table movements with anyone on the table. 7) The automatic tool changer and automatic pallet changer are particularly dangerous when they are in operation and all personnel should be kept clear of their operation zone. 8) Inspection or changes of tools in the magazine of the ATC should be carried out only when the ATC is in the manual operation mode. 9) If, for whatever reason, the ATC or APC should stop moving during an operation and it should become necessary to inspect them without first cutting off power, always secure an emergency escape zone and never touch the problem unit directly with your hands. 10) Never attempt to clean the machine or inspect it while it is operating. Always bring it to a complete stop before conducting such operations.

Rev. 8-21-01


SAFETY

AT THE END OF THE DAY 1) 2) 3) 4)

Clean the machine. Locate the turret at the predetermined retraction position. Before leaving the machine, turn off all power switches. Turn off power to the machine in the following sequence: CONTROL OFF button on the operation panel. The main power disconnect. WHEN A PROBLEM OCCURS

1) 2) 3) 4)

Stop all spindle (s) and axes movement by pushing the closest EMERGENCY STOP switch. Contact the maintenance person to determine what action to take. Use only the fuses and other replacement parts of the specified rating. Be extra careful when handling the following high-voltage units: Main Breaker Servo Drive unit (BL-IID) VAC drive unit Power cables OTHER GENERAL PRECAUTIONS

1) Wear suitable safety clothes. 2) Keep work areas clean as well as the machine. 3) Do not touch controls with wet hands.


Rev. 8-21-01

Notes

EL501

Notes

EL501

OSP 5000/5020 CONTROL DOCUMENTATION ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501

.

DOCUMENTATION The following is a list of the common manuals that come with every Okuma machine: OPERATION MAINTENANCE OPERATION & MAINTENANCE SPECIAL FUNCTIONS #1,2,3 or 4 ELECTRICAL SCHEMATICS ALARM & ERROR LIST PROGRAMMING DRIVE UNITS PARTS BOOK The following is a brief description of the subject matter of each manual. OPERATION Manual This manual 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 parameters in the control. MAINTENANCE Manual This manual has information pertaining to the electrical side of the machine. A description of the boards and the power requirements along with the layout of the electrical components are shown in this manual. OPERATION & MAINTENANCE Manual This manual has the information pertaining to the mechanical side of the machine. Foundation and leveling information along with lubrication specifications are in this manual.

Rev. 1-16-01


DOCUMENTATION

SPECIAL FUNCTIONS Manuals These manuals are labeled #1,2,3,or 4. These manuals contain information pertaining to the operation, parameter settings, and alarms associated with special functions on the machine. The following is a list of some of the topics found in these manuals: ELECTRICAL SCHEMATICS These are the electrical diagrams for the machine. There is a standard set of schematics that pertain to the standard machine. If the machine has special options, there will be a separate set of schematics that will 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. PROGRAMMING This manual contains information pertaining to the programming functions of the machine. DRIVE UNITS This manual has information pertaining to the BL-IID,VACII, and VACIII. PARTS Book This manual contains layouts of the parts on the machine. The rest of this section provides a topic directory. It is intended as a reference guide when looking for certain information about an Okuma CNC machine. Some manuals are specific to a certain application or a certain machine and might not be mentioned here. For example, there is a manual for first time users of MC-V, MC-H, and MCR-B type machining centers that is labeled OPERATION GUIDE.


Rev. 1-16-01

DOCUMENTATION

Rev. 1-16-01

Topic

Manual

Section

Air Blower Alarms Print Out Function Alarm & Error Display Animation Any-angle Chamfering Applications Automatic Operation Auto Pallet Changer Construction Manual Operation Sequence Number Auto Tool Changer Adjustment Logic Table Manual Operation Prep of Cutting Tools Tool Adjustments Sequence Numbers Specifications Axis Nomenclature Travel Back-End Cutting Device Bar Feeder Belt Tension BDU/BLD Alarms Troubleshooting Bubble Memory C-axis Brake Information Control Angle Joint Mechanism Operation Rapid Feedrate Troubleshooting Calendar Timer Carriage Feedrate

Special Functions Alarm & Error List Special Functions Maintenance Special Functions Special Functions Operation Operation

Spare Air Blower Alarms Alarm Data Print Out Self-Diagnostics Animation Function Any-angle Chamfering Applications Operation/Funct & Oper

Operation & Maintenance Operation & Maintenance Maintenance

Auto Pallet Changer APC Logic Tables

Operation & Maintenance Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance

Maintenance Diagnosis Messages ATC ATC ATC ATC Machine Specifications

Operation & Maintenance Operation & Maintenance Special Functions Special Functions Operation & Maintenance Maintenance Maintenance Maintenance Operation

Operation Machine Specifications Back-End Cutting Bar Feeder Insp & Maint Brushless Servo Brushless Servo Brushless Servo Applications

Operation & Maintenance Operation & Maintenance Maintenance Maintenance Operation & Maintenance Maintenance Special Functions

Machine Operation Machine Specifications C-axis C-axis Machine Specifications C-axis Calendar Timer

Operation & Maintenance

Machine Specifications


DOCUMENTATION

Topic

Manual

Section

Rapid Feedrate Travel Chip Air Blow Chuck Clamping Force Construction Cutting Soft Jaws Error Detection High/Low Chucking Indexing Installation Long Stroke Maintenance Precautions Pressure Adjustment Proximity Switch Adj. Spindle Speed Chart Circular Thread Cutting Consumable Items Control Software Load Control Auto Functions Basic Functions Board Operation Check Data Display CPU Inspection Description Diagnostics Installation Req. Operation Operation Functions Panel Layout Periodic Maintenance Peripheral Functions Specifications Structure Coolant High/Low Pressure Unit Tank

Operation & Maintenance Operation & Maintenance Operation & Maintenance

Machine Specifications Machine Specifications Operation

Operation & Maintenance Operation & Maintenance Operation & Maintenance Special Function Special Functions Special Functions Operation & Maintenance Special Functions Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Special Functions Operation & Maintenance Maintenance

Machine Operation Machine Operation Machine Operation Chucking Error Detection Chuck High/Low Select Index Chuck Machine Operation Long Stroke Chucking Machine Operation Machine Operation Machine Operation Machine Operation Machine Operation Circular Thread Cutting Spare Parts Troubleshooting

Operation Operation Maintenance Operation/Maintenance Maintenance Maintenance Maintenance Maintenance Operation Operation Operation/Maintenance Maintenance Operation Operation Maintenance

Specifications Specifications Maintenance & Inspection Apps/Maint & Insp Troubleshooting Special Features Maintenance & Inspection Maintenance & Inspection Operation Specifications Oper/Appended Figures Maintenance & Inspection Specifications Specifications Structure

Special Functions Maintenance Operation & Maintenance

Coolant High/Low Coolant Unit Periodic Maintenance


Rev. 1-16-01

DOCUMENTATION

Topic

Manual

Section

Cooling Unit Coordinate Conversion CPU Power Supply Cross-slide Feedrate Rapid Rate Travel CRT Display Panel Cut-Off Device Cycle Start Disable Cycle Time Calculation Reduction DC Code Control DNC-A Data Setting Dimensional Drawings Door Interlock

Maintenance Special Functions Maintenance

Cooling Unit Coordinate Conversion Troubleshooting

Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation Operation Special Functions Special Functions Special Functions Special Functions Special Functions Special Functions Operation Operation & Maintenance Oper & Maint/ Special Functions Special Functions Maintenance Operation Operation Special Functions Maintenance Operation & Maintenance/ Maintenance Maintenance Special Functions Special Functions Operation & Maintenance Operation

Machine Specifications Machine Specifications Machine Specifications Applications Display of CRT Panel Cut-Off Device Cycle Start Disabling Cycle Time Calculation Cycle Time Reduction DNC-A DNC-A Data Setting Machine Specs/General Mach Oper/Front Door Interlock Auto Door Open/Close Troubleshooting Program Creation Applications Edit Interlock Function Appended Figures Spare Parts List/ Electrical Spare Parts Machine Executable Cond External M Signal External Prog Select Machine Specifications Applications/ Program Management Periodic Maintenance

Door Open/Close EC Power Supply EIA/ISO Code Chart Edit Aux. Mode Edit Interlock Electrical Equip Layout Electrical Spare Parts Executable Conditions External M codes External Prog Select Feedrates File Management

Rev. 1-16-01

Filters Floppy Disk IBM/OSP Format

Operation & Maintenance

Loading Software Handling Maintenance Foundation Requirements

Maintenance Operation Maintenance Operation & Maintenance

Special Functions


NC Mach Prog I/O Functions Troubleshooting Floppy Disk Handling Maint & Insp Handling & Installation

DOCUMENTATION

Topic

Manual

Section

Gauging Attachment Spare Parts Print Out Function Gib Adjustment Headstock Alignment Lubrication Hydraulics Circuit Diagram Oil Requirements Power Unit Operation Pressure Adjustments Pressure Settings Spare Parts Installation Interlock Function Leveling Limit Switch Insp. Layout Loader Interlock Logic Table Layout Lubrication Adjustments Chart Specifications Symbols M-Tool Flat Turning Power/Torque Chart Spindle Speed Machine Dimensions Distance Between Ctrs Maximum turning dia Swing over bed Swing over carriage Machine Height Machine Operation Machine Specifications Magnetic Relays Manual Data Input

Operation & Maintenance Operation & Maintenance Special Functions Operation & Maintenance

Optional Specifications Optional Specifications Gauging Data Functions Periodic Maintenance

Operation & Maintenance Operation & Maintenance

Periodic Maintenance Periodic Maintenance

Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation Operation & Maintenance Maintenance Operation & Maintenance Special Functions Maintenance

Technical Data Machine Operation Machine Operation Mach Oper/Maint Machine Operation Spare Parts Handling & Installation Operation Handling & Installation Troubleshooting Appended Diagrams Loader Interlock Logic Table

Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance

Periodic Maintenance Periodic Maintenance Periodic Maintenance Prep of Machine for Oper

Special Functions Operation & Maintenance Operation & Maintenance

M-Spindle Flat Turning Machine Operation Machine Specifications

Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Maintenance Operation

Machine Specifications Machine Specifications Machine Specifications Machine Specifications Machine Specifications Machine Operation Machine Specifications Troubleshooting Operation


Rev. 1-16-01

DOCUMENTATION

Rev. 1-16-01

Topic

Manual

Section

Manual Mag. Op Panel Manual Operation Math Operation Function Maximum Tool Dimensions Motors Spindle Carriage Cross-slide Hydraulic Pump Guideway Lube Pump Headstock Lube Pump Coolant Pump C-axis M-tool Spindle Specifications Net Weight Oil Mist Operation Operation Monitor Optional Specifications OSP 5000/5020 Control Check Data Display Description of Comp Periodic Maintenance Self Diagnostics Structure Summary of Operation Troubleshooting Overload Detection Overload Monitor Pallet Dimensions Panel Layout Parameters Periodic Maintenance Phase Matching Function Pick-Off Attachment Pitch Error Comp. Pneumatic Circuit Diagram Position Encoder Insp. Power Chuck & Cylinder

Maintenance Operation & Maintenance Operation Operation & Maintenance

Appendix Operation Applications ATC

Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation Special Functions Operation & Maintenance

Machine Specifications Machine Specifications Machine Specifications Machine Specifications Machine Specifications Machine Specifications Machine Specifications Machine Specifications Machine Specifications Machine Specifications Machine Specifications Operation Operation NC Operation Monitor Operation

Maintenance Maintenance Maintenance Maintenance Maintenance Maintenance Maintenance Special Functions Special Functions Operation & Maintenance Maintenance Operation Operation & Maintenance Special Functions Special Functions Special Functions Operation & Maintenance Maintenance Operation & Maintenance

Maintenance & Insp/Diag Maintenance & Insp Maintenance & Insp Maintenance & Insp Structure Summary of Operation Troubleshooting Overload Detection Overload Monitor Machine Specifications Appendix Applications/Parameters Periodic Maintenance Phase Matching Function Pick-Off Attachment Pitch Error Comp. Appended Diagrams Troubleshooting Technical Data


DOCUMENTATION

Topic

Manual

Section

Power Requirements

Operation & Maintenance/ Maintenance Maintenance Operation & Maintenance Operation & Maintenance Operation Operation Maintenance Maintenance Maintenance Special Functions Special Functions Operation & Maintenance Operation Operation Operation & Maintenance Operation & Maintenance Special Functions

Installation/ Power Requirements Brushless Servo Machine Operation Handling & Installation Applications Applications C-Axis Appended Figures Troubleshooting Robot Interlock Tape Punch Interface Safety Precautions Applications Applications Periodic Maintenance Appended Diagrams Slide Hold Function

Operation & Maintenance Operation & Maintenance/ Parts Book/Elec Schem. Operation/Oper & Maint

Appendix Spare Parts List/ D-drawings Specifications/General

Operation & Maintenance Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Maintenance/Special Functions Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Maintenance Special Functions Special Functions Maintenance Operation & Maintenance

Machine Specifications Spindle Drive Unit Machine Specifications Technical Data Machine Specifications C-axis/Spindle Orientation

Power Transistor Insp. Pre-start Checklist Preparation for Delivery Program Format Program Selection Pulse Generator Relay Layout Relay Inspection Robot Interlock RS232C Safety Precautions Sequence Number Search Sequence Restart Shear Pin Replacement Skeleton Diagrams Slide Hold During Thread Cutting Solenoid Valve Layout Spare Parts Specifications Spindle Diameter Drive Unit Gear Ranges Nose Dimensions Nose Type Orientation Power/Torque Chart Speed Range Taper Through Hole Size Structure of OSP Sub Programs Swing Arm Loader SSR Output Table Specifications

Machine Operation Machine Specifications Machine Specifications Machine Specifications Structure of OSP Sub Programs Swing Arm Loader Troubleshooting Machine Specifications


Rev. 1-16-01

DOCUMENTATION

Topic Tailstock Adv/Ret During Rotate Auto-tailstock Adj. Bearing Life Chart Center Work Interlock Dimensions High/Low Thrust Live Center Load Operation Position Setting Positioning Function Pressure Adj. Spindle Diameter Spindle Taper Spindle Travel Swing Operation Thrust Chart Timing Belt Adj. Working Range Diag. Tape Data I/O Tape Format Tape Punch Interface Tape Reader Operation Technical Data Through-the-Tool Coolant Timing Belt Replacement Toolholder Dimensions Tool Interference Chart Offsets Life Management Retraction Settings Touch Setter Spare Parts Trace Transportation of Machine Troubleshooting Mechanical Spindle

Rev. 1-16-01

Manual

Section

Special Functions Operation & Maintenance Operation & Maintenance Special Functions Operation & Maintenance Special Functions Operation & Maintenance Operation & Maintenance Operation & Maintenance Special Functions Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Special Functions Operation & Maintenance Operation & Maintenance Operation & Maintenance Special Functions Operation Special Functions Operation Operation & Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance

Adv/Ret During Rotate Machine Operation Optional Specs Cancellation of CW int. Technical Data Tailstock High/Low Machine Operation Machine Operation Machine Operation Programmable Tailstock Machine Operation Machine Operation Machine Operation Machine Operation Tailstock Swing Machine Operation Periodic Maintenance Optional Specs. Tape Data I/O Program Creation Tape Punch IF Tape Reader Handling Technical Data Operation Maintenance Technical Data

Operation & Maintenance Operation Special Functions Special Functions Oper & Maint/Oper Operation & Maintenance Operation & Maintenance Special Functions Operation & Maintenance Maintenance Operation & Maintenance Maintenance

Technical Data Operation Tool Life Management Tool Retraction Cycle Mach Oper/Oper Touch Setter Touch Setter Tool Path Display Handling & Installation Troubleshooting Insp & Maint Spindle Drive


DOCUMENTATION

Topic Turret Alignments Control Card Control Unit Coolant Trottle Adj. ID Tool Size Index Speed Adjust Limit Switch Inspect Lubrication NC Turret OD Tool Size Offsets Troubleshooting Tool Capacity Type Unloader by M Code VAC Diagnostics Fuse Replacement I/O Signal Table Layout Status Indicators Troubleshooting Work Catcher Work Counter Working Range Diagram Work Reset Zero Offsets

Manual

Section

Operation & Maintenance Maintenance Maintenance Operation & Maintenance Operation & Maintenance Operation & Maintenance Maintenance Operation & Maintenance Maintenance Operation & Maintenance Operation Operation & Maintenance Operation & Maintenance Operation & Maintenance Special Functions

Periodic Maintenance Turret Control Turret Control Machine Operation Machine Specifications Periodic Inspection Troubleshooting Lubrication NC Turret Machine Specifications Operation Troubleshooting Machine Specifications Machine Specifications Unloader Adv/Ret

Maintenance Maintenance Maintenance Maintenance Maintenance Maintenance Special Functions Special Functions Operation & Maintenance Special Functions Operation

Spindle Drive Unit Spindle Drive Unit Spindle Drive Unit Spindle Drive Unit Spindle Drive Unit Spindle Drive Unit Work Catcher Work Counter Technical Data Work Reset by M Code Operation


Rev. 1-16-01

Notes

EL501

Notes

EL501

OSP 5000/5020 CONTROL MACHINE DEFINITION ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501

.

MACHINE DEFINITION Machine Tool A machine tool is a power driven machine used to shape solid work by removing material with a suitable cutting tool or by deformation of the metal. Numerical Control Machine A Numerical Control (NC) machine is a machine tool whose actions is controlled by direct insertion of numerical data by way of coded instructions. An NC machine is positioned automatically along a pre-programmed path by these coded instructions. These instructions are letters, numbers, and other symbols that are translated into binary code. Computerized Numerical Control Machine A Computerized Numerical Control (CNC) machine is an NC machine that uses a computer as the control system. A CNC is composed of two major components: the machine tool 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 items to exist: 1. Main Processing Unit - The main processing unit has a central processing unit (CPU) which is the nerve center or main controller of the CNC and an Arithmetic/Logic Unit (ALU) which handles all arithmetic and logical functions within the control. With the miniaturization of electronic circuits, the CPU and ALU circuitry are built into the same IC chip and have adopted the name microprocessor (µp). 2. Memory - The memory stores all data, whether temporary or permanent, that is used by the microprocessor. 3. Servo System - The servo control system is needed to control axis movement and spindle rotation. 4. Input/Output system (I/O) - This area of the (CNC) carries out the sending and receiving of information to external devices. The following information describes these four areas in more detail to give the student a basic understanding of how a control functions:

Rev. 8-21-01


MACHINE DEFINITION MICROPROCESSOR All operations that take place in the CNC are under direct control of the CPU. The CPU directs the flow of data in a computer system. It constantly keeps track of what is taking place within the control by performing a series of diagnostic operations. If any hazardous conditions are detected it will shut down operations to prevent damage to the machine or injury to an operator. The microprocessor (µp) acts on instructions from programs stored in memory. It runs the executive program (Control Software) which defines the capabilities of the machine. This program initiates all operations and controls all data management functions. Without the executive program the µp could not function. The ALU determines axis position, spindle and axis speed, and performs program calculations in a CNC control. It also determines what to do if a limit switch is activated or an overload is detected. The ALU performs all the calculations and logical decisions necessary when processing information. 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: Permanent, Long-Term, or Temporary. Permanent Storage Data resident in permanent storage is information that will be required for all applications. This data is not updated under normal operating conditions. This type of memory is referred to as nonvolatile memory. The data is not lost when the machine is turned off. The most common storage device in this category is ROM (Read Only Memory). ROM comes in different styles. PROM (Programmable Read Only Memory) - Data is stored in this device through electronic means and cannot be erased. If data is unusable or must be changed a new PROM must be made. EPROM (Erasable Programmable Read Only Memory) - After data is stored in the EPROM, it can later be erased by placing the device under an ultra violet light source. This restores the EPROM to a blank state and new information can then be entered. This device usually has a clear plastic window on top of the chip to expose the components to the UV light source. Under normal operating conditions this window is covered with a piece of tape to prevent accidental changing of the data. On Okuma controls, this chip contains the System Boot Program.


Rev. 8-21-01

MACHINE DEFINITION EEPROM (Electrically Erasable Read Only Memory) - Similar to the EPROM, the stored information in an EEPROM can be erased by using a higher than normal current rather than a UV light source. Because of this ability, the EEPROM can be erased and new data stored while it is in the CNC control. A new type of permanent memory device is appearing on some computers and CNC controls which is referred to as Flash Memory. This device is also a nonvolatile memory device. It is basically a combination of EPROM and EEPROM technology. Flash memory has the advantage of having the physical size of the EPROM and the quick erase capability of the EEPROM. Long-Term Storage There are certain types of data that need to be stored for a long period of time, but will need to be changed or deleted periodically. Information such as part programs, parameters, tool offsets, etc. can be stored in this type of device. Two types of long term memory storage devices currently being used on Okuma controls are C-MOS and Bubble memory. C-MOS Memory - This is a RAM (Random Access Memory) type device. Under normal operating conditions this type of memory would lose the stored information when power is shut off. A device that loses stored data when power is turned off is said to be volatile. To prevent the loss of this information, a battery is attached to the unit to maintain backup power in the event machine power is lost. Bubble Memory - This is a non-volatile storage device. It does not lose information when power is lost. Data is stored on tiny bubbles of a ferrous material that is magnetized to represent the binary information. Large quantities of data can be stored in a very small area. However, unlike C-MOS, the data must be read in a set order (serially) which makes it slow in responding with information. Temporary Storage Some information is only needed once, or for a limited number of times, and then is discarded. This type of information is stored in temporary memory. Active programs or numbers that are continuously changing would fall into this category. RAM - This type of memory is used to run the active programs such as the machine operating system or the active part programs. Once power is cut off to the machine, this memory is lost. Okuma uses both D-RAM and S-RAM. D-RAM stands for Dynamic Random Access Memory. Its memory is constantly being refreshed. S-RAM stands for Static Random Access Memory. Its contents can be saved by battery back-up.

Rev. 8-21-01


MACHINE DEFINITION

Register - This is a small (one or two bytes in size) temporary device designed to store data for a very short period of time. Registers are used to hold numbers during arithmetic operations or to hold memory addresses during data transfer. They temporarily house data entering and leaving the microprocessor chip. SERVO SYSTEM Every CNC has to have some means of controlling axis movement and/or spindle rotation. A servo system needs a command signal, a servo control amplifier, a motor, and a feedback device. The main processing unit acting on instructions from a part program will send the positioning and speed information to the servo control unit which will convert the information it receives into a command signal. This command signal is sent to the servo 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 feedback device is needed to monitor actual servo movement. The feedback device sends a signal back to the servo control unit and/or the servo amp. This feedback signal is compared with the command signal. If they are not the same or very close to being the same the servo control unit will send out an alarm signal to the main processing unit which will stop machine operation. I/O Devices I/O devices connect the CPU with the outside world through interfaces. The interfaces are electronic circuits that permit controlled data flow from the CPU and its memory components to various peripherals. Tape Reader This is one of the first I/O devices ever used on an NC control and was carried over to the CNC. This unit reads a paper tape which has a number of holes arranged in a specified pattern along its length. Each pattern represents a code or character which can be deciphered by the control.


Rev. 8-21-01

MACHINE DEFINITION

Disk Drives A floppy disk drive is constructed similar to a record player. A platter or disk coated with a ferrous material is rotated while a read/write head is moved over the surface and magnetizes the ferrous material in patterns representing binary data. Data is stored in concentric circles on the surface of the disk. Each circle is referred to as a track. Each track can be divided into a number of sectors. When data is written on the disk, the head actuator pushes or pulls the read/write head over the surface of the disk until it is aligned with the proper track. The sectors are then searched until the proper location is found to read or write the data. On a hard disk drive, the head floats above the surface of the platter. If it were 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 readers and disk drives are also referred to as permanent storage devices. RS-232 Interface Data is sometimes generated or stored using a device that is not a part of the CNC control, i.e., external disk drive, PC (Personal Computer), main frame computer, etc. This data can then be transferred from the external device to the CNC control via an RS-232 port. This port can also be used for DNC (Direct Numerical Control) communications. DNC has several levels of operation. In its simplest form it transfers data from an external device to the CNC control. In some applications it has the capability of transferring all control of the machine to an external computer. External Switches The simplest form of an I/O device is the external switch. Examples of input devices are limit switches, proximity switches, pressure switches, etc. Relays, solenoids, LEDs, and lamps are examples of output devices.

Rev. 8-21-01


MACHINE DEFINITION

LATHE A Lathe is defined as a machine tool for the removal of material from a workpiece by gripping it securely in a holding device and rotating it under power against 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 turret that holds the tool toward and away from the spindle. The origin of the coordinate system is the center of the spindle. Okuma lathes can be Flat bed or Slant bed type lathes. The slant bed allows the chips to fall into the chip pan rather than on tools or slideways. Figure 3-1 shows the axis nomenclature for an Okuma lathe.

Fig. 3-1


Rev. 8-21-01

MACHINE DEFINITION

MACHINING CENTER A machining center is an NC machine that can perform milling, drilling, boring, and tapping operations. On machining centers, the rotating tool machines the workpiece as it moves across the face of the tool. The workpiece moves due to the movement of the table. The rotational axis is perpendicular to the table on vertical machining centers and parallel to the table on horizontal machining centers. The origin of the coordinate system is the center of the table. Figure 3-2 shows the axis nomenclature for the vertical machining center. The X axis is the table longitudinal movement and is positive when fed left. The Y axis is the saddle crosswise 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 horizontal machining center. The X axis is the table longitudinal movement and is positive when fed right. The Y axis is the spindle head vertical movement and is positive when fed upward. The Z axis is the saddle crosswise movement and is positive when fed towards the operator. The rotating motion of a rotary table is positive when fed clockwise. Fig. 3-4 shows the axis nomenclature for the traveling column type machining center. Fig. 35 shows the axis nomenclature for the double column type machining center.

VERTICAL MACHINING CENTER X axis: Longitudinal movement of the table (positive when fed to the left) Y axis: Crosswise movement of saddle (positive when fed toward the operator) Z axis: Vertical movement of Spindlehead (positive when fed upward)

Rev. 8-21-01


MACHINE DEFINITION

HORIZONTAL MACHINING CENTER

X axis: Longitudinal movement of the table (positive when fed to the right) Y axis: Vertical movement of Spindlehead (positive when fed upward) Z axis: Crosswise movement of saddle (positive when fed toward the operator) B axis: Rotating motion of NC rotary table (positive when fed clockwise)


Rev. 8-21-01

MACHINE DEFINITION

TRAVELLING COLUMN TYPE HORIZONTAL MACHINING CENTER X axis: Longitudinal movement of the table (positive when fed to the right) Y axis: Vertical movement of Spindlehead (positive when fed upward) Z axis: Crosswise movement of Column (positive when fed away from the operator) B axis: Rotating motion of NC rotary table (positive when fed clockwise)

Fig. 3-4

Rev. 8-21-01


MACHINE DEFINITION

DOUBLE COLUMN MACHINING CENTER X axis: Longitudinal movement of the table (positive when fed toward the operator) Y axis: Spindlehead crosswise movement (positive when fed leftward) Z axis: Spindle Quill vertical movement (positive when fed upward) W axis: Crossrail vertical movement (positive when fed upward)

Fig. 3-5


Rev. 8-21-01

MACHINE DEFINITION

GRINDER A grinder is a machine tool that employs a rotating abrasive wheel instead of a cutting tool. The purpose of grinding is to leave a finely finished surface on the metal and at the same time to remove the small amount of stock left after the previous finishing operation has brought 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 work coordinate system is based on the workpiece. For external grinding, the origins of the work coordinate system is located at the end point of the center on the headstock. See figure 3-6. For internal grinding, the origin is similar to that of lathes. The center of the chuck holding the workpiece is the origin. See figure 3-7. The origins of the wheel coordinate system is referenced to the grinding wheel itself for both OD and ID grinding. See figure 3-8.

Rev. 8-21-01


MACHINE DEFINITION

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-S)

d)

ID Grinding (GI-N)

Work Coordinate System for ID Grinding Fig. 3-7 Okuma America Corporation 3-12

Rev. 8-21-01

MACHINE DEFINITION

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) ID Grinding (GP-N, GU-S)

d) ID Grinding (GI-N)

Wheel Coordinate System for ID Grinding Fig. 3-8

Rev. 8-21-01


.

Notes

EL501

Notes

EL501

OSP 5000/5020 CONTROL MACHINE OPERATION ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501

CH .

MACHINE OPERATION The OSP 5000 series family has been around since 1981. In 1985 Okuma incorporated the graphics function into the 5000 series control. In 1988 Okuma introduced the OSP 5020 series control whose speed and accuracy was dramatically increased. The newly developed highprecision digital servo technology and 32-bit double-engine architecture increased the machines cutting feedrate from 1.25 m/min to 15 m/min. The following is a chart of the OSP 5000 series controls. For the rest of this manual, if the specific control type is not mentioned, the topic being discussed refers to all these controls.

OSP 5000 Family

OSP 5020

OSP 5020L OSP 5020M OSP 5020G

OSP 5000

OSP 5000L-G OSP 5000M-G OSP 5000G-G OSP 5000N OSP 5000L OSP 5000M OSP 5000G

OSP 500

OSP 500L OSP 500M OSP 500G

OSP 5

OSP 5

Basic Construction of the Operation Panels Okuma machine tools with the OSP 5000 series controls mainly consist of four panels. 1. 2. 3. 4.

NC Operation Panel (Common Panel) Machine Operation Panel Pendant Operation Panel Option Panel

NC Operation Panel The NC operation panel is common on all Okuma machines. The 5000 series controls are equipped with a 12-inch CRT. The 500 series controls are equipped with a 9-inch CRT. A picture of a 5020M and a 5020L NC operation panel can be seen on page 4-31 and 4-33 respectively. The following is a description of the OSP 5000 series NC operation panel. This control has eight function keys located below the CRT. These function keys are used to access the different menus on the control. Each mode key has a different set of menus. Depending on which mode the control is in, the function keys will help the user to access the menus associated with these individual modes.

Rev. 8-21-01


Lathe The following is an outline of the menus associated with the different operating modes on the (OSP 5020L) control. for LATHES

AUTO

The following shows the functions available when the AUTO mode key is pressed. PROGRAM SELECT

ACTUAL POSIT

PROGRAM

F1

F2

F3

Used to select a part pro-gram for a desired cutting operation

Used to display coordinates of the actual position of the axes in relation to the zero offset

PART

Used to display a part program

BLOCK DATA

F4

TOOL LAYOUT

F5

Used to display the data in one BLOCK DATA

CHECK DATA

F6

F7

Used to display the data of the tools to be used

Used to display I/O signals and various other data

EXTEND

F8 Used to access other menus

D NUMBER SEARCH

RESTART

F1

F2

Used to search for the specified BLOCK DATA of the part program currently selected by turret selection (also possible by locating the cursor)n

Used to search for the specified BLOCK DATA of the part program currently selected; the data up to that BLOCK DATA are all read

F3

SP SELECT

SP - N SEARCH

F4

F5

Used to selected a scheduled program

Used to search for a specified BLOCK DATA in the scheduled program

EXTEND

F6

F7


A STD/EXT GRAPHIC

F1 Used to select the standard or enlarged graphic display

F2

NORMAL SCALE

ENLARGE

TRACE/

SCALE

ANIMATE

F3

F4

F5

Used for setting the scaling on the standard graphic display

Used for setting the scaling on the enlarged graphic display

Used for selecting the tool path/ animation display

MATERIAL

F6 Used for displaying blank material, chuck and tailstock


CLEAR

EXTEND

F7

F8

Used for clearing the display

Used to return to first menu

Rev. 8-21-01

Lathe

B

C

B AUTO SCALE

SCALE SET

F1

F2

Used to set scaling to automatically match the program

SCALE QUIT

F3

F4

F5

F6

F7

Used for setting the required scaling

Used to quit normal scale setting

ENLARGE

FRAME REDUCE

SCALE QUIT

F1

F2

F8

C FRAME

Used to enlarge the frame

F3

F4

F5

F6

Used for contracting the frame

F7

F8

Used to quit enlarge scale setting

D LAYOUT EXEC.

F1

LAYOUT QUIT

F2

F3

F4

F5

Begins display of tool data being used

Rev. 8-21-01

F6

F7 Ends display of tool data being used


F8

Lathe

MDI The following shows the functions available when the MDI mode key is pressed. All the functions are the same as in AUTO except for the PROGRAM SELECT (F1) is DATA INPUT and function F6 is blank. DATA INPUT

ACTUAL POSIT

PROGRAM

PART

F1

F2

F3

Press this key and then enter desired codes to perform MDI functions



BLOCK DATA

F4

CHECK DATA

F5

F6

F7 Used to display I/O signals and various other data


EXTEND


A

MANUAL The following shows the functions available when the MANUAL mode key is pressed. All the functions are the same as in DATA INPUT except F1 is blank.

F1

ACTUAL POSIT

PROGRAM

F2

F3


PART


BLOCK DATA

F4

CHECK DATA

F5

F6


F7 Used to display I/O signals and various other data

EXTEND


A


Rev. 8-21-01

Lathe The following describes what is shown in the Actual Posit, Part Program, Block Data and Check Data menus.

Actual Position

ACTUAL POSIT

F1

F2

PART PROGRAM

F3

BLOCK DATA

CHECK DATA

F4

F5

F6

F7

EXTEND

F8

By using the PAGE key on the NC operation Panel, various screens can be accessed after the ACTUAL POSIT function key has been pressed. The following bullets describe what the different screens show:

P

• • • •

Displays the actual position data of the individual axes in enlarged characters. This actual position is in relation to the zero offset. Simultaneous display of actual position data and the NC program being executed. Simultaneous 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 absolute position encoder, tool offset and shift data.

PART PROGRAM PROGRAM SELECT

ACTUAL POSIT

F1

F2

PART PROGRAM

F3

BLOCK DATA

TOOL LAYOUT

F4

F5

CHECK DATA

F6

F7

EXTEND

F8

By using the PAGE key on the NC operation Panel, various screens can be accessed after the PART PROGRAM function key has been pressed. The following bullets describe what the different screens show:

P

• • • •

Rev. 8-21-01

Displays the NC program for the currently selected turret, A or B. Simultaneous display of NC program for both turrets, A and B. Display of data entered through the keyboard in MDI mode. Display of the scheduled programs. Okuma America Corporation 4-5

Lathe

BLOCK DATA PROGRAM SELECT

ACTUAL POSIT

PROGRAM

F1

F2

F3

PART

BLOCK DATA

TOOL LAYOUT

F4

F5

F6

CHECK DATA

F7

EXTEND

F8

By using the PAGE key on the NC operation Panel, various screens can be accessed after the BLOCK DATA function key has been pressed. The following bullets describe what the different screens show:

P • • • •

Displays the data in the block currently being executed. Displays the data in the NEXT block to be executed. Displays the data in the block succeeding (QUEUED) the next block. Displays the data last stored in the buffer (READ) register.

CHECK DATA DATA INPUT

F1

ACTUAL POSIT

F2

PART PROGRAM

BLOCK DATA

F3

F4

CHECK DATA

EXTEND

LAYOUT

F6

F7

F8

TOOL

F5

By using the PAGE key on the NC operation Panel, various screens can be accessed 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). Displays EC outputs Displays Machine Operation Panel inputs. Displays Machine Operation Panel outputs. Displays machines specification codes. Displays machines model code. Displays machines machine specification codes. Displays history of alarms (last 12 alarms). Displays ATC I/Os (if applicable). Displays post process gauging data (if applicable). Displays in process gauging data (if applicable). Okuma America Corporation 4-6

Rev. 8-21-01

Lathe Data Setting Mode Keys (Tool Data, Edit Aux, Zero Set and Parameter)

TOOL DATA BACK UP

F1

ADD

CONST. ADD

CONST. SUB

F2

F3

F4

Used to add to currently stored data

Used to add parameter set data

Used to subtract parameter set data

GUIDE ON/OFF

F5 Used to turn on and off graphic guide display

ITEM ↑

F6

ITEM ↓

F7

EXTEND

F8

Used to select displays Used to access related to tool data other menus

E By using the ITEM ↑ or ITEM ↓ key, various screens can be accessed after the TOOL DATA mode key has been pressed. The following bullets describe what the different screens show: • • •

• • •

P 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 tool interference data. The tool interference data (TOOL FORM SELECT) are displayed and can also be changed in this menu. (not available for the graphics specification) Use the P key to access tools # 13 to 32 if applicable. Displays tool group data Displays post process gauging results. Setting and displaying of ATC tool data (if applicable). E

SET

F1

F2

F3 Used to add parameter set data

Rev. 8-21-01

GUIDE ON/OFF

CAL

F4


ITEM ↑

F6

ITEM ↓

F7

EXTEND

F8

Used to select displays Returns to main related to tool data


menu in Tool Data

Lathe

EDIT AUX DATE

DIR

PIP

EDIT

FREE

LIST

IGF

F1

F2

F3

F4

F5

F6

F7

Used to enter and display date when preparing a file or other data

Used to display the filenames in the directories

Used to access the file transfer data

Used to edit a file.

Used to display the remaining memory capacity

Used to display contents of the active file

Used to access the IGF function (option)

TIME

INIT

DELETE

RENAME

F1

Used to enter and display time

F2

Used to initialize (format) a directory

F3

Used to delete a specified file

F4

Used to rename a file

TAPE CONV

F1

Available on Tape conversion specification

MULTIPIP

F5

Used to output all program files

PROTECT

F6

F3

F4

F5

F8

Used to access more menus

EXTEND

F7

Used to protect a file

F8


DATA PIP

F2

EXTEND

EXTEND

F6

Used to transfer or backup parameters

F7

F8

Returns to main menu of Edit Aux

F


Rev. 8-21-01

Lathe

F INPUT

OUTPUT

D-PIP QUIT

VERIFY

F1

F2

F3

Inputs A.TOP file from peripheral device

Outputs A.TOP file to peripheral device

Compares data sent to or from peripheral with data in memory

F4

F5

F6

F7

F8

Used to terminate data transfer procedure

ZERO SET

SET

Rev. 8-21-01

ADD

BACK UP

CAL

F1

F2

F3

Used to set new data


Calculates data from the actual position (RAPA)

F4

F5

F6

Used to immediately back up data. On newer OSP 5020 (1994 and newer)


F7

F8

Lathe

PARAMETER SET

ADD

CAL

F1

F2

F3




BACK UP

F4

F5 Used to immediate ly back up data. On newer OSP 5020 (1994 and newer)

ITEM ↑

F6

ITEM ↓

F7

F8

Used to access displays related to parameter data.

By using the ITEM ↑ or ITEM ↓ key, various screens can be accessed after the PARAMETER mode key has been pressed. The following bullets describe what the different screens show: • • • • • • • • •

User Parameters Chuck/Tailstock Common 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. These pages can be accessed by pressing the

P

key on the NC Operation Panel.


Rev. 8-21-01

Machining Center The following is an outline of the menus associated with the different operating modes on the Machining Center (OSP 5020) control. AUTO Mode PROGRAM SELECT

ACTUAL POSIT

PROGRAM

F1

F2

F3

Used to select a part pro-gram for a desired cutting operation


LIBRARY P. SET

F1

F2

Used to store library programs which are basically subroutines. NUMBER SEARCH

RESTART

F1

F2

Searches for a sequence number

Prepares for a sequence restart

PART

BLOCK DATA

SEARCH

ATC/APC

CHECK DATA

F4

F5

F6

F7



Used to search for particular Check Data screen

Used to display the status of the ATC or APC


TOOL DISPLAY

PERSONAL

DIAGNOSIS

AXIS CHANGE

MESSAGE

F3

F4

F5

Used to display the tool data page.

Used to display print data.

Used to display any messages pertaining to the ATC or APC.

NUMBER STOP

SP SELECT

SP - NO. SEARCH

F3

F4

F5

Stops at a number sequence

Selects a scheduled program.

Searches for a scheduled program number

F6 Used to display data the individual axes.


EXTEND

F7 Used to display any messages.


EXTEND

F6

F7

F8 Used to return to first menu

Graphics option

Rev. 8-21-01

EXTEND


G

Machining Center

G GRAPHIC

TRACE/ ANIMATE

F1

F2

TOOL KIND

MATERIAL

F3

F4

Displays graphics

Changes display between tool paths and animation.

Turns on or off the display function for tool kinds

GRAPHIC

GRAPHIC DATA

AUTO SCALE

F1

Displays graphics

F2

F3

Used to access drawing data mode.

Used to automatica lly set the drawing area.

Displays blank material

F4

GRAPHIC ERASE

DATA ON/OFF

F5

F6 Turns on or off the data displayed during graphics.

AREA CHANGE

ANGLE CHANGE

F5

F6

I

F1

F2

ZEROSET

RELATI PRESET

F3

F4

Turns on or off the high-speed drawing mode.

EXTEND

F8 Used to display other menus

EXTEND

F7

F8

Used to view angle change mode.

J RELATI

F7

Deletes graphic display

Used to access area change mode.

HIGH DRAW

J

EXTEND

F5

F6

Used to show a point relative to the program zero.


F7

F8

Returns to main menu.

Rev. 8-21-01

Machining Center

J MARKER

F1

F2

F3

F4

F5

SET QUIT

F6

Changes view point marker

F7

F8

Ends area/angle view change.

I SET

F1

Used to set the data.

Rev. 8-21-01

ADD

F2

SELECT

F3

QUIT

F4

F5

Used to add to existing data

F6

F7

Ends data setting mode.


F8

Machining Center

MDI The following shows the functions available when the MDI mode key is pressed. All the functions are the same as in AUTO except for the DATA INPUT (F1) function. DATA INPUT

ACTUAL POSIT

PROGRAM

PART

F1

F2

F3

Press this key and then enter desired codes to perform MDI functions



BLOCK DATA

SEARCH

ATC/APC

CHECK DATA

F4

F5

F6

F7





EXTEND


MANUAL The following shows the functions available when the MANUAL mode key is pressed. All the functions are the same as in DATA INPUT except F1 is blank.

F1

ACTUAL POSIT

PROGRAM

F2

F3


TOOL SET

F1

F2

PART


PART PROGRAM

F3

BLOCK DATA

SEARCH

ATC/APC

CHECK DATA

F4

F5

F6

F7





BLOCK DATA

SEARCH

ATC/APC

CHECK DATA

F4

F5

F6


F7

EXTEND


EXTEND

F8

Rev. 8-21-01

Machining Center The following describes what is shown in the Actual Posit, Part Program, Block Data and Check Data menus.

Actual Position

ACTUAL POSIT

F1

F2

PART PROGRAM

F3

BLOCK DATA

CHECK DATA

F4

F5

F6

F7

EXTEND

F8

By using the PAGE key on the NC operation Panel, various screens can be accessed after the ACTUAL POSIT function key has been pressed. The following bullets describe what the different screens show:

P • • • •

Displays the actual position data of the individual axes in enlarged characters. This actual position is in relation to the zero offset. Simultaneous display of actual position data and the NC program being executed. Simultaneous 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 absolute position encoder, tool offset and shift data.

PART PROGRAM PROGRAM SELECT

ACTUAL POSIT

F1

F2

PART PROGRAM

F3

BLOCK DATA

TOOL LAYOUT

F4

F5

CHECK DATA

F6

F7

EXTEND

F8

By using the PAGE key on the NC operation Panel, various screens can be accessed after the PART PROGRAM function key has been pressed. The following bullets describe what the different screens show:

P

• • • • Rev. 8-21-01

Displays the NC program for the currently selected turret, A or B. Simultaneous display of NC program for both turrets, A and B. Display of data entered through the keyboard in MDI mode. Display of the scheduled programs. Okuma America Corporation 4-15

Machining Center

BLOCK DATA PROGRAM SELECT

ACTUAL POSIT

PROGRAM

F1

F2

F3

PART

BLOCK DATA

TOOL LAYOUT

F4

F5

F6

CHECK DATA

F7

EXTEND

F8

By using the PAGE key on the NC operation Panel, various screens can be accessed after the BLOCK DATA function key has been pressed. The following bullets describe what the different screens show:

P

• • • •

Displays the data in the block currently being executed. Displays the data in the NEXT block to be executed. Displays the data in the block succeeding (QUEUED) the next block. Displays the data last stored in the buffer (READ) register.

CHECK DATA DATA INPUT

F1

ACTUAL POSIT

F2

PART PROGRAM

BLOCK DATA

F3

F4

CHECK DATA

EXTEND

LAYOUT

F6

F7

F8

TOOL

F5

By using the PAGE key on the NC operation Panel, various screens can be accessed after the CHECK DATA function key has been pressed. The following bullets describe what the different screens show:

P

• • • • • • •

Displays servo data related to individual axes. Displays EC inputs (machine side inputs). Displays EC outputs Displays Machine Operation Panel inputs. Displays Machine Operation Panel outputs. Displays machines specification codes. Displays machines machine specification codes.

• • • •

Displays history of alarms (last 12 alarms). Displays ATC I/Os (if applicable). Displays post process gauging data (if applicable). Displays in process gauging data (if applicable).


Rev. 8-21-01

Machining Center Data Setting Mode Keys (Tool Data, Edit Aux, Zero Set and Parameter)

TOOL DATA BACK UP

ADD

CONST. ADD

CONST. SUB

GUIDE ON/OFF

ITEM ↑

ITEM ↓

F1

F2

F3

F4

F5

F6

F7


Used to add parameter set data

Used to subtract parameter set data

Used to turn on and off graphic guide display

EXTEND

F8

Used to select displays related to tool data

Used to access other menus

E

By using the ITEM ↑ or ITEM ↓ key, various screens can be accessed after the TOOL DATA mode key has been 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 P key to access tools # 13 to 32 if applicable. Displays tool interference data. The tool interference data (TOOL FORM SELECT) are displayed and can also be changed in this menu. (not available for the graphics specification) Use the P key to access tools # 13 to 32 if applicable. Displays tool group data Displays post process gauging results. Setting and displaying of ATC tool data (if applicable). E

SET

F1

F2

F3 Used to add parameter set data

Rev. 8-21-01

GUIDE ON/OFF

CAL

F4


ITEM ↑

F6

ITEM ↓

F7

EXTEND

F8

Used to select displays Returns to main related to tool data


menu in Tool Data

Machining Center

EDIT AUX

DATE

DIR

PIP

EDIT

FREE

LIST

IGF

F1

F2

F3

F4

F5

F6

F7

Used to enter and display date when preparing a file or other data

Used to display the filenames in the directories

Used to access the file transfer data

Used to edit a file.

Used to display the remaining memory capacity

Used to display contents of the active file

Used to access the IGF function (option)

TIME

INIT

DELETE

RENAME

F1

Used to enter and display time

F2

Used to initialize (format) a directory

F3

Used to delete a specified file

F4

Used to rename a file

TAPE CONV

F1

Available on Tape conversion specification

MULTIPIP

F5

Used to output all program files

PROTECT

F6

F3

F4

F5

F8


EXTEND

F7

F8


Used to protect a file

DATA PIP

F2

EXTEND

EXTEND

F6

Used to transfer or backup parameters

F


F7

F8

Returns to main menu of Edit Aux

Rev. 8-21-01

Machining Center

F INPUT

OUTPUT

D-PIP QUIT

VERIFY

F1

F2

F3

Inputs A.TOP file from peripheral device

Outputs A.TOP file to peripheral device

Compares data sent to or from peripheral with data in memory

F4

F5

F6

F7

F8

Used to terminate data transfer procedure

ZERO SET

SET

Rev. 8-21-01

ADD

BACK UP

CAL

F1

F2

F3




F4

F5

F6

Used to immediately back up data. On newer OSP 5020 (1994 and newer)


F7

F8

Machining Center

PARAMETER BACK UP

SET

ADD

CAL

F1

F2

F3




F4

F5 Used to immediate ly back up data. On newer OSP 5020 (1994 and newer)

ITEM ↑

F6

ITEM ↓

F7

F8

Used to access displays related to parameter data.

By using the ITEM ↑ or ITEM ↓ key, various screens can be accessed after the PARAMETER mode key has been pressed. The following bullets describe what the different screens show: • User Parameters • Chuck/Tailstock • Common 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. These pages can be accessed by pressing the

P

key on the NC Operation Panel.


Rev. 8-21-01

MACHINE OPERATION NC Status Display Lamps RUN

This lamp comes on when the machine is running in Auto or MDI mode.

S.T.M.

This lamp comes on when a command other than axis motion is executed. If an S, T, or M command is executed, this lamp will stay on until the confirmation signal is received. The S.T.M. lamp will flicker if a spindle speed, speed range, or tool change command is changed during automatic mode operation. Changing one of these three commands can be done with the manual operation intervention function.

SLIDE HOLD

This lamp comes on when the Slide Hold button on the machine operation panel is pushed. With two-saddle lathes, this lamp will also come on when the designated commands for one saddle are being completed and the other is placed in slide hold mode. This condition only occurs when the single block function is activated.

PROGRAM STOP

This lamp comes on when the control sees a program stop (M00), 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 programmed with the dwell command.

LIMIT

This lamp turns on when an axis has reached the soft-limit position. It will start flickering if: 1) 2)

ALARM

The active spindle speed reaches the specified limit. The selected spindle speed is too high or too low for the selected gear range.

This lamp will come on whenever the control detects certain alarm conditions. An alarm number will be displayed on the CRT. Details concerning the alarm displayed are provided in the Alarm & Error List manual.

Mode Selection Keys The mode keys are classified into two groups, data setting mode and operation mode. Data Setting Mode:

Rev. 8-21-01

TOOL DATA

Pressing this key will allow the operator to check, set, or modify tool offset data. This mode is also used to set tool management, cutter compensation, and tool nose radius compensation data.

ZERO SET

This mode is used for checking and or setting the zero offsets of the individual axes.

PARAMETER

This mode is used for setting, checking, or modifying the various parameters. Okuma America Corporation 4-21

MACHINE OPERATION EDIT AUX

This mode is used for editing or transferring programs. This mode is also used for setting the date and time. Any kind of file handling would be done through this mode key.

Operation Mode: MANUAL

This mode is used for manual operation of the machine. For example, jogging the axes or using the pulse handle would be done in this mode.

MDI

Manual Data Input mode is used when a block of commands are entered through the keyboard on the control.

AUTO

This mode is used for automatic operation. In this mode a stored NC program is entered and executed.

IGF

This mode key is not classified as one of the two groups mentioned above but is used to access the Interactive Graphics Function. This is an on board graphics programming option.

When any one of these mode keys are pressed, an indication lamp on the upper left side of the key will turn on. When going from one of the three operation modes to one of the data setting modes, the indication lamp will 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 input one of these symbols, use the UPPER CASE key. The SP key is used to insert a space. The CTRL key is a control key which is not used under normal conditions. The HT key is also not used under normal applications. It stands for horizontal tabbing. BS

This is the back space key. Each time this key is pressed, the last character entered is erased. This key is also used to display the next page of a file or directory.

CAN

This is the cancel key. This key is used to delete a block (line) of data.

WRITE

This is the enter key. This key is pressed whenever data is set or after inputting the name of the program to be executed.

Numeric Keypad The numeric keypad is used to input the numeric characters. Included in the numeric keypad are the operator keys. These are the basic arithmetic keys. _

The subtraction key can be used to input a minus or hyphen symbol.

+

This key is used to input the addition symbol.

*

This key is used to input the asterisk symbol for multiplication. It is also used as the wild card symbol when working with files.

/

This key is used to input the division or forward slash symbol. Okuma America Corporation 4-22

Rev. 8-21-01

MACHINE OPERATION Cursor Keys These four arrow keys are used for moving the cursor on the CRT. Page Keys These two keys are used for changing the display page on the CRT. In some cases, the item up and item down function keys (F6 and F7) are used to change the display screen when going from one page to the next in a menu (i.e. Parameter mode). Turret Keys These two keys are used to select A or B turret display menus on lathes with two-saddle and twoturret capability. LATHE Machine Operation Panel The following is a description of the various switches on a machine operation panel for an OSP 5020L type control. CYCLE START

Press this button to start machine operation in Auto or MDI 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 active, the machining cycle will stop when an axis movement command is read and decoded. Press the cycle start button to resume axis movement. EMG. When this button is pushed all power to the machine is STOP shut off except for the power to the control. SLIDE JOG

The four slide jog buttons are used to manually jog the axes. The Feedrate override dial is effective in this mode.

FEEDRATE

The feedrate override dial is used to modify the commanded feedrate for optimizing the cutting operation. Override range is 0 to 200 % in 15 steps. This rotary switch setting is ignored during the thread cutting function(G33). The Feedrate override switch is effective if: 1) G00 is programmed in MDI mode. 2) Single Block mode is ON in AUTO mode. 3) Jogging the axes in MANUAL mode.

Rev. 8-21-01


MACHINE OPERATION This rotary switch is not effective in Auto mode with G00 programmed and Single Block mode off. PULSE HANDLE

The pulse handle is used to manually feed the individual axes. The control must be in Manual mode to use the pulse handle. A magnification selection and an axis selection button determines which axis movement is initiated. The magnification selection is used to select the axis feed amount per pulse (notch).

1/1 10/1 50/1 SPINDLE

Axis moves 1µm/pulse (.001 mm)(.0001in/pulse in inch mode). Axis moves 10µm/pulse (.01 mm)(.001in/pulse in inch mode). Axis moves 50µm/pulse (.05 mm)(.005in/pulse in inch mode). These buttons are used to manually turn and stop the spindle.

STOP

Stops the spindle rotation after the CCW or CW buttons have been pressed.

CCW

Makes the spindle turn 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 rotate clockwise. Forward rotation will stop as soon as the button is released.

For the CCW and CW buttons to work properly, the following conditions must be met: 1. 2. 3. 4.

The spindle speed has been entered beforehand through MDI. The spindle gear range selection (M41M44) has been made. For center work, the tailstock is advanced. Chuck fulfills the spindle rotation condition: Chuck closed during OD gripping. Chuck open during ID gripping.

On machine models with DC spindle drive motors, it is not possible to go from CW to CCW instantaneously. SPINDLE OVERRIDE The spindle override rotary switch is used to modify the commanded spindle speed. This switch will not override the maximum allowable spindle speed or the spindle speed set by the G50 code. COOLANT The coolant keys are used to control the coolant supply condition. AUTO and MANUAL OFF

Coolant is not supplied regardless of the operation mode selected.


Rev. 8-21-01

MACHINE OPERATION AUTO ON

Coolant on/off mode is controlled by M codes. (M08-ON M09-OFF)

MANUAL ON

Coolant is supplied in any operation.

Auto and Manual modes cannot be on at the same time. SPINDLE GEAR This function allows the operator to place the spindle in neutral. This enables the chuck to be rotated by hand. The control has to be in Manual mode. This function is only for models with a spindle speed change mechanism where some kind of mechanical gear shifting and a neutral is involved. The following keys are associated with this function. NEUTRAL When this key is pressed the spindle is placed in the neutral state. The gear position data is saved and can be recalled even after the power has been turned off and back on again. ENGAGE By pressing this key, the spindle gear range selected previously is automatically selected. The selected range is displayed on the CRT at the MACHINE STATUS display on the ACTUAL POSITION display screen. The corresponding M code will be shown (M41 M44). The lamp at 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 when operating in Auto or MDI modes. For a machine with a mechanical gear change mechanism but no neutral position, the ENGAGE key LED will flicker during gear change operation. The LED will flicker until the confirmation signal is read. The Cadet (LNC-8) has this feature. The spindle speed does not change when the gear range is changed only the torque is increased or decreased. LOAD MONITOR

This function is an option which is used to monitor the cutting load of the feed axes or the spindle.

TOOL INDEX

This button is used to rotate the turret. Push it once and the turret will index one position. Keep the button pressed, the turret will rotate until the button is released. For two-saddle or two-turret models, the turret to be index has to be selected via the turret select keys (INDIVIDUAL MODE) on the machine operation panel. In most cases the X or Z axis have to be at the positive variable soft limit before the turret will index. This can be checked by observing the LIMIT status lamp on the NC operation panel. As a precaution, a visual inspection of the turret should be made before attempting to rotate the turret.

Rev. 8-21-01


MACHINE OPERATION

LIGHTING

This key is used to turn on or off the work light on the machine.

SINGLE BLOCK

When this function is used, the control will execute one block (line) of a program at a time. This function is used in AUTO mode when machining a part for the first time. CYCLE START must be pressed after each block of data is processed.

BLOCK DELETE

When this key is turned on, the blocks in a program that are preceded by a forward slash (/) will not get executed.

OPTIONAL STOP

If this key is turned on, the control will stop executing a program when it sees an M01 (optional stop) command. It will complete all the commands on the same block as the M01 and then stop. When this key is turned off, the M01 command is ignored.

DRY RUN

Turn on this key when checking a newly prepared part program in AUTO mode. With this 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 is factory set to 2,400 mm/min.

MACHINE LOCK

When a part program is executed with this key activated, all commands in the part program are executed without actual machine operation. The simulated operation can be checked on the CRT. In this mode, the cutting feedrate is determined by the programmed spindle speed.

MID AUTO MANUAL

Press this key to interrupt an AUTO mode operation; carry out the required manual mode operation, and resume the AUTO mode operation.

INDIVIDUAL MODE These keys are available on two-saddle machines. On these machines, normal operation is made in the simultaneous 4-axis control mode. These two keys are used to select the required operation mode: Individual A turret operation: A B

ON OFF

With this setting, only the A turret is activated in the operation modes.

Individual B turret operation: A B

OFF ON

With this setting, only the B turret is activated in the operation modes.

Individual A/B turret operation:


Rev. 8-21-01

MACHINE OPERATION A B

ON ON

A and B turrets are activated individually according to the designated synchronizing commands.

Normal operation: A OFF Normal machining cycle is performed according to B OFF the programmed commands. INTER LOCK

This key is used to activate the following keys: DRY RUN MACHINE LOCK INDIVIDUAL MODE The INTERLOCK key must be pressed at the same time as the aforementioned keys in order to activate those functions.

CRT DISPLAY

This key is used to turn off the CRT display. It is used to extend the life to the CRT.

SEQUENCE This key is used to restart the AUTO mode operation which has RESTART been interrupted due to a tool breakage or a machining cycle was too long. For details refer to the Operation Manual. CONTROL ON/RESET

Press this switch to turn on the power supply to the control and the servo systems. The main switch on the side of the control cabinet 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 OFF

Press this switch to turn off power to the control and the servo systems. Always press this button first before turning off the main switch.

NC PANEL EDIT LOCK The EDIT AUX and PARAMETER mode keys are (OPT)(PL) disabled when the key is placed in this position. UNLOCK (ON)(|)

All controls on the NC and Machine operation panels are enabled.

LOCK (OFF)(O)

All controls on the NC operation panel are disabled.

Stroke End Limit Cancel/Load Mode Panel This small panel is found on the right inside wall of the control cabinet on the LNC-8 (Cadet) and the LB 15. The following is a description of the switches on this panel. Load Mode Load Start

Turning this toggle switch on will put the control in the Load mode to load new software. Pushing this button will initiate the loading procedure.

System Reset Pushing this button resets the control. This is sometimes referred to as a soft boot. Stroke End With this toggle switch set to ON, the operator is allowed to use Limit Cancel the Pulse Handle to move an axis off of a stroke end limit switch. Rev. 8-21-01


MACHINE OPERATION Machining Center Machine Operation Panel The following is a description of the various switches on the machine operation panel for an OSP 5000/5020M type control. A picture of this panel can be seen on page 4-34. AXIS SELECT

This set of keys allows the operator to choose which axis he or she wants to move in Manual mode. The pulse handle mode key is turned on if the operator wishes to go into PH mode.

RAPID +/

Press the RAPID + or RAPID to feed the designated axis in the plus or minus direction. The axis will move as long as one of these button are pressed and the control is in Manual mode.

RAPID This rotary switch is effective when the RAPID +/ push OVERRIDE buttons are used and during programmed rapid feed modes (G00, G60, etc.). This setting can be observed in the Block Data screen of the CRT (fm). SPINDLE ORIENTATION Pressing this key while holding down the INTERLOCK RELEASE key will orient the spindle. The spindle will be positioned at a preset angle to allow for proper 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 completed, the light will stay on until the spindle is given a command to rotate or the RELEASE key is pressed. CW

Pressing this key while holding down the INTERLOCK RELEASE key will initiate spindle rotation in the clockwise direction. The control must be in Manual mode. The spindle speed is dependent on the S command given through MDI mode before pressing the CW key. The spindle speed commanded (So) and the actual spindle speed (Sr) can be viewed in the Block Data screen on the CRT.

STOP Press this key to stop the spindle rotation. CCW This key has the same function as the CW key except the spindle will rotate in the counter clockwise direction. RELEASE Pressing this key will place the spindle in a neutral state. This allows the operator to rotate the spindle by hand. This push button is effective only when the spindle is at rest and the tool clamping mechanism is on. SPINDLE This is a spindle speed override rotary switch. The spindle gear OVERRIDE range is automatically selected when an S command is given. The spindle override switch will effect the speeds that fall within the gear range selected.


Rev. 8-21-01

MACHINE OPERATION

Rev. 8-21-01

JOG +/O/

These keys are called the JOG feed buttons. Press the JOG +/ keys to move the selected axis in a plus or minus direction. The control must be in Manual Mode. To stop the axis motion, press the JOG OFF key (O). While the axis is moving, pressing a JOG feed button which requires the axis to go in the opposite direction will stop the axis motion and start the axis moving in the new direction.

JOG SPEED

This is the jog feedrate selector switch. The jogging feedrate can be adjusted in inches or millimeters per minute through this switch. This feedrate can be observed on the Actual Position page of the CRT.

FEEDRATE

This is the cutting feedrate override switch. This switch is effective for programmed cutting feedrates (G01, G02, and G03). This setting is ignored during tapping cycles (G74 and G84). The override rate is set at 100% when M136 is programmed regardless of the switch setting. When the M137 code is commanded and executed, the cutting feedrate override switch becomes effective.

COOLANT

When this key is pressed, the coolant pump motor is turned on and coolant is sprayed on 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, an oil mist is delivered to the tool. An example of this would be a tapping function.

A. B. NOZ.

This key is the air blower nozzle switch. The nozzle used for the oil mist is also used for the air blower. This function is used to blow chips away from the cutting area.

OIL HOLE

This key is used to manually spray coolant. This push button is used when a machining center has the Through-The-Tool Coolant Supply System. High pressure coolant is sprayed out from the drill tip. The drill is cooled and lubricated and chips are removed from the drilling area.

A. B. ADAPT

This key is used when an air blow adapter is mounted to the machine. This function is used as an air only blower.

SHOWER

This key is used mostly to wash off chips on a pallet before moving the pallet away from the chip conveyor.

LIGHT

This key turns on or off the work light.

CRT OFF

This key is used to turn off the CRT display to prolong the service life of the CRT.

LUB.

When this key is pressed, the axis slideways are lubricated. Each time this key is pressed, the axis lube pump runs for 60 seconds.

CHIP CON

This key is used to turn on and off the chip conveyor.

RESET

This button resets the control. This button is also used to clear certain types of alarms. Okuma America Corporation 4-29

MACHINE OPERATION

NC PANEL EDIT LOCK The EDIT AUX and PARAMETER mode keys are disabled when the key is placed in this position. UNLOCK

All controls on the NC and Machine operation panels are enabled.

LOCK

All controls on the NC operation panel are disabled.

CYCLE START

The cycle start button is used to start machine operation of a scheduled program (AUTO) or a block of instructions (MDI). It is also used to restart a program after slide hold has been pressed.

SLIDE HOLD

Axis movement and program execution are temporarily stopped when this button is pushed. On machining centers this switch can be deactivated by using the M140 command.

EMG. STOP

When this button is pressed all power except for the control power is shut off.

NC Operation MIRROR IMAGE

Each axis on a machining center has a key for turning on and off the mirror image function. 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 RELEASE panel. This is to prevent certain keys from accidentally being turned on.

MACHINE LOCK

This function is used to check a new program. The actual position values are displayed on the CRT as the program is executed but actual machine movements are prohibited. The INTERLOCK RELEASE key must be held down to turn on this function.

DRY RUN

Dry run is a function for running the machine at the feedrate set by the cutting feedrate rotary switch. NC optional parameter No. 2 bit 2 determines whether dry run is effective or not. This function is also effective while the machine lock function is active. This function is used mostly to check the cutting feedrates of a new program.

BLOCK SKIP

Any block preceded by a forward slash (/) can be disregarded when the block skip key is switched on. These three Block Skip switches are assigned codes of /1, /2, and /3. / is equal to /1.

CYCLE STOP

When this key is turned on, the machine will stop after the execution of a main program. Okuma America Corporation 4-30

Rev. 8-21-01

MACHINE OPERATION S.T.M. LOCK

This is the function to check the program by executing the axis movement commands without miscellaneous commands.

AXIS COM. CANCEL

This is the axis command cancel function. An axis can still be moved by Manual mode or manual intervention operation.

OPTIONAL STOP

With this key activated, the program will stop executing when the control sees the optional stop command (M01).

SINGLE BLOCK

This function is used to check the program, block by block. The machine stops after every block and cycle start must be pressed to execute the next block of the program.

MID AUTO MANUAL

When this key is turned on, a manual operation can be performed during AUTO mode. The procedure on how to carry out this manual intervention function is described in detail in the Operation manual.

PULSE HANDLE SHIFT

With this key on, axis motion control by the pulse handle can be inserted into the program. An example of this would be when machining a cast workpiece on which stock removal varies.

SEQ. RESTART

When a machining cycle is interrupted during automatic 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 resolve the problem.

The (on or off) condition of the NC operation keys are saved (backed up). If, for example, the DRY RUN key is turned on and the power to the machine is then turned off, the control will remember that and turn the DRY RUN mode on when the control is powered up again. If a key is turned on or off, and the back up key is not pressed or the allotted time has not elapsed (three to six minutes) before the power is turned off the control will not retain the condition of the key just pressed. ATC Operation

Rev. 8-21-01

ATC

Pressing this button will put the control in the ATC mode of operation. This allows the operator to move the ATC in manual mode. The ATC DATA screen on the CRT can be accessed by pressing the atc/apc function key (F6).

APC

Pressing this button will put the control in the APC mode of operation. This allows the operator to move the APC in manual mode. The APC DATA screen on the CRT can be accessed by pressing the atc/apc function key (F6).

INTER LOCK RELEASE

When this key is pressed, the spindle orientation completion conditions and the tool change position conditions are ignored. It will not ignore other mechanical conditions.


MACHINE OPERATION 1 CYCLE START

Pressing this key automatically carries out one complete automatic tool change cycle. This operation consist of a series of tool change cycles in which a tool picked up from the magazine is set into the spindle and the tool that was in the spindle is returned to the magazine. This operation is only allowed when the message READY is displayed on the CRT with the ATC sequence number set at 01.

RETURN CYCLE START

This button can be pressed with the ATC operation sequence set to any number. If the tool change arm has not completed its 180 degree rotation, pressing this button will start the tool return cycle and no tool change cycle will occur. If this button is pressed after the tool change arm has completed its 180 degree rotation, the automatic tool change cycle will be completed.

1 STEP ADVANCE

Pressing this key advances the ATC operation one step at a time. If the RUN message is being displayed on the CRT, this key will not work. If the sequence does not advance because of some unfulfilled condition, it is possible to ignore those conditions and continue operations. Pressing the 1 Step Advance key while holding down the INTERLOCK RELEASE key will allow the operation to continue. If a mechanical condition is not met, the operation is not allowed to continue and the RUN message is displayed on the CRT.

1 STEP REVERSE

The function of this key is the same as the 1 STEP ADVANCE key except the operation is done in reverse.

If the E-STOP button is pressed while the tool change arm is in operation, the signals AHP (X,Y, and Z-axis tool change position) and SHP (spindle orientation complete) turn off. This sometimes renders the ATC operation keys inoperative. If so, press the 1 STEP ADVANCE key while pressing the INTERLOCK RELEASE key, and the tool change sequence will advance to the next step. The tool in the spindle will be clamped when the ATC cycle is interrupted by an E-STOP condition. This will render the ATC operation keys inoperative. In this case, press the TOOL UNCLAMP button on the operation panel at the side of the main operation panel. APC Operation The control must be in MANUAL mode and the APC key on for the following keys to be effective. 1 CYCLE START

When this key is pressed, one automatic pallet change cycle is carried out. During this operation, the pallet on the machine is unloaded to the APC and the pallet on the APC is loaded to the machine. This operation is effective only if the READY message is displayed on the CRT.

RETURN CYCLE START

When this key is pressed, the automatic pallet change cycle is carried out in the reverse order back to sequence number 01. This will return the pallet to the machine.

1 STEP ADVANCE

The automatic pallet change cycle will advance step by step every time this key is pressed. This operation is ineffective if the RUN message is displayed on the CRT. Okuma America Corporation 4-32

Rev. 8-21-01

MACHINE OPERATION 1 STEP REVERSE

The function of this key is the same as the 1 STEP ADVANCE key except the steps are reversed.

If the E-STOP button is pressed while the shifter is moving, the shifter retraction position signal is turned off. This sometimes renders the APC operation keys inoperative. If so, press the 1 STEP ADVANCE key while pressing the INTERLOCK RELEASE key. This should advance the automatic pallet change cycle one step at a time. When the RUN status lamp is on, the ATC/APC operation keys mentioned above are inoperative. Press the RESET key to turn off the RUN lamp. In other words, these keys are ineffective when the control is in AUTO or MDI operation mode. Pendant Operation Panel The pendant operation panel will differ from machine to machine. These types of panels are mostly used on double column machining centers. Most of the switches on this type of panel are the same as the switches on the Machine Operation panel. For a description of the switches on this panel, please refer to the Operation manual of the machine in question. 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/close and the Touchsetter option. On machining centers the Power ON and OFF buttons are located on an option panel located on the control cabinet door. The following is a description of the controls that are on this option panel. A picture of this panel can be seen on page 4-35. Puncher SERIAL

This is the RS-232C interface connector. This interface connector is called the CN0 port and is now standard.

PARALLEL

This is the parallel port interface.

AC 100V 2A This is the power receptacle for the Paper tape puncher. HOUR METER The first hour meter with the lightening symbol is the power on time meter. It accumulates the amount of time the machine has been on. The second hour meter is the NC Running Time meter. It accumulates the length of time the RUN lamp on the NC operation panel is on. Operation End Mode

Rev. 8-21-01

BUZZER

This is the Operation End Buzzer activation switch. If this switch is on, the buzzer will sound at the end of a program run. The length of time it sounds is set by MC user parameter word No. 7.

LIGHT

This is the Operation End Light activation switch. If this switch is on, the YELLOW light on the pendant arm will come on when an end of program code is read. Okuma America Corporation 4-33

MACHINE OPERATION

ERROR

This is the Error Light activation switch. If this switch is on, the RED error light will come on if an alarm state is detected.

AUTO POWER OFF

This switch is called the Auto Power Shut Off switch. If this switch is on, the power will shut off automatically after the execution of an End of Program (M02) command or after executing an End of Tape (M30) command in a main program. This switch is ineffective when single block mode is on. On some of the new machines this function is a parameter setting. (Optional Parameter Bit 14 bit 0)

Control On/Off POWER ON

This is the Power On button. Press this button after turning on the main circuit breaker on the side of the control cabinet to power up the machine.

POWER OFF

This is the Power Off button. Press this button first before turning off the main circuit breaker when turning off the machine. If any peripherals are hooked up to the machine, they should be powered off first.

EMG.

This is an extra emergency stop button. If any of the E-stop buttons are pushed in, the red indicator lamp on this panel will be on. The green indicator lamp will come on as soon as the main breaker is turned on. It turns off as soon as the Power On button is pressed.

STOP


Rev. 8-21-01

Rev. 8-21-01

NC-STATUS

OKUMA

RUN

SLIDE HOLD

STM

PROGRAM STOP

LIMIT

ALARM


MODE P AUTO

A

!

@

F2

F3

F4

F5

F6

F7

F8

&

H

I

O

P

V

F1

"

B

-

\

W

MDI

MANUAL

#

$

C J

D

’

?

K

^

EDIT AUX

PARAMETER

E

F

L

M T

Q

R

S

X

Y

Z

;

:

ZERO SET

(

TOOL DATA

)

G HT %

N SP

[

U

<

,

]

>

CTRL UPPER CASE

B

7

8

9

/

BS

P

P

4

5

6

*

CAN

1

2

3

+

0

.

=

-

WRITE

OSP5020L

MACHINE OPERATION

A

MACHINE OPERATION


COOLANT

CYCLE START

SINGLE BLOCK

BLOCK DELETE

OPTIONA L STOP

MACHIN E LOCK

MID AUTO MANUAL

PULSE HANDLE

I

X

SLIDE JOG

Z

1/1 10/1 50/1

SLIDE HOLD

EMERGENCY STOP

FEED RATE 70 80 50 30 10 5 2 0

90 100 110 120 130 150 200

OKUMA

CONTROL OFF LOAD MONITOR

SPINDLE OVERRIDE

%

DRY RUN

JOG

+

-

O

SPINDLE GEAR

CW

CCW

%

110 90 100 120 80 130 70 50

CONTROL ON/RESET

I

STOP SPINDLE

150 200

ON

TOOL INDEX

AUTO SET

LIGHTING

INDIVIDUAL MODE

A INTER LOCK

B CRT DISPLAY

SEQUENCE RESTART

NC PANEL UNLOCK

I-L

CRT

I

EDIT LOCK

LOCK

SR

E5409-770-002

Rev. 8-21-01

Rev. 8-21-01

AXIS SELECT


X

Y

4

5

NC OPERATION MIRROR IMAGE X

MIRROR IMAGE Y

INTER LOCK RELEASE

MACHINE LOCK

ORIENTATIO N

SPINDLE

CW

STOP

Z

MIRROR IMAGE Z

MIRROR IMAGE 4

DRY RUN

BLOCK SKIP 1

BLOCK SKIP 2

CYCLE STOP

S.T.M. LOCK

+ RAPID % OVERRIDE 30 50 10 70 5 80 0

MID AUTO MANUAL

AXIS COM. CANCEL

OPTIONAL STOP

SINGLE BLOCK

PULSE HANDLE SHIFT

SEQ RESTART

ATC

APC

AAC

INTER LOCK RELEASE

1 CYCLE START

RETURN CYCLE START

1 STEP ADVANC E

1 STEP REVERSE

I

CYCLE START

O

SLIDE HOLD

JOG

RAPID

1

ATC OPERATION BLOCK SKIP 3

90 100

+

110 90 100 120 80 130

OIL MIST

70

INCH / MIN JOG MM / MIN SPEED 1000 40 20 500 8 200

150 200 4 100 2 50 0.04 1

A.B.ADAPT

A.B. NOZ.

LIGHT

LUBE

// RESET

CCW

%SPINDLE OVERRIDE

50

o

COOLANT

OIL HOLE

%

SHOWER

CHIP CON

FEED RATE

70 80 90 100 60 105 2000 80 110 50 120 40 130 4000 160 30 140 150 6000 240 20 160 10 170 10000 400 5 0 180 200

NC PANEL

EMERGENCY STOP

UNLOCK EDIT LOCK

LOCK

MACHINE OPERATION

OPTIONAL

OPTIONAL

PUNCHER


SERIAL

MACHINE OPERATION

OPTIONAL

HOUR METER

PARALLEL

Xh

OPERATION END MODE BZ BUZZER

READY EMG STOP LIGHT POWER ON

01234

6 11

POWER OFF AC100V

Xh

2A

01234

6 11

ERROR AUTO POWER LIGHT OFF

EMG STOP RESET

Operational Panel above Tape Reader

Rev. 8-21-01

MACHINE OPERATION

MG MANUAL

INDEX START

MANUAL INT

CW

CWW

EMG. STOP RESET

ATC Magazine Operation Panel

MANUAL TOOL CHANGE

TOOL CHANGE CYCLE

TOOL CLAMP

TOOL UNCLAMP

Manual Tool Change Operation

LS EMERGENCY X

Y

Z

4

5 TOUCH

IGF

- > LOADING

RETURN - > LOADING/SYS RESET SYS. RESET

SENSOR

Check Panel

Rev. 8-21-01


LOAD START

LOAD MODE

MACHINE OPERATION

MDI Operation MDI is an abbreviation for Manual Data Input. One block (line) of data is entered at a time. Each block of data entered is executed once the CYCLE START key is pressed. To execute a block of commands in MDI, do the following: 1. Press the MDI mode key. The following functions are displayed: DATA INPUT

F1

ACTUAL POSIT

PART PROGRAM

BLOCK DATA

F3

F4

F2

CHECK DATA

F5

F6

F7

[EXTEND]

F8

2. IN is displayed on the lower left side of the screen (21st line). Enter the desired commands. On lathes with the OSP 5020 series control, 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 useful to know when troubleshooting a machine side problem. Code M03 M04 M05 M40 M41 M42 M55 M56 M83 M84 M86 M87

Description Spindle rotation (CW) Spindle rotation (CCW) Spindle stop Spindle gear range neutral for Lathe 1st gear 2nd gear Tailstock quill retract Tailstock quill advance Chuck clamp Chuck unclamp Turret indexing direction (CW) Turret indexing direction (CCW)

G00 X Y Z S

rapid positioning X axis positioning Y axis positioning Z axis positioning Spindle rotation speed in RPM.


Rev. 8-21-01

Notes

EL501

Notes

EL501

OSP 5000/5020 CONTROL CONSTRUCTION ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501

CH .

CONSTRUCTION This section will cover the basic construction of the electrical side of any Okuma machine tool with a 5000/5020 series control. The various power supplies, the boards in the control rack and in the EC I/O rack (mostly on M/Cs), and the different servo systems found on Okuma machine tools with the 5000/5020 series control will be discussed. Every Okuma machine tool comes with a set of electrical schematics and there is a System Configuration Sheet at the beginning of these schematics which shows a basic electrical layout of the machine. The system configuration sheet for some machining centers can be seen in the maintenance manual for the machine in question. An example of a System Configuration Sheet is shown on the following page. Power Supplies Most Okuma machines are designed to work on 208 volts AC incoming power. On some machines, a multi-tap transformer is standard. As a precaution, the incoming power and 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 is supplied to a newly installed machine. If more than one machine tool is connected to the same single power source, the Power Source Inductance should be noted if power related problems start occurring. Power Source Inductance can be obtained by dividing the value in the table by the number of machine tools connected to the single power source. Wiring inductance in 50 meters (164 ft ) of cable is approximately 12 µH when general cable is used.

VAC Unit D45 D30 D22 D11 D6

Applicable Motor

Power Source Inductance 220V 37/30 kW to 55/45 kW Less than 45 µH. 22/18.5 to 37/30 kW Less than 70 µH. 22/15 to 30/22 kW Less than 110 µH. 11/7.5 to 15/11 kW Less than 230 µH. Less than 7.5/5.5 kW Less than 350 µH.

Power Source Inductance 200V Less than 115 µH. Less than 170 µH. Less than 230 µH. Less than 480 µH. Less than 850 µH.

If the Power Source Inductance is too high, the following problems will arise. • • •

Rev. 10-09-02

Deceleration time will be extended. During deceleration, the motor will generate noise. Transistor modules in the servo drives will fail prematurely.


CONSTRUCTION If the system is operated in an environment where the inductance is too high, the control will generate an excessive power source voltage fluctuation alarm. To verify the incoming power source is sufficient, divide the KVA rating of the machine by [the square root of 3 (1.732) times the incoming voltage]. This will give you the amount of current (amperage) needed to operate the machine. KVA

I (amperage) =

3 X incoming voltage

Another way to verify if the incoming power is sufficient is to check the impedance of the incoming power. Impedance is the total opposition to the flow of current in an AC circuit. When the spindle decelerates 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 calculation: Vdec - Vstop X100% = Vvar (Vvar should be less than 6% at 220V or 15% at 200V) Vstop

In other words, (Vdec minus Vstop) divided by Vstop times 100% should be less than 6%. Vstop is the voltage measured across the same to terminals of the spindle drive unit when it is at a standstill. Vdec is the voltage measured across the same two terminals when the spindle starts to decelerate. When determining the Vdec the programmed spindle speed should be the maximum programmable spindle speed for the machine. The measuring device should be an analog volt meter or an oscilloscope. Some of the latest DVMs are fast enough, i.e. Fluke 87.

R S T E

SDU

U V W E

AC SPINDLE MOTOR

V


Rev. 10-09-02

CONSTRUCTION

A power supply is defined as a device for converting external alternating current (AC) into the direct current (DC) needed to run a computers electronic circuits. The incoming power gets branched off to various power supplies in the system. The system configuration sheet shows how 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 step down transformer takes the incoming single phase power and converts it to 100 and 120 volts single phase AC. This power source also provides the -24 volts DC working 24 volts which controls or turns on the various solenoids and relays on the machine. The EC control power source provides power to such things as the operation panel, work light, hour meter, and the ISO 24 volt power supply.

Rev. 10-09-02


MAIN BOARD II-B

CRP BOARD 9 CRP BOARD II C (OPTIONAL) BUBBLE CARD 256 BYTE

MAIN CARD 11 or 12 RAM 0.5M 2M BYTE

MAIN CARD 13

OPTICAL COMMUNICATION I/F SPC6 CARD

SVP BOARD II-D

EC BOARD

RS-232-C

PULSE HANDLE PUNCHER


SENSOR (OPTIONAL)

BLII-D

LIMIT SWITCH

X-AXIS Z-AXIS

TAPE READER

DC POWER SUPPLY

VAC III

SPINDLE MOTOR DRIVE UNIT

OPUS 5020

HYDRAULIC PUMP MOTOR

OPERATIONAL PANEL

POWER SOURCE UNIT

220V 1 ph

POSITION ENCODER

AC100V 1 ph

AXIS DRIVR MOTOR

EC CONTROL POWER SOURCE

AC220V 3 ph

X-AXIS Z-AXIS

SPINDLE PULSE GENERATOR

SOLENOID SPINDLE MOTOR

DC24V

AC220V 3ph

CONSTRUCTION

SYSTEM BUS

Rev. 10-09-02

CONSTRUCTION

The servo systems (axes and spindle drives) receive the incoming 3 phase power and convert it to the DC voltage (300 Vdc) needed to drive the motors. These power supplies will be discussed in the servo systems part of this section. 220 volts single phase AC also gets sent to the OPUS power supply unit (CPU power supply) which provides all the power needed for the control rack. On machining centers, 220 volts single phase also gets sent to the EC I/O rack. Once there, the voltage gets distributed and rectified as needed for the I/O boards. OPUS 5000/5020 Power Supply Unit Okumas CPU power supply converts the incoming 220 AC voltage into the various stabilized DC voltages needed to run the OSP 5000/5020 control. It controls the On/Off sequence. It provides power to the CPU first and makes sure the CPU is the last to power off. There are two types of CPU power supplies on 5020 controls: RLP and RHP. The RHP (Rack High Power) outputs the following voltages: + 5V + 12V +24V

For the integrated circuits (ICs) in the control. For the bubble memory, position encoder, main spindle pulse generator, and the manual pulse generator (Pulse Handle). For the bubble memory and tape reader.

The RLP (Rack Low Power) outputs all of the above DC voltages plus: ISO +24V

For the photo-couplers used in the CNCs I/O system.

The ISO 24V is an isolated power source used to protect the internal circuitry of the control. The ISO 24V is generated externally when an RHP is used. It is generated by a DC power supply that converts 120 volts AC to 24 volts DC. The ISO 24V circuitry does go through the RHP for monitoring purposes. The RLP and RHP are located or housed in the CPU rack. The first CPU power units that came out with the OSP 5000 series control were called HP and LP. When the graphics capability was incorporated into the control, the power units were labeled GHP and GLP. These four CPU power supplies output all the voltages mentioned above. These four units are physically larger than the RLP and RHP units. They are located above the CPU rack. Some of the latest models (5020 controls) still use the GHP CPU power supply instead of the RHP.

Rev. 10-09-02


CONSTRUCTION

The RHP power supply has two pins that can be jumpered to disable the ISO under voltage alarm function. These two pins should only be jumpered for troubleshooting purposes. The location of these two pins can be seen in figure 5-2. Make sure to remove this jumper after checking this power source. Only the + 5 volts supply is adjustable on these CPU power supplies. It is factory set at 5.1 volts. If an adjustment is necessary, measure the voltage between the check terminals 0V and +5V. Make sure to check this voltage under a full load (machine on). When making adjustments, make sure to turn the +5V adjustment potentiometer 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 lowvoltage detection function. On the non-rack type CPU power supplies, a toggle switch is used to disable this 5 volt low-voltage alarm detection function. On the rack type power supplies, the machine must be powered off and the power supply has to be removed from the control rack. Once the CPU power supply is removed from the rack, the shorting jumper on the PCB has to be moved to the UV OFF position as shown below.

UV1

UV2

V1

COM

ON

OFF

UV

VBCOM

Once the adjustment procedure is completed, make sure to move the shorting jumper back to the UV ON position. This will ensure that the 5 volt monitoring circuit is re-activated. ISO UV OFF

CN2

+5V ADJ. +5V 0V +12V +24V

0V ISO +24V

OKUMA O P U S 5 00 0 R HP P O W E R S U P P LY

CN1

Fig. 5-2 Okuma America Corporation 5-6

Rev. 10-09-02

CONSTRUCTION

The following is a description of the alarm and CPU status LEDs located on the control rack. For the non-rack type CPU power supplies the alarm LEDs are located on the power supply itself. Alarm LEDs AC TEMP UV OV

Input voltage dropped too low. Temperature in power supply rose too high. Under voltage or possible short circuit. Voltage rose too high. (over voltage)

ISO 24V +24V +12V +5V

One of these LEDs will be on when a UV or OV alarm occurs to indicate which voltage source is affected.

CPU status LEDs POWER RUN BUS Error ECC Error DIA Error LOOP Error CYCLE Error WPRT Error

There is 5 volts going to the mother board (back plane). Main board is plugged into mother board. CPU is operational or running. More than one error occurred at the same time. The CPU stops running. Error in the main memory of the system. An error occurred during the self-diagnosis function. The CPU interrupt time has exceeded its limit. The CPU tried to access a peripheral device and did not get a response within the specified time (17 micro seconds). The CPU tried to access a user inhibited address.

Printed Circuit Boards In 1981 Okuma introduced the industrys first 16 bit CNC which incorporated Motorolas 68000 microprocessor chip. This chip had the capability of multiplying two 16 bit numbers in 3.2 millionths of a second. Okuma still uses Motorolas family of 68000 microprocessor chips as the nerve center of the OSP 5000/5020 series control. The following is a description of each major unit that makes up the control rack of the OSP 5000/5020 series control. The control (or logic) rack is referred to as the OPUS (Okuma Processing Unit and System).

Rev. 10-09-02


CONSTRUCTION

Main Board IIB

Main Processor Board

The MB-IIB is the main control board for the OSP 5000/5020. It consists of a main processor and associated interfaces for data communication. The system features a high performance Motorola 68000 microprocessor with a clock frequency of 15Mhz. The MB-IIB controls the IC memory (ROM), bubble memory, slave processors, and interface circuits. A system bus (mother board or back plane) and a local bus (ribbon cables) are provided for system expansion purposes. Typically the 5000 controls have the MB main board and the CRT display is green in color. The 5000*-G controls can have the MB-II, MB-IIA or MB-IIB main boards. These controls have graphics capability and have a color display. The 5020* controls have the MB-IIB main board and also have graphics and color display. Bubble Card

Bubble Memory

This memory is used to store control software, machine parameters, and part programs. Bubble cards come in the following capacities: 4, 8, 12, 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 of bubble memory. These CMOS memory cards have a back up battery pack mounted on them. To replace this battery, the main board is pulled out of the rack and the battery pack is replaced. A super charge capacitor retains the memory while the battery is being replaced. A911-1511 A911-1512 A911-1513 A911-1514

4Mbit X 1 4Mbit X 2 4Mbit X 3 4Mbit X 4

If Alarm 2045 is displayed one of two things must be done to clear the Alarm: The first is to perform the procedure below after the Battery has been replaced. The procedure only works if you are getting Alarm 2045 with a code of 0000010C. The 1 being the determining factor. 1. Software Load Mode Switch on. 2. Control Power on . After booting Control Floppy Loading Wait will appear. 3. Press the & key, (Upper Case I), C-Mos Memory Initial Test Wait will appear. 4. Press the Load Start Button. C-Mos Memory Initial Test Start will appear. 5. When completed C-Mos Memory Initial Test Finished will appear. 6. Turn the Load Mode Switch off and push System Reset. Finished. If a code other than 1 is displayed, the System Software must be reloaded. Okuma America Corporation 5-8

Rev. 10-09-02

CONSTRUCTION Main Card 11, 12 RAM When the machine is turned on, the software is downloaded from bubble memory to RAM. 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 MC 11 or three MC 12 cards may be mounted on the MB-IIB but a combination of both kinds is not permitted. The CPU can only access one or the other. As of January 94 the MC 11 card is no longer being used on new models.

Rev. 10-09-02


CONSTRUCTION

The following is a summary of the main control boards memory capability on the 5000/5020 series control. A listing of the memory cards and their part numbers is shown below. Also shown are which memory cards are compatible with the different main boards associated with the 5000/5020 series control. On Okuma controls, the bubble memory capacity is usually referred to in bits and ram memory capacity is referred to in bytes. 1Mbit X 1 = 256Kbit X 4 = 128Kbyte

Main Board A911-1520 MB-IIB The maximum bubble memory capacity on the MB-IIB is 32 Mbits. A911-1509 MB-IIA The maximum bubble memory capacity for the MB-IIA is 32 Mbits. The 1220 card is sometimes referred to as 256 Kbit X 4. A911-1500 MB-II The maximum bubble memory capacity for the MB-II is 16 Mbits.

A911-1100 MB The maximum bubble memory capacity on the MB board is 16 Mbits. The MB board is sometimes referred to as the MB0 board.

Bubble Memory A911-1224 4 Mbit X 1 A911-1225 4 Mbit X 2 A911-1226 4 Mbit X 3 A911-1227 4 Mbit X 4

A911-1220 A911-1221 A911-1222 A911-1223 A911-1224 A911-1225 A911-1226 A911-1227 A911-1220 A911-1221 A911-1222 A911-1223

128 Kbyte 1 Mbit X 1 1 Mbit X 2 1 Mbit X 4 4 Mbit X 1 4 Mbit X 2 4 Mbit X 3 4 Mbit X 4 128 Kbyte 1 Mbit X 1 1 Mbit X 2 1 Mbit X 4

Ram Cards A911-1522 MC 11 .5 Mbyte A911-1523 MC 12 2 Mbyte The MB-IIB has no standard ram memory on it. The rams maximum capacity is 6 Mbytes. A911-1501 MC1-II .5 Mbyte A911-1505 MC5-II 1.5 Mbyte A911-1510 MC9 1 Mbyte The maximum ram capacity for the MB-IIA is 2 Mbytes. This board has .5 Mbytes of standard ram memory. A911-1501 MC1-II .5 Mbyte A911-1505 MC5-II 1.5 Mbyte A911-1510 MC9 1 Mbyte The MB II has .5 Mbytes of standard ram and a maximum capacity of 2Mbytes.

A911-1220 A911-1221 A911-1222 A911-1223

128 Kbyte 1 Mbit X 1 1 Mbit X 2 1 Mbit X 4

A911-1105 MC 5 384 Kbytes A911-1101 MC 1 128 Kbytes The MB has 128 Kbytes of standard ram and a maximum capacity of .5 Mbytes


Rev. 10-09-02

CONSTRUCTION

The following is an explanation of the different board configurations which can be found on Okuma machines with the OSP 5000 series control. Not all the boards are mentioned here, just the standard set of boards that are found with the particular main board. Main Board MB0 (128K of RAM)

MBII (.5 M of RAM) MBIIA (.5 M of RAM) Memory As mentioned in the previous table, the MBIIA can use any array bubble memory cards. RAM

MBIIB (no RAM)

MC1 (128 Kbytes of ram) MC5 (384 Kbytes of ram)

MC1-II (.5M) MC9 (1M) MC5-II (1.5M) Servo Control

MC 11 (.5M) MC 12 (2M)

AB0 (axis board)for LDU’s AC1 (axis card)

SVPII,IIB, or IIC

SVPIID

SVP0 (BDU’s) TB0

TB1 (for M/C), TB2 TB2-1, (flat panel) TB2C, TB2C-1 (VAC II)

Any array of 1megabit X 4 bubble memory sections

Any array of 4 megabit sections and new CMOS memory cards

SPC1 (axis card) SPC6 (VAC II & III)

I/O boards EC board for lathe ECP board for M/C

same ECPII

same ECPIIA

Video Control MC2(PTR & panel IF) MC4-1 (PTR & panel IF) MC4-2 (PTR & panel IF)

CRPII

CRPIIC CRP-9 (monographic)

Communication Boards MC2-II (PTR IF) FDC II (3.5” FDD) MC3 (RS-232C and FRP card (8” FDD to puncher IF) 3.5”FDD) FDC board (8” FDD) MC13 (RS-232C only) *FDC board could also be labeled FDO MC3 (Com and Puncher) FDC board (8” FDD)

Rev. 10-09-02


CONSTRUCTION

Main Card 13 (A911-1521) RS-232 card This card contains the RS-232-C interface and is mounted on the MB-IIB with the component sides of both boards facing each other. Tape readers, punchers, printers, PCs, and any other peripheral which conforms to the RS232-C standard can be connected via this interface. Main Card 15 (A911-1526)

Sub CPU card

This is an optional card on the OSP 5020M controls only. It incorporates a 32 bit double engine architecture. A microprocessor (M68020) and a math co-processor (M68881) for the Hi-speed/ Hi-Accuracy machining centers are the two engines on this card. This option is referred to as Hi²NC. Main Card 16 (A911-1516)

Sub CPU card

This card is standard equipment on the OSP 5020M controls. This card performs the multi-axis contouring functions for the machining centers. Main Card 17 (A911-1517)

Sub CPU card

This is an option card employed when the One-Touch 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 communication with the OSP 5000/5020 NC operation panel. It transmits the video signal to the NC operation panel for the CRT display. This board is comprised of a Character IF, a Color Graphic IF, and a Serial IF. The 1692 board is the standard board. The 1693 board is used if the TM-APT (Remote programming station) option is purchased with the machine. Character IF This interface is used to control the character display mode (half-size, normal size, and enlarged size). After being combined with the color-graphics IF video signals, the character IF signals are transmitted to the NC operation panel as video signals and the characters are displayed at the CRT. Color-Graphics IF The graphic controller provides a total of 4 color graphic screens. Graphic control is possible only by using the graphic controller. After being combined with the character IF video signal, the color graphic video signal is transmitted to the NC operation panel, with the color graphic signal then being displayed at the CRT. Okuma America Corporation 5-12

Rev. 10-09-02

CONSTRUCTION Serial IF The Serial IF is used for data communication between the CRP board and the NC operation panel. The CRP board transmits the LED indicator data and buzzer data to the NC operation panel. The NC operation panel in turn transmits the keyboard data and the switch data of the machine operation panel back to the CRP board. The status of the switches and lamps can be viewed at the Panel I/O screen in the Check Data function. CRP 9 (A911-1580)

CRT Processor board

This board has the same function as the CRPII-C board. The only difference is the CRP 9 board has no graphics support. It does not have the Color graphics IF. The CRP 9 board is standard on the OSP 500 control. SVP-IID

Servo Processor board

This board is used to control the brushless servo motors. The SVP board determines the axis speed and position. The SVP is equipped to handle one DA/AD, one pulse generator, one pulse handle, and six sensors. The three major signals that are computed by the SVP are RAPA, RCON, and RDIFF. RAPA is the actual axis position data coming from the absolute position encoder used on the axis servo motors. RCON is the computed 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 system. Up to 10 axes may be controlled by one OSP 5020 CNC. There are three versions of the SVP-IID board. The part number for the standard SVP board used on lathes is A911-1531. The part number for the standard SVP board used on machining centers is A911-1533. This board has no DA interface (IF). Machines with more than five axes use the SVP board part number A911-1531 along with the SVP board part number A911-1532. The 1532 board has an SPC5 card mounted to it which receives the clock signals from the SPC4 card. The SPC5 card is only used with the 1532 board. The DA IF generates a full scale +/- 10 volts analog signal which is used for spindle speed control. The AD IF is a 0 to 10 volts signal which is used to display the spindle load status at the CRT. The pulse generator IF is used for spindle speed and position feedback. The pulse handle IF is used for determining and storing the number of notches the pulse handle has moved. The six sensors are used for touch setter options. Prior to the design of the SVP-IID, the SVP-IIC was used in conjunction with the TB board. The TB board provided timing for the SVP as well as providing the DA signal for the spindle. These two functions have now been combined into the SVP-IID board. Rev. 10-09-02


CONSTRUCTION SPC1 (A911-1534)

Additional 1 axis card

This card contains one axis control, position encoder IF, and sensor IF. Up to 3 SPC1 cards may be mounted on an SVP IID. SPC2 (A911-1535)

Additional Pulse Handle card

This card contains two additional pulse handle circuits. This card is frequently used on Grinders. SPC3 (A911-1536)

Additional Pulse Generator and DA card

This card contains an additional pulse generator and DA IF. An example of where this could be used is on a machine with a sub-spindle. SPC4 (A911-1537)

Clock Driver card

When additional SVP-IID boards are used this card is used to transfer the clock signals from one board to the next. A ribbon (flat) cable is used to transfer these signals. SPC6 (A911-1538)

Fiber Optics card

This card is used when high-speed communications is needed. This card serves as an I/O card and has no CPU. The SPC6 is mounted on the SVP-IID board and is connected to a highprecision VAC unit by a fiber optic cable. EC Board (A911-1120)

Electrical 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, indicator lamps, and relays, etc. This board has 72 inputs and 40 outputs. Up to 6 EC boards can be added to the OSP 5020 CNC. The EC boards are labeled E0 to E5 and the address setting switch has to be set accordingly. This board is used on Lathes and Grinders. ECP Board IIA

Electrical Control Processor board

This is the Electrical Control board for the OSP 5020M controls. It is also used on some OSP 5020L controls that have special functions, such as robot or gantry loader systems. It contains a main processor with main memory and back-up memory. This board has a high-speed 16 bit microprocessor with a clock frequency of 15 MHz. This board has the following features: up to 3 DA channels, 2 channels for F-type encoders, EC bus IF. The main memory is a 128Kbyte D-RAM. This type of RAM is continually being refreshed to keep it from losing any data. The back-up memory is a 48Kbyte S-RAM. This type of RAM is a C-MOS type memory device whose contents are retained by a 3.6 V lithium battery. The backup memory is used to save tool location and position data. It also saves APC data. Okuma America Corporation 5-14

Rev. 10-09-02

CONSTRUCTION There are three versions of the ECP-IIA board. The ECP-IIA (A911-1542) has three DA channels, (A911-1547) has one DA channel, and (A911-1548) has no DA channel. The DA channels are for the D type servo drives and VAC I (spindle drive unit). The ECP board converts the spindle motor speed command into an analog voltage and sends it to the VAC. If a High-Precision VAC (VAC II & III) is used, this signal comes from the SVP board. The ECP board can handle two F-type encoders which provide the feedback signals from the EC controlled servo drives of the ATC and APC. The EC bus IF 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 and 32 outputs. ECP Card 3 (A911-1143)

Expansion card

This card provides an additional 2 channels for Pulse Generator interface. It also provides 4 additional inputs and 4 additional outputs. ECP Card 4-II (A911-1544)

Expansion card

This card provides an additional 3 channels for position encoders and 3 channels for DA interface. FDC II BOARD (A911-1703)

Floppy Disk Control board

This board is used exclusively for 3.5 inch FDD control. It has no RS-232C IF or printer IF.

Rev. 10-09-02

Floppy DiskSize 3.5"

Manufacturer

Model

Y.E. Data Co.

3.5"

Y.E. Data Co.

8"

Hitachi

YD-686C-1501C (1.0/1.6M dual-type) YD-702-6037 (1.0/2.0M dual-type) FDD412A


Guaranteed Signal Cable Length 4.5m Max. 0.5m Max. 6m Max.

CONSTRUCTION

RS Board (A911-125*)

RS-232C Interface board

This is a communication board with RS-232C protocol. It can have up to four channels. The last digit in the part number will coincide with the number of channels the board has. CCP Board (A911-1594)

Communication Control Processor board

This is a high-performance, serial communication board used with the DNC option. This board allows for high-precision, high-speed serial 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 level for RS-422 protocol. TCC-A (A911-1598) TCC-B (A911-1599)

Turret Control card

The TCC is used for high-speed turret indexing. A single TCC can control 2 turrets, using a hydraulic drive system. The TCC-A card has a built-in CPU along with 2 resolver IFs, 2 solenoid IFs, 2 contact IFs, and a local bus. The TCC-A is the main control card and the TCC-B is the valve control card. A learning function monitors the indexing position each time the turret indexes, with each subsequent indexing operation becoming more precise.


Rev. 10-09-02

CONSTRUCTION EC I/O Rack The EC I/O rack is external or separate from the OPUS control rack. This rack is found mostly on Okuma machining centers. This rack consist of a Driver/Receiver board and some individual I/O boards. The D/R board is also called the EC Control Unit and acts as the interface between the ECP-IIA board and the EC I/O rack. A power supply unit is housed on the I/O rack. This power supply provides all necessary power to the I/O boards. The I/O boards are equipped with signal status LEDs. DR (A911-1270)

Driver/Receiver board

I-PT (A911-1275)

Input board

This board has 32 inputs. Power supply to this board is +5 volts DC. O-AC1 (A911-1271)

AC SSR Output board

This board can handle a total of 8 output signals. This board has a maximum load of 1 amp. The LED turns on when a minimum of .1 amp is detected. Power 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. This board has a maximum load of 1.6 amps and the SSRs can handle 24 volts DC. It also has 8 output signals. O-TRP (A911-1268)

Power Transistor Output board

This board has a total of 16 output signals. The maximum load this board can handle is 2 amps. Power to this board is +5 volts DC. The transistors in this board can handle 24 volts DC. O-TR (A911-1273)

Transistor Output board

This board can handle a total of 32 output signals. This board is used for driving small indicating lamps. Power supplied to this board is +5 volts DC. The transistors on this board can handle 60 mA. O-TRH (A911-1278)

Transistor High Output board

This board is the same as the O-TR board except its transistors can handle 150 mA. This board is used to drive slightly larger indicating lamps. O-RR (A911-1274)

Reed Relay Output board

This board has 8 outputs. It is used for driving small power relays. Power delivered to this board is +5 and +12 volts DC.

Rev. 10-09-02


CONSTRUCTION Fieldnet I/O Unit The Fieldnet unit basically consist of two parts: I/O units (substation) and Fieldnet card (main station). Fiber optic cables are used to transmit data between the Fieldnet card and the I/O units. The Fieldnet card is the interface between the ECPIIA board and the machine side components. A block diagram is provided in figure 3. The following is a description of the boards associated with the Fieldnet I/O unit. FN Card (A911-1840)

Fieldnet card

This card acts as the interface between the Fieldnet I/O unit and the ECP IIA board. It is mounted on the ECPIIA board. It converts electrical signals to optical pulses that are sent out to the CCOP cards. The FN card also converts optical pulses it receives from the CCOP cards to electrical signals . The fieldnet card is referred to as the main station of the 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) Optical card

Communication Control

This card converts optical pulses it receives from the FN card to electrical signals needed to control the I/Os on the APC. It also converts electrical signals coming from the APC to optical pulses and send them to the FN card. This card is used exclusively for the APC. This card is referred to as a substation card. FCOM (A911-1846)

Terminal card

This card is used to connect the common terminals (N24A1) for solenoids and switches used to control the APC. CCOP2 (A911-1847) Optical card 2


This card combines a CCOP and an FIPC. This card is a substation capable of handling 32 inputs. CCOP3 (A911-1848) Optical card 3


This card is used when more than 32 inputs are needed. This extension card is connected to the CCOP2 substation. Only two CCOP3 cards can be connected to the CCOP2 card. If more than 96 inputs are needed, an additional CCOP2 card has to be added.


Rev. 10-09-02

CONSTRUCTION FIPC2 (A911-1843)

Fieldnet Input Photo Coupler card

This card has 16 inputs. This card is mounted to the CCOP card. This card reads the signals sent from various switches and relay contacts associated with the APC. FOHT (A911-1849)

Fieldnet Output High Transistor card

This is an output card capable of handling 32 outputs. This card is used for turning on LEDs 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 is used to turn on solenoids, lamps, and relays. One communication card (CCOP*) can handle up to four FOPT cards.

E4982-702-002-5M E4982-702-002-4M E4982-702-002-2M E9101-I06-001 E4982-702-003 E9101-I06-002 E9101-I06-003 E9101-I06-006

Rev. 10-09-02

Fiber Opitic Cable Part Numbers

(5 meters)Single Core (4 meters) Single Core (2 meters) Single Core (3 meters) Single Core (6 meters) Double Core (10 meters) Double Core (5 meters)Double Core (1 meter) Double Core


CONSTRUCTION

The following is information on how to troubleshoot a fiber optic cable. The first step in checking a fiber optic cable is to do the light check. Simply put a light source around one end of the fiber optic cable. If a light source is seen at the other end of the cable, the cable is good. There will be some cases where the 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 either good or bad. PASS Perfect

T h e o u t s id e ed g e is clean cut and a line that is less than 2/3 of the cir cumfer enceo f t he fiber itself.

A piece of the outside edge is broken but is le s s t h a n 1 / 5 o f t h e circumference o f t he fiber. FAIL

A piece of the outside edge is broken whick is mo re t ha n 1 /5 o f t he circumference o f t he fiber. T h e o u t s id e ed g e is clean cut but a line that is more than 2/3 of the circumference o f t he fiber itself.


Rev. 10-09-02

CONSTRUCTION

SERVO SYSTEMS This section will cover the different types of servo systems used on Okumas 5000/5020 series CNC machines. A servo system can be defined as a system for the automatic control of motion by means of feedback. The controlled motion can be for positioning and/or velocity (RPM). Okuma uses servo systems to control axis positioning and spindle revolution. Most of the servo systems on machines 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 Okuma machines.

AXIS DRIVES LDU 600 Some of the older lathes that use the early 5000L CNC control have the LDU 600 axis drive servo system. LDU stands for Linear Drive Unit. This is a thyristor control system which controls the rotational speed of a DC motor by regulating the firing angle of the thyristors. This system utilizes PPS technology where the input voltage is converted into a series of gate pulses with phase angles. PPS stands for Pulse Phase Shifting. A block diagram of the LDU 600 can be seen below.

Rev. 10-09-02


CONSTRUCTION

LDU TR Some of the older machining centers with 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 the pulse is proportional to the amplitude of the incoming DA signal at the pre-determined sampling time. A block diagram of the LDU TR system is shown below.


Rev. 10-09-02

CONSTRUCTION BDU The next axis drive servo system Okuma introduced was a flux vector Brushless Drive Unit. This servo system incorporates AC drive technology. This drive system also utilizes PWM technology. The DC power supply (DCPS) for this servo system can provide power for up to six drive amplifiers. One drive amplifier can handle one BL (brushless) motor. There are two types of BDU axis drives. The BDU-A which is used for axis positioning and the BDU-D which is used for magazine or table positioning on ATCs and APCs. The BDU-A system receives a digital command signal (RCON) from the SVP board. A block diagram can be seen in Figure 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 PCBs.

DCPS VH

SVP

VL

BDU/BLD TYPE A

BL MOTOR

ABSOLUTE POSITION ENCODER

SPEED AND POSITION FEEDBACK Fig. 5-5 The BDU-A and BDU-D use the same type of DCPS. This DC power supply converts the incoming 220 VAC to 300 VDC. There are seven LED indicators on the PCB of the DCPS. The following table shows what they mean. Description of LEDs on BDU style DCPS. LED PS MCON Dis LV HV PH Over Dis

Rev. 10-09-02

Color Green Green Yellow Red Red Red Red

Description Power is supplied to the DCPS. Relay MCS on DCPS is energized. The switching regulator is turning on and dumping VH to VL. Low voltage-The 300 VDC dropped below 220 VDC. High voltage was detected. The 300 VDC went above 430 VDC. A Phase Loss was detected in one of the 3 phases coming into the DCPS. The regeneration circuit was left on for too long.


CONSTRUCTION There are five check terminals on the lower right side of this same PCB board. The voltage levels that should be measured are shown below the individual check terminals. The middle terminal is the common and extreme caution should be taken when attaching a lead to this terminal because there is a 100K ohm 2 watt (green) resistor right above this terminal that has 220 VAC going through it! Figure 5-5A illustrates how close the resistor is to the check terminal.

The BDU type power supply has a Push Switch on it which is used to discharge the C5 capacitor before doing any work on it. Do not press this push button when power is still being supplied 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 SVC board on the BDU-A drive amplifier has ten LED indicators on it. The following table describes what they mean. Description of LEDs on the SVC board of a BDU-A type drive amplifier. LED PH Loss VR Loss IOCM IOCS LV HV OC SAT SAOP PSON

Color Red Red Red Red Red Red Yellow Yellow Yellow Green

Description Phase loss in 220 VAC supplied to the BDC board. The + or - 12 VDC and/or 5 VDC has dropped below specifications. Instantaneous Over Current in the Motor. Instantaneous Over Current in the Servo amplifier. Low Voltage High Voltage Over Current-Is triggered at 10 % of IOCM trigger level. Saturation-Drive amplifier received a heavy load. Sub Amp Operation-Turns off when machine ready signal is received. Power is supplied to drive amplifier.


Rev. 10-09-02

CONSTRUCTION

The BDU-D type axis drive as mentioned previously is used for controlling the ATC magazine and the APC pallets. The two big differences about this drive compared to the BDU-A is the command signal is an analog signal and comes from the ECP board. A block diagram of this servo system can be seen in Figure 5-6.

The BDU-D drive amplifier is composed of four parts: base unit, BDC board, SVC-1 board, and SVC-2 board. The SVC-1 board has eight LED indicators on it. The following table describes what they mean. Description of LEDs on SVC-1 board of a BDU-D drive amplifier. LED D0 D1 D2 APA MPR E8 CPU ALA

Color Yellow Yellow Yellow Red Red Red Green Red

Description Used for inspection purposes during assembly. Used for inspection purposes during assembly. Used for inspection purposes during assembly. This LED turns on whenever RCON and RAPA do not match. This LED turns on whenever the MPR data from the encoder is abnormal. This LED turns on whenever the E8 data from the encoder is abnormal. CPU is in normal operation. CPU is running. This Alarm LED turns on when the APA,MPR, or E8 LED turns on.

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 SVC board on the previous page for a description of these LEDs.

Rev. 10-09-02


CONSTRUCTION BLD The BLD type drive system is basically a 2nd generation of the BDU drive. Like the BDU drives, the BLD series has two types of drives, the BLD-A and BLD-D. The block diagram for these drives are the same as the BDU types and can be seen in Figure 5-5 and 5-6. The BLD type drives are physically smaller then the BDU type drives. It is possible to replace a BDU drive with a BLD type drive. The BLD type drives only have single phase 220 VAC going to their PCBs. On the BLD-A, the BDC and SVC boards are combined and called the SVC-A board. Like the BDU drives, the same DCPS is used for both BLD-A and BLD-D drives. The PCB on this power supply only has two LEDs on it. The following table shows what they mean. LED PSON OH

Color Green Red

Description Power is supplied to the DCPS. Over Heat-The regeneration circuit is staying on too long.

The following is a description of the LEDs found on the BLD-A type axis drive amplifier. Description of LEDs on BLD-A type drive amplifier. LED PSON SAOP MOL LV VR IOCS IOCM F.OL HV Amp Sat

Color Green Yellow Red Red Red Red Red Red Red Yellow

Description Power is supplied to the servo amp via connector 10. Sub Amp Operation-Turns off when machine ready signal is received. Motor Over Load Low Voltage The + or - 15VDC and/or the 5 VDC has dropped below specification. Instantaneous Over Current in the Servo amplifier. Instantaneous Over Current in the Motor. Fin Over Load-Heatsinks are getting too hot. High voltage was detected. The 300 VDC went above 430 VDC. Amp Saturation-Drive amplifier received a heavy load.


Rev. 10-09-02

CONSTRUCTION The BLD-D type drive amplifier is also composed of four parts: base unit, BDC board, SVC-1 board, and SVCA-2 board. The SVC-1 board has the same LED indicators as the SVC-1 board on a BDU-D drive amplifier. These LEDs are located on the lower left side of the SVC-1 board. In addition, the LEDs that are on the SVC-2 board on the BDU-D drive amplifier are incorporated into the SVC-1 board of the BLD-D except for the PSON LED which is still on the SVCA2 board. The following table describes these LEDs which are located on the lower right side of the SVC-1 board. Description of LEDs on right side of the SVC-1 board on a BLD-D type drive amplifier. LED SAOP.N IOCS IOCM VR F.OL M.OL LV HV

Color Yellow Red Red Red Red Red Red Red

Description Sub Amp Operation-Turns off when machine ready signal is received. Instantaneous Over Current in the Servo amplifier. Instantaneous Over Current in the Motor. The + or - 15VDC and/or the 5 VDC has dropped below specification. Fin Over Load-Heatsinks are getting too hot. Motor Over Load Low Voltage High voltage was detected. The 300 VDC went above 430 VDC.

There is a characteristics table for the D type servo drives (Servo Characterisitics Table). This table defines the characteristics of the D type drive amplifier. These characteristics vary from machine to machine and are dependent on the type or size of motor the drive amp is controlling. There are 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 the BLD-D drive amp when it is first installed in the field is the DA zero check. With the machine powered up and the axes at a standstill, check the voltage at check terminal DAC on the SVC # one board. Hook the common lead of the DVM to the COM check terminal and the positive to the DAC check terminal. Adjust the DA Zero potentiometer until the DVM reads 0.00 volts DC. Set VNFB and VLG to the value given in the Servo Characterisitics Table. The next adjustment that should be made is VCOM which needs to be adjusted until the correct DIFF value (on characteristics table) is seen on the CRT during rapid movement (GOO).

Rev. 10-09-02


CONSTRUCTION BLIID The latest type of axis drive servo system is the BLIID. This is the 3rd generation drive. This drive combines the DCPS and two drive amplifiers into one package. If a third axis is needed, a BLIID with one axis control is installed. The BLIID is not interchangeable with its predecessors. Like the 1st and 2nd generation drive amplifiers, there are two types of BLIIDs: BLIID-A and BLIID-D. The BLIID-A is composed of two parts: SVCII board and Power board. A block diagram of a BLIID-A can be seen in Figure 5-7. The following table describes the LED indicators on the SVCII board of a BLIID-A. Description of LEDs on BLIID-A type drive amplifier.

LED PON OP OCM OCS OV UV ROH BOH LOSS OCS OCM OP

Color Green Yellow Red Red Red Red Red Red Red Red Red Yellow

Description Power is supplied to the control board (SVCII). Sub Amp Operation of first axis-Turns off when machine ready signal is received. Instantaneous Over Current in the Motor of first axis. Instantaneous Over Current in the Servo amplifier of first axis. The inverter DC voltage (VH) is abnormally high. The inverter DC voltage (VH) is abnormally low. The regenerative discharge circuit is overheating. The power board is overheating. The control circuit voltage has dropped below specification. Instantaneous Over Current in the Servo amplifier of second axis. Instantaneous Over Current in the Motor of second axis. Sub Amp Operation of second axis-Turns off when machine ready signal is received.


Rev. 10-09-02

CONSTRUCTION BL-IID Type D The BL-IID type D is used for some ATC magazines and tool change arms, table positioning on some APCs and for crossrail positioning on some double column machining centers. This drive receives an analog command signal from the ECP board. This D type drive is not used on machines with the OSP 7000 control. The BL-IID D type is composed of four parts: power board, SVCII board, and two SVC-1 boards. Each SVC-1 board controls an axis. The SVC-1 board used on a BL-IID type D is the same as the SVC-1 board on the BLD-D. A block diagram of a BL-IID type D drive can be seen in figure 5-8. Position Feedback

R S T

ECPIIA

Speed and Position Feedback

SVC #1 (1 st axis)

BL Motor

Absolute Position Encoder

SVC #1 (2 st axis)

BL Motor

Absolute Position Encoder

Position Feedback

Speed and Position Feedback

Fig. 5-8 The BL-IID type D axis drive as mentioned previously is used for positioning some ATCs, APCs and crossrails. The two 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 drives. The SVC-1 board has eight LED indicators on it. The following table describes what they mean.

LED

Color

Description

D0 D1 D2 APA MPR E8 CPU ALA

Yellow Yellow Yellow Red Red Red Green Red

Used for inspection purposes during assembly. Used for inspection purposes during assembly. Used for inspection purposes during assembly. This LED turns on whenever RCON and RAPA do not match. This LED turns on whenever the MPR data from the encoder is abnormal. This LED turns on whenever the E8 data from the encoder is abnormal. CPU is in normal operation. CPU is running. This Alarm LED turns on when the APA, MPR, or E8 LED turns on.

Rev. 10-09-02


CONSTRUCTION

The following table describes the LEDs which are located on the lower right side of the SVC-1 board on BL-IID type D drive. LED

Color

Description

SAOP.N IOCS IOCM VR F.OL M.OL LV HV

Yellow Red Red Red Red Red Red Red

Sub Amp Operation - Turns off when machine ready signal is received. Instantaneous Over Current in the Servo amplifier. Instantaneous Over Current in the Motor. The + or – 15DC and/or the 5 VDC has dropped below specification. Fin Over Load-Heatsinks are getting too hot. Motor Over Load Low Voltage High voltage was detected. The 300 VDC went above 430 VDC.

There is characteristics table for the BL-IID type D servo drives. This table defines the characteristics of the BL-IID type D drive amplifier. These characteristics vary from machine to machine and are dependent on the type or size of motor the drive amp is controlling. There are three settings that should be looked at when a machine is first installed or a BL-IID type D drive amplifier is replaced. These are VLG, VNFB, and VCOM.

Before removing the drive unit. The BDU servo system has a capacitor discharge switch on the DCPS (power supply). If a BDU drive unit or power supply has to be removed, power off and then 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 have an LED that stays on if the capacitors are still charged. In most cases the LED on the BLD servo system will slowly extinguish as soon as you power off. On BL-IIDs the LED does not extinguish right away. If necessary the NFB breaker on the unit itself can be turned off to discharge the capacitors immediately. If the breaker is not turned off, it will take 5 or 10 minutes for the capacitors to discharge.


Rev. 10-09-02

CONSTRUCTION

In Okuma language, the BDU, BLD, and BLIID type A drives are referred to as NC controlled axis drives. These drive amplifiers are used for high accuracy positioning. They receive a digital command 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 magazine of the ATC, the pallets on the APC, and the crossrail on double column machining centers. The latest drive amplifiers (BLIIDs) use IGBT technology. These Insulated Gate Bipolar Transistors generate less heat. Hybrid ICs along with IGBTs have helped in reducing the physical size of drive amplifiers.

Rev. 10-09-02


CONSTRUCTION

Spindle Drives Some of the older lathes that use the early 5000L CNC control have the SDU 600 spindle drive servo system. SDU stands for Spindle Drive Unit. Like the LDU 600 axis drive, this is a thyristor control system that controls the rotational speed of a DC motor by regulating the firing angle of the thyristors. This system uses a tach generator as the feedback device for the motor and an optical pulse generator as the feedback device for the spindle. A block diagram of the SDU 600 can be seen below.


Rev. 10-09-02

CONSTRUCTION

Some Okuma machines are equipped with Fanuc spindle servo drives and motors. This servo system utilizes an optical encoder for the motor speed feedback and a pulse generator for spindle speed and position feedback. On machining centers, the command signal is generated by the ECP board. On 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 type of spindle servo system found on Okuma machines utilizes a Yaskawa drive amplifier and a Yaskawa spindle motor. This system uses a resolver for motor speed feedback and a pulse generator for spindle speed and positioning feedback. The command signal origination is the same as the Fanuc spindle servo system. See diagram below. The velocity command signals from the ECP and SVP boards are analog.

Rev. 10-09-02


CONSTRUCTION

In 1985, Okuma introduced its own VAC spindle drive amplifier. All the characteristics of this spindle servo system are basically the same as the Yaskawa system. The feedback system and 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 II, the command signal is generated by the SVP IID and converted from digital to optical pulses by the SPC6 card. The spindle speed and position feedback is sent to the VAC Card I (CN 13) where it is converted into optical pulses and sent back to the SPC6 card. This drive has a dark brown face plate.


Rev. 10-09-02

CONSTRUCTION

In 1994, Okuma introduced the VAC III. The VAC III is very similar to the VAC II except for its physical size. The VAC card I was incorporated into the VAC control board. The spindle speed and position feedback are sent to the VAC control board (CN 2) where it is converted into optical pulses and sent back to the SPC6 card. Like the BL IID axis drive amplifiers, the VAC III utilizes IGBTs and hybrid ICs which have helped in reducing the physical size of this latest Okuma spindle drive amplifier.

Diagnosing a spindle drive alarm. When the control receives an alarm signal from the spindle servo system, it generates a generic alarm which the control sends to the CRT. This A level alarm is number 110 on lathes and 109 on machining centers. If this generic SDU alarm appears on the CRT, refer to the appropriate maintenance manual to decipher the alarm condition. The VAC has three operation status LEDs labeled M1, M2, and M3 and thirteen numbered status LEDs on its control PCB. During normal operation, M1, M2, and M3 are off and the thirteen status LEDs show the status of the I/O signals on the VAC. In an alarm condition, the on/off condition of these status LEDs can mean different things depending on the on/off condition of the operation status LEDs (M1, M2, and M3). The signal assignment of the status LEDs can be determined by looking in the maintenance manual. The VAC II and VAC III spindle drive amplifiers do not use a generic SDU alarm. The A level alarms associated with VAC IIs and IIIs on lathes range from 1102 to 1142. On machining centers these alarms range from 300-335. These two latest types of spindle drive amplifiers also have two seven segment display LEDs which show an alarm number. Again, the meaning of these status LEDs and alarm numbers can be deciphered by looking in the proper maintenance manual.

Rev. 10-09-02


CONSTRUCTION

DC Brushless Motor Okuma has used Brushless Motors since the BDU drives were introduced in the early 80s. The information on the name plate of the motor is explained below.


Rev. 10-09-02

CONSTRUCTION

Checking BL Motors Demagnetization:

The following is a procedure on how to check a BL motor for demagnetization. Once the motor is off the machine, check the smoothness of the shaft when rotated by hand. It should be resistance free when the shaft is turned by hand. One way to check the magnet without a scope is to jumper across U and V, then rotate the shaft. An intermittent drag (resistance) should be felt as the shaft is rotated. A thump, thump sensation. Check U to W, and V to W with the same procedure. Next jumper all three (U, V and W) together, a constant drag should be felt as the shaft is rotated.

Megger Check Connect both leads of the megger across any two of the three terminals (U, V or W). If the megger indicates a short or an open, the motor is defective (2MÙ to 3MÙ is normal). With one lead connected to the case of the motor, an open should be indicated when the other lead is connected to U, V or W terminal (Check all three). Resistance Check Use the table on the next page to verify normal winding resistance on BL motors.

Rev. 10-09-02


CONSTRUCTION

Resistance Readings of BL Motors The following are common resistance readings found on the windings of the BL motors listed. These values were taken at an ambient temperature of 68° F; although the effects of rising temperature are generally small on the resistance reading in these motors, a slightly higher reading might be found then what is mentioned in this table.

BL Motor

Resistance reading across UV or W

BL Motor

Resistance reading across UV or W

BL-H10E-20T BL-180E-20T BL80E-20T

BL-H20E-20T BL-120E-20T

BL-MH101E-12S BL-MH101E-12SB BL-MH101E-20S BL-MH101E-20T BL-MH101E-20SB BL-MH301E-20SB BL-MH301E-12S BL-MH301E-12SB BL-MH301E-20S BL-MH301E-20T BL-H700E-10T BL-MS75E-20T BL-MS140E-20T

BL-MH201E-12S BL-MH201E-12SB BL-MH201E-20S BL-MH201E-20T BL-MH201E-20SB BL-MH201E-30T BL-MH401E-12S BL-MH401E-12SB

BL-MS50E-20T BL-MS125E-20T

BL-MS50E-30T BL-MS125E-30T BL-MS50E-30TB

SR series BL-S10E-30T BL-MS75E-30T BL-MS140E-30T


Rev. 10-09-02

CONSTRUCTION

Rev. 10-09-02


CONSTRUCTION

FEEDBACK DEVICES A CNC control needs some kind of feedback from its servo systems in order to control the machines axes accurately. A feedback device provides speed and positioning information. The following is a summary of the different types of feedback devices found on Okuma machines with the 5000 series control. A brief description of each type is also included. The early 5000 controls have DC drives as mentioned earlier in this section. The LDU 600 and LDU TR utilize a tachometer and a D6 absolute position encoder for axis speed and position feedback. The SDU 600 utilizes a tachometer and a pulse generator for spindle speed and position feedback. All the other Okuma axis drives which use the BL motor have an absolute position encoder (E,F,FB,or FC) for speed and position feedback. Some machines utilizes MPRs or Inductosyn transducers along with the absolute position encoder for high accuracy positioning. All of the Okuma AC spindle servo systems utilize a resolver and a pulse generator for speed and position feedback. The Fanuc spindle servo system is the 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 lathes have turrets that are driven by a BL motor which have an HC type absolute position encoder.

Tachometer Commonly referred to as a tachgenerator this type of device is used for velocity (speed) feedback. This device generates a DC voltage. On Okuma machines, the tachgenerator is used to monitor actual motor speed. The faster the DC motor turns the higher the DC voltage level. If the rotation direction is changed, so will the polarity of the voltage generated by the tachgenerator. Most tachgenerators are rated for a certain voltage level. For example, if a tachgenerator is rated at 7v/1000rpm, the voltage generated by the tachgenerator will be 7 vdc when the motor is turning at 1000 rpm, 14 vdc when the motor is turning at 2000 rpm and so on. This voltage signal should be a DC level, with very little noise or ripple. Most tachgenerators used on the Okuma axis drive motors are rated at 7 volts per 1000 rpm and 20 volts per 1000 rpm for the SDU 600. The voltage that the tachgenerator is rated at can be determined by looking at the characteristics sheet for the axis or spindle drive in question. Again, this type of feedback device is found on any machines with DC spindle drives.


Rev. 10-09-02

CONSTRUCTION

Absolute Position Encoder This Okuma patented device is used for axis speed and position feedback. The D6 type is only used on DC axis servo systems (LDUs). The axis servo systems which utilize the BL motor (BDU, BLD, or BLIID) use the E,F,FB, or FC type absolute position encoder. The E and F types are being phased out. If an E or F type is replaced, it is replaced with an FB or FC. The FC type absolute position encoder is the newest and is physically shorter (approx. 3/4 of an inch) then the older styles. Hence, the FB,F, or E types cannot take the place of an FC. The E, F, FB, and FC types are capable of making 2048 revolutions before turning over(back to zero). An HC type absolute position encoder has been developed for high speed turrets and rotary tables. The output shaft of the HC can turn 7200 revs before turning over. The absolute position encoder uses a multi-pole resolver (MPR) for lower digit positioning (.0001) along with pulse type heads for upper digit positioning (123.4560). The control sends a 5 kHz sine and cosine signal to the MPR in the absolute position encoder. The CNC control generates a clock signal (81.92 Mhz) which it compares to the phase offset between the sine signal and the MPR feedback signal. The control counts the number of clock pulses per phase shift and multiplies this number by the distance per pulse. 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 revolution. This The E8-1 rotor rotates one position for every 360° phase shift. This feedback signal is sent back to the OSP control. The parallel pulse signals from the pulse type heads are digitized inside the encoder and also sent back serially to the OSP control. The absolute position encoder is physically attached to the BL motor. In some cases this encoder is used on ATC magazines which are hydraulically driven. This encoder is referred to as an encoder with shaft. This encoder has a casing around it with a shaft sticking out where as the more common absolute position encoder has no casing around it and has a coupler that is mounted onto a shaft in the BL motor.

Procedure for Replacing Absolute Position Encoders Removing Encoder From Motor 1. Unscrew the four clamping bolts (M4 or M5) to remove the back cover of the motor. 2. Remove the cover and resin frame. It may not be easy to remove by hand due to the adhesion of packing. In this case, the cover can be removed by lightly hitting the cover with a soft hammer. Positively prohibit hitting it with a metallic hammer or hitting it hard with a soft hammer since the parts may be broken. 3. Disconnect the encoder input/output connector (ribbon cable) by pulling down the lock levers on both sides of the connector. 4. The encoder diaphragm is attached to the motor chassis by four special long head bolts. Remove these bolts to detach the encoder diaphragm from the chassis of the motor.

Rev. 10-09-02


CONSTRUCTION Removing the encoder from the motor shaft. The encoder input shaft and the motor shaft are joined by an M5 hexagon socket head bolt. There is a hole in the center of the encoders printed circuit board. The encoder can be removed from the motor shaft by inserting the long side of an M5 Allen wrench through this hole, inserting it into the head of the hexagon bolt. Insert a pipe into the short side of the wrench (or use a T handle wrench)and loosen the bolt. It might be necessary to secure the motor shaft so that it does not rotate while this bolt is being loosened. If there is a pulley attached to the motor shaft, for example, holding the pulley by hand will be sufficient to secure the motor shaft. When the pulley cannot be held by hand, take into consideration placing a prop between slide table and body. This completes the procedure for removing the Absolute Position Encoder. Installing the encoder to the motor (Basically, install the encoder in the reverse order of removal.) Installing the encoder to the motor shaft. Prepare and confirm the following items before installing 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 to the motor shaft, adjust the positional relationship of the encoder to the motor on the two following items. •

Align the motor shaft adjusting key slot and the encoder input shaft adjusting pin.

•

Align the diaphragm phase adjusting pin of encoder and the adjusting pin hole made in the motor flange. (The adjusting pin hole made in the motor flange is placed at the bottom right viewed from the encoder installing side.

Adjust the positional relationship of the motor shaft and encoder input shaft and lightly tighten the encoder input shaft M5 bolt with the allen wrench through the center of encoders printed circuit board. At this time, while the bolt is still loose, align the diaphragm phase adjusting pin of the encoder with the adjusting pin hole made in the motor flange. If the input shaft is tightened in the condition that the pin and hole are not aligned correctly, it will cause the diaphragm to be distorted, so that the encoder cannot be installed properly. Therefore, care should be taken to align the pin and hole. Remount the four special long head bolts to attach the encoder diaphragm to the chassis of the motor. Finally tighten the input shaft to 60kg/cm(854inch pounds).


Rev. 10-09-02

CONSTRUCTION Connecting the encoder input/output (ribbon cable) connector. Since this connector has a protruding portion to prevent an error during insertion, care should be paid to its insertion direction. (Insert the connector with its protruding portion pointed at the center (inside) of shaft. Turn the lock levers towards the inside. At this time, check for a clicking noise. If the connector is not inserted sufficiently, the clicking noise will not be heard or felt. Install the cover and resin frame The installation of the encoder is completed. At this point, refer to the Parameter section to redefine the Stroke End Limits and Zero Offsets. If the absolute position encoder is replaced on a machining center, only the Zero Offset has to be redefined.

MPR Some machines have an MPR (MultiPolar Resolver) mounted directly to the ballscrew. This MPR is the same as the MPR in the absolute position encoder. The MPR is used in conjunction with the absolute position encoder to provide greater accuracy. This resolver has eight poles; four sine poles and four cosine poles. The sine and cosine signals are generated by the OSP control. As the stator (located in the center of the eight poles) rotates, a feedback signal is generated. This feedback signal will be phase shifted up to 360 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 between the feedback and sine signals. There is a set number (163,840) of clock signals within a 360 degree phase shift. By knowing the distance the axis travels for each clock pulse, the control counts the number of clock pulses per 360 degree phase shift and multiplies the number by this set distance to determine how much the axis has traveled.

Inductosyn The bigger the machine, the longer the axis ballscrew. The longer the ballscrew , the more room there is for error due to heat expansion of the ballscrew. An inductosyn feedback system is a practical way of compensating for ballscrew growth. It is also used on machines requiring high accuracy positioning. An inductosyn feedback used in conjunction with the absolute position encoder enables the control to detect axis positioning in units of .1 microns. An inductosyn transducer is a high accuracy multi-pole position data device. There are linear and rotary inductosyns. The linear inductosyn uses an inductive scale that is attached to the table of the machine. A reference signal is sent to this scale. On the other side is the slider which has a sine and cosine pickup coil. As the slider is moved across the face of the scale, two signals are induced (sine & cosine) which are 90° out of phase. These two signals are sent to the preamp board where they are combined and sent back to the OSP control as the POS(position) signal.

Rev. 10-09-02


CONSTRUCTION

It is critical that the sine & cosine signals are 90 degrees out of phase. This can be checked by looking at CT1 and CT2 on the preamp board. The VR1 potentiometer on the pre-amp board is adjusted to get the desired POS signal. The desired signal is a steady sinewave anywhere from 6 to 12 Vpp at the POS check terminal. The POS signal is compared to the reference signal. Like the resolver, the control determines the phase offset between the POS and reference signals and calculates how much the axis has moved. Rotary inductosyn transducers work in the same way. Instead of a scale and slider you have a rotor and stator. Okuma uses inductosyn transducers mostly on machining centers. The data from the MPR and inductosyn feedback devices are used for positioning purposes.

VAC Resolver VAC spindle motors have a resolver mounted to it to determine actual motor speed. The control sends a sine and cosine signal to the stator. The rotor induces a feedback signal. This signal is 7812 hertz when the motor is stopped. The control determines the actual motor speed and direction by the frequency level of this 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 motor to spindle speed ratio can be determined by looking in the Operation and Maintenance manual.

Pulse Generators Okuma uses pulse generators for spindle speed and position feedback. One exception is machines with Fanuc spindle drives and spindle motors. The Fanuc motor uses an optical encoder for motor speed feedback. Encoder is a more common name for a pulse generator. Pulse generators on Okuma machines can be of the optical or magnetic type. The optical encoder (pulse generator) contains a glass or metallic disk with a number of lines etched on its surface. The outer row divides one revolution into a specific number of units. The inner row contains the marker pulse which indicates to the control where to start counting. Similar to an inductosyn transducer, two signals are generated (A and B phase) by the pulse generator which are 90° out of phase. These two signals are sent back to the control. The 90° phase difference for these two signals is how the control determines which direction the pulse generator is turning. The control monitors the frequency of these signals to determine how fast it is turning.


Rev. 10-09-02

CONSTRUCTION The magnetic pulse generator does basically the same thing. Instead of a light source, a rotary disc is attached to the spindle assembly. In the magnetic pulse generator are magnetic resistor devices which produce the A and B phase signals mentioned above. There is a marker pulse (Z phase) on this same rotary disc which is used to orient or position the spindle. On Okuma machine tools, the pulse generator is used 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 signals are used to monitor the spindle speed.

Rev. 10-09-02


CONSTRUCTION

The following table shows test points on the Okuma VACII or VACIII and the correct signal profile for the magnetic pulse generator

TCC Resolver This resolver is used for turret positioning. A sine and cosine signal is sent to it from the control and a feedback signal is sent back to determine the distance traveled. This type of resolver is seen mostly on the Okuma LR, LT, and Cadet M series lathes. The adjustment procedure for this feedback device can be seen in the maintenance manual for the specified machine.


Rev. 10-09-02

Notes

EL501

Notes

EL501

OSP 5000/5020 CONTROL DIAGNOSTICS ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501

CH .

DIAGNOSTICS

This section will cover the CRT displays (menus) which are often used for troubleshooting purposes. This section will also discuss the different types of alarms that are generated by the control. For the most part, three CRT display menus are used for diagnosing a machine problem. These modes can be accessed as long as the machine is in one of the three operation modes. They can be accessed by pressing the appropriate function key. ACTUAL POSIT BLOCK DATA CHECK DATA

F2 F4 F7

ACTUAL POSITION The Actual Position mode is used to show axis position data. In this mode, the actual position can be viewed in enlarged characters. The part program can be viewed along with the actual position data. The Load Display can be viewed in this 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 currently selected. If a program has been selected, the program name along with the block number currently active is also shown on the first line. XA ZA XB ZB

Actual X axis position data of A turret Actual Z axis position data of A turret Actual X axis position data of B turret {seen on two-saddle or} Actual Z axis position data of B turret { two-turret machines }

Pressing the Page up or Page down key will bring up the next menu. Pressing the A or B turret select keys will show the individual turret conditions. XA(B) Actual X axis position Xd Remaining distance to X axis target point ZA(B) Actual Z axis position Zd Remaining distance to Z axis target point Fx X axis feedrate in mm/min Fz Z axis feedrate in mm/min N Sequence number T Tool change command S Actual spindle speed in rpm CA Actual position of the spindle in degrees

Rev. 8-21-01


DIAGNOSTICS On this same menu, the program is shown on the right side of the CRT. The line identified by the arrow-up mark ( ) is the block being executed. The right arrow symbol ( ) indicates the blocks read and stored into the buffer. Pressing the Page Down key will show the machine state and load display menu. This page shows the following additional information. M V

Spindle gear range Surface cutting speed

The right side of the CRT shows the load status of the spindle, X and Z axes. Another menu in the Actual position mode shows the following information. Program Distance Shift Machine Tool Offset Pitch

Actual position data Remaining axis travel amount of the individual axes Shows the actual position value from the zero offset Shows the raw data coming from the absolute position encoder (RCON) Shows the active tool offset amounts Shows the pitch error compensation data when applicable

Machining Center The following is a description of the data shown in the individual menus of the Actual Position mode on a 5000/5020M series control. X X axis position Y Y axis position Z Z axis position B B axis position in degrees CO Work coordinate system number F Actual feedrate S Actual Spindle speed H= Tool length offset number D= Cutter radius compensation number O Currently active subprogram name N Sequence number (block number) Gear Spindle drive gear condition Touch Sensor Reverse display indicates the Touch Sensor is on. Touch Probe Reverse display indicates the Touch Probe is on. The Load Status display screen on the right side of this display screen shows the load conditions of the spindle and individual axes. Okuma America Corporation 6-2

Rev. 8-21-01

DIAGNOSTICS The following data is on a third page of the Actual Position mode. Local Coordinates The distance referenced to the origin of the local coordinate system Work Coords (APA) The distance referenced to the origin of the work Work Coords coordinate system Machine Coords The distance referenced to the machine origin (zero offset) Feedback Coords Raw data coming from the absolute position encoder (RAPA) Target Value The programmed destination point Distance Remaining The distance remaining to the programmed destination point Manual Shift Actual The manual shift amount of axis in the current operation Manual Shift Total The total manual shift amount Pitch Error Comp Shows the pitch error compensation at the present position A-Mtd This indicates the normal running operation 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 show the programmed conditions of the machine one block at a time. The operator can see what block of information is being, or will be executed. The following pertains to 5000/5020L controls.

Lathe

The CURRENT screen shows the program data of the currently executed block. The left side of the screen shows the G and M codes that are in effect. The following is a description of the data shown in the Block Data mode. X Target value of X axis Z Target value of Z axis Xa Target value of X axis in thread cutting mode Za Target value of Z axis in thread cutting mode Xb Starting point of thread cutting in X axis Zb Starting point of thread cutting in Z axis Xc Target point of thread cutting in X axis Zc Target point of thread cutting in Z axis I Programmed I value (radius of cut with respect to the X axis) K Programmed K value (radius of cut with respect to the Z axis)

Rev. 8-21-01


DIAGNOSTICS

Lathe

Ia End point of arc Ka End point of arc C Target value of C axis F Programmed F value (feedrate) Fa Programmed dwell time (G04) E Programmed E value (specifies the lead variation rate per pitch) S Programmed S value (spindle speed) T Tool number Ta Tool offset number Tx Tool offset value with respect to X axis Tz Tool offset value with respect to Z axis P Programmed P value (synchronization command for 4 axes cutting) W Target value for W axis SB Rotary tool command WA (on LT 15-M) N Sequence 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/min fz Feedrate of Z axis in mm/min fm Axis traverse speed in mm/min fr Axis traverse speed in mm/rev Sb Rotary tool spindle speed Om Main program name Pr Programmed number of main program repetitions Pe Actual number of programs executed BC Block counter (number of lines executed) Buffer Data Full Buffer register is full Empty Buffer register is empty The three other menus in the Block Data mode are: NEXT QUEUED READ

Displays the data to be executed after the CURRENT data. Displays the data to be executed after the NEXT data. Displays the latest block of data stored in the buffer register.


Rev. 8-21-01

DIAGNOSTICS

Machining Center The Block Data menus on 5000/5020M controls are very similar to the menus on lathe controls. The four menus are labeled: CURRENT, BUFFER, SECOND BUFFER, and THIRD BUFFER on machining center controls. On some controls the fourth menu is labeled like the lathe controls, READ. The block data soft key allows the operator to access the menus that show the programmed conditions of the machine one block at a time. The operator can see what block of information is being, or will be executed. The CURRENT screen shows the program data of the currently executed block. The left side of the screen shows the G and M codes that are in effect. The following is a description of the data shown in the Block Data mode on 5000/5020M controls. X Y Z B I J K F Fd Ft F1 S Tc Tn M H D Ha Np Hc

Target value of X axis Target value of Y axis Target value of Z axis Target value of B axis Programmed I value (radius of cut with respect to the X axis) Programmed J value (radius of cut with respect to the Y axis) Programmed K value (radius of cut with respect to the Z axis) Programmed F value (feedrate) Feedrate command value (0.001mm/12.8msec) Feedrate (F1 digit command option) Feedrate (F1 digit command option)(feedrate setting command) Programmed S value (spindle speed) Active tool number Next tool number M command value Tool offset number Cutter radius compensation number Work coordinate system number Hole number in coordinate calculation Work coordinate system number

The following data is shown on the right side of the screen no matter which menu is selected in the Block Data mode. Sr So fm fr Pr Pe Nr Ns

Rev. 8-21-01

Actual spindle speed Programmed spindle speed (overridden) Axis traverse speed in mm/min Axis traverse speed in mm/rev Programmed number of main program repetitions Actual number of programs executed Hole number for restart Sequence specified by the sequence stop Okuma America Corporation 6-5

DIAGNOSTICS

Cr Ce BC EMPTY EXIST

Number of times the subprogram is to be repeated Number of times the subprogram has been repeated Block counter (number of lines executed) No data in buffer register Data in buffer register

CHECK DATA The check data soft key allows the operator to check the individual I/Os of the machine. From a maintenance standpoint, the check data mode is one of the most useful functions on the control. This mode can be accessed while the machine is in any of its three operation modes. The different menus are accessed by pressing the Page up or Page down buttons. The following menus pertain to the 5000/5020L controls. Axis This menu displays data related to the various axes on the machine. The menus are labeled Axis (1),Axis (2), etc. A description of the data is provided. RDIF RAPA RCON RSKP1 RSKP2 RSKP3 RSKP4 QSPPC RSVPVAR1 RSVPVAR2 RD6PRD RIDSYND RLASER RTRTM RLOAD RHTRT

Following error of axis drives, difference between RCON and RAPA Actual position data coming from the absolute position encoder The calculated actual position data Coordinates of touch point (sensor 1) Coordinates of touch point (sensor 2) Coordinates of touch point (sensor 3) Coordinates of touch point (sensor 4) Spindle position (PG outputs 4096 pulses/rev) Servo processor variable Servo processor variable Output from a type F position encoder Inductosyn scale output data Output from a laser beam measuring device Turret rotation time during tool change (The time duration from the moment the turret is unclamped and reclamped during a tool change.) Displays the actual percentage of torque (load) on the servo motors Rotation speed of a high-speed turret in rpm


Rev. 8-21-01

DIAGNOSTICS

Lathe

EC I/Os

The EC input and output screens show the status of the machine related electrical devices. An example of an EC input would be a signal from a proximity switch or a pressure switch. A confirmation signal is usually an EC input that the control is looking for before it moves on to its next operation. An example of an EC output is a signal coming out of the control to turn on a light or energize a solenoid.

MDI OPERATION

N

CHECK DATA

no. 1 2 3 4 5 6 7 8 9 10 11 12

0

UNIT 1 INCH

EC INPUT 01: data bit7 TCLA 11101111 00000010 TLA8 TCLB 10010001 00000100 TLB8 SSP/ 11000110 CCC2 11100000 01011111 IN24 SBA/ 11111111 00111001 OIL/ 11111111 IDC/ 11001100 10000000

bit6 CPA/ TLA7 CHP2 TLB7 TSP/ CCC1 EOF/ SLA/ IILC

bit5 OPA/ TLA6 CHP1 TLB6 STR TSRT SCSF SA/ TLXF

bit4 OFA TLA5 SPL5 TLB5 RST TSLM ALM/ TMA/ TLZF

bit3 TLAC TLA4 SPL4 TLB4 DROP TSOA APA/ OHA/ SPZ

bit2 TLAB TLA3 SPL3 TLB3 SOA/ TSRF SEA/ OLA/ SPC

bit1 TLAA TLA2 SPL2 TLB2 BOF TSA2 LOA/ CBA/ CHOP

bit0 TLA9 TLA1 SPL1 TLB1 BOL TSA1 LA/ ECON CHCL

TSP/ MIN

DROP EXOR

DRCL CTIM

CDA/ TRST

CDM LOTC

MANS

ESIN ESUE

=

DATA INPUT

F1

ACTUAL POSIT

F2

Part Program

F3

BLOCK

CHECK DATA

DATA

F4

F5

F6

EXTEND

F7

EC Extend I/Os If a machine needs extra I/Os, an additional EC board is added to the control rack and these I/Os can be viewed in the Extended EC I/O menus.

Rev. 8-21-01


F8

DIAGNOSTICS

Panel I/Os

Lathe

Panel inputs and outputs are the I/Os pertaining to the machine operation panel and any option panels the machine might have. These I/O signals communicate with the control via the CRP board. A button being pressed on the machine operation panel is an example of a panel input. An LED being turned on is an example of a panel output signal. When an I/O signal is active (high or 1 or true), the signal name is shown in reverse display. Signal names with a forward slash (/) indicate these signals are normally active signals. This allows for quick diagnosis of a problem. Spec Code This menu shows which specification codes have been turned on. These codes activate software 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. If the maintenance person is not sure of the machine type he or she can look at this menu to verify the type. Machine Spec Code These codes indicate the type of hardware applications or upgrades that have been added to the machine. These modifications are usually done during assembly. Alarm Message List This page shows what type of alarms have occurred. CPU and P type alarms are not displayed on this menu. The latest alarm is added to the top (No. 1) and the last one (No. 12) is dropped. The list can be cleared by typing in ALMC and pressing the WRITE button. If an accurate time is needed of when an alarm occurred, reset the time. The time and date can be reset by going into the Edit Aux. mode and pressing the F1 function key for the date and the Extend function key (F8) for the time.


Rev. 8-21-01

DIAGNOSTICS

Machining Center The following information pertains to the 5000/5020M controls. The display screens in the Check Data mode are numbered. The individual menus can be accessed by pressing the Page up or Page down keys or by using the Search command. Press the soft key SEARCH (F5) and input the desired page number then press the WRITE key. Pressing the SEARCH key and immediately pressing the WRITE key will automatically bring up an index of the different menus in check data mode. Entering the number of the desired menu and pressing the WRITE key will access the desired menu. This is a faster way of accessing a certain menu in the check data mode. Panel I/Os These I/Os have the same function as the Panel I/Os on the lathe controls. NC I/Os These signals are used by the microprocessor on the main board to communicate with the rest of the machine. Because of the excellent diagnostic capability of the OSP control, these I/Os are rarely looked at when troubleshooting a problem. Machine I/Os These I/Os are equivalent to the EC I/Os on the lathe controls. These signals monitor switch conditions and control solenoids and lamps on the machine itself. Machine EX I/Os These signals are extended inputs and outputs that are used when extra Machine I/Os are needed. NC Spec Table These specification codes are used to turn on the software files needed for the particular machine the OSP control is controlling. MC Spec Table These specification codes are used to tell the control what type of hardware the machine has. The machines Management Data Card will show which codes should be turned on. These specification codes are labeled EC spec codes on the Management Data Card.

Rev. 8-21-01


DIAGNOSTICS NC Axis Data This menu displays the data related to the NC servo drives(X,Y,Z). One page shows the ODIF, RAPA, and load percentage of the individual axes in larger letters. The data displayed on the other page is shown below. RDIF ODIF RCON RAPA RSAPA

The difference between RCON and RAPA The RDIF when acc/dec is active The calculated position Position encoder output The raw data from the absolute position encoder when contact with the touch setter is detected. RSVPVAR1 Servo data RSVPVAR2 Servo data Machine Axis Data This menu 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 RCON RAPA RCOM

Difference between RCON and RAPA Calculated value Encoder output The commanded value

CA MG1 MG2 MG3 W

Carrier axis Magazine axis Magazine axis number 2 Magazine axis number 3 APC shifter arm axis

Pressing the Extend function key (F8) and then the Axis Change function key (F6) will show the W axis (pallet shifter arm) data. Alarm List This function is the same as the alarm list function on the lathe control. System Variables System variables are values the programmer can access through the control (NC) for checking the condition of the machine. For example, tool length and its diameter could be accessed through these variables. (VTOFH and VTOFD) Okuma America Corporation 6-10

Rev. 8-21-01

DIAGNOSTICS

ALARMS The OSP control is designed to make the most of its built-in computer capabilities. The selfdiagnostics function of the control constantly monitors the internal conditions of the CNC. The control also monitors external conditions, such as machine conditions, program data, and operator input conditions. When a fault is detected, the control displays an alarm or error message. Depending on the severity of the alarm, the machine can be brought to a complete stop immediately or the work process can be completed and then the machine will stop. When an alarm message is displayed, the alarm light on the NC operation panel turns on and the message is displayed on the 2nd line of the CRT. CPU alarms are displayed on the central portion of the CRT. A CPU alarm will display an access address. This access address indicates which board the CPU was trying to access when the alarm occurred. Of the 8 digits displayed, only the six digits from the right are used when looking up which board was being accessed. It is important to know what type of main board is in the control rack (MB, MBII, MBIIA, or MBIIB) when checking the access address tables. An error message is usually a warning that the operator 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. Machining centers also have a diagnostic message display function for ATC and APC operation. These message displays can be accessed by pressing the EXTEND (F8) function key and then the DIAGNOSIS (F5) function key. A description of these messages can be found in the Maintenance manual of the machine in question. When deciphering what an alarm means, it is useful to know how to count in Hexadecimal. It is also useful to know how to convert from hex to binary or octal. The following is a brief explanation of the different numbering systems used in computer technology. In decimal, each position to the left of the decimal point indicates an increased power of ten. In binary, base two, each place to the left signifies an increased power of two. The binary system represents all numbers as strings of the digits one and zero. Either digit represents a bit which is the smallest unit of information in a computer system. A nibble is four bits and a byte is eight bits. A word is two bytes (16 bits) and a long word is two words (32 bits). Any one of these units can occupy a single storage location and can be processed as a single unit by the computer. Hexadecimal is a base 16 numbering system. One Hexadecimal number represents four bits. Octal is a base eight numbering system. One Octal number represents three bits.

Rev. 8-21-01


DIAGNOSTICS The following is a chart showing the different numbering systems. Decimal

Binary

Hexidecimal

Octal

0

0000

0

0

1

0001

1

1

2

0010

2

2

3

0011

3

3

4

0100

4

4

5

0101

5

5

6

0110

6

6

7

0111

7

7

8

1000

8

10

9

1001

9

11

10

1010

A

12

11

1011

B

13

12

1100

C

14

13

1101

D

15

14

1110

E

16

15

1111

F

17

The following table gives an example of how to convert from one numbering system to another. The hexadecimal word CE is shown in the table below. This hex word converts to 11001110 in binary.

binary Hex

bit 7 2³ 8 1

bit 6 2² 4 1

bit 4 2º 1 0

bit 3 2³ 8 1

bit 2 2² 4 1

C bit 7 2¹ 1

Octal

bit 5 2¹ 2 0

bit 6 2º 1 3

bit 1 2¹ 2 1

bit 0 2º 1 0

E bit 5 2² 0

bit 4 2¹ 0 1

bit 3 2º 1

bit 2 2² 1


bit 1 2¹ 1 6

bit 0 2º 0

Rev. 8-21-01

DIAGNOSTICS The following table provides a description of the different types of alarms the control can generate. Alarm Type CPU Alarm

Machine Condition All machine functions stop.

Possible Operations No operations are possible.

Reset Procedure Power off and back on again.

CPU status is displayed on CRT. Same as above.

Changing display is not possible. Same as above.

Replace defective part if necessary. Same as above.

Changing displays is possible. Machine operation is not possible. Manual operations are possible.

Press the RESET button.

1–15

Alarm P 50–99 Alarm A 100–399 1100–1199 (L) Alarm B 400–899

Alarm # is displayed on CRT. All axes movement stops.

All commands in the currently executed block are completed.

W00–W***

MDI and Auto operation are not possible. The program being New programs executed will be cannot be executed completed. The until this alarm is control will stop the reset. machine when it sees an M02 or an M30. All machining All operations are functions work possible. normally.

Error Messages

Same as above.

Alarm C 900–999 1900–1907 (L)

Alarm D

Same as above.

2000–2999

Rev. 8-21-01




The alarm state is cleared by removing the cause of the alarm. Error messages are cleared as soon as another function is performed.

DIAGNOSTICS

The following is an example of what appears on the screen when a CPU level alarm occurs.

1-1 CPU - ALARM BUS ERROR (CYCLE OVER) CPU STATUS (M1,M0,PRT,CYO,MMB,DIA,LOP,ECC) = 10 FUNCTION CODE = 10A1 ACCESS ADDRESS = FFFF7E2A INSTRUCTION REGISTER = 10BC D0 = 434E3000 D4 = 20200004 A0 = FFFFDE90 A4 = 00888000 US = 000762EC

D1 = 00010600 D5 = 80000000 A1 = 00001D0C A5 = 00880000 SR = 00000004

D2 = 434E3000 D6 = 00000000 A2 = 000015B8 A6 = 00075B80 PC = 000235E0

D3 = 00000000 D6 = 00000000 A3 = 0000A128 A7 = 00072FFC

SBP MONITOR >

If this alarm occurs, look up the access address displayed on the screen in the access address tables at the end of this section. Make sure to verify which vintage Main Board is in the machine. There are three different tables, one for the MB-IIB, MB-II & IIA and 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 two left most digits are dropped when looking for the address.


Rev. 8-21-01

DIAGNOSTICS

Rev. 8-21-01


DIAGNOSTICS


Rev. 8-21-01

DIAGNOSTICS

Access Address (MB II B) Address

Board and Card

Address

Board and Card *1

000000 - 07FFFF 080000 - 0FFFFF 100000 - 17FFFF 180000 - 1FFFFF 200000 - 3FFFFF 400000 - 5FFFFF 600000 - 7FFFFF 800000 - 8FFFFF 900000 - AFFFFF 800000 - BOFFFF B10000 - CFFFFF D00000 - D1FFFF D20000 - D3FFFF D40000 - D5FFFF D60000 - D7FFFF D80000 - D9FFFF DA0000 - DBFFFF DC0000 - DDFFFF DE0000 - DFFFFF

Main card 11 (first) or 12 (first) Main card 11 (second) or 12 (first) Main card 11 (third) or 12 (first) Main card 12 (first) Main card 12 (second) or (first) Main card 12 (third) or (first) Not-used area Main card 10 Not-used area Main board IIB Not-used area CCP board or CCP card (eighth) CCP board or CCP card (seventh) CCP board or CCP card (sixth) CCP board or CCP card (fifth) CCP board or CCP card (fourth) CCP board or CCP card (third) CCP card (second) CCP board or CCP card (first)

F00000 - F1FFFF F20000 - F77FFF F78000 - F7BFFF F7C000 - F7CFFF F7D000 - F7DE3F F7DE40 - F7DE5F F7DE60 - F7DEF7 F7DE80 - F7DEBF F7DECO - F7DEDF F7DEE0 - F7DEFF F7DF00 - F7DF3F F7DF40 - F7DF5F F7DF60 - F7DF9F F7DFA0 - F7DFBF F7DFCO - F7DFFF F7E000 - F7FCFF F7FD00 - F7FFFF

ECP board II and Card 1-II (volatile RAM) Not-used area ECP board II and card 1-II (non-volatile RAM) Main card 2 (panel 1F) Not-used area ECP card 4-II ECP card 3 (PG, EC I/O) Main card 3 (RS232C) Main card 3 (puncher, centronics) ECP card 2 (EC I/O) Not-used area ECP card 4-II Not-used area Main card 2-II of main card 2, 4 Not-used area User-inhibited area ECP board II(D/A, R1C, encoder, ECBUS)

Address

Board and card *2

E00000 - E77FFF E78000 - E7FFFF E80000 - EFFFFF F00000 - F7FFFF F800000 - F87FFF F88000 - F8FFFF F90000 - F97FFF F98000 - F9FFFF FA0000 - FA7FFF FA8000 - FAFFFF FB0000 - FCFFFF FD0000 - FEFFFF FF0000 - FF7FFF FF8000 - FFCFFF FFD000 - FFDFFF FFE000 - FFFFF

Not-used area CRP board 9 ECP board II 9 (second) ECP board II (first) SVP board II (first) SVP board II (second) SVP board II (third) SVP board II (fourth) SVP board II (fifth) Timing board CRP board II Not used area System I/O area Not-used area Local I/O area Not-used area

FFD000 - FFD05F FFD060 - FFDO7F FFD080 - FFD09F FFD0A0 - FFD0BF FFD0C0 - FFD0FF FFD100 - FFDCFF FFDD00 - FFDE1F FFDE20 - FFDE5F FFDE60 - FFDE7F FFDE80 - FFDEBF FFDEC0 - FFDEDF FFDEE0 - FFDEEF FFDEF0 - FFDEFF FFDF00 - FFDFBF FFDFCO - FFDFEF FFDFF0 - FFDFFF

IJP card 3 IJP card 5 IJP card 6 Not-used area Main card 14 Not-used area Main board IIB Main card 7 Not-use area Main card 13 Main board IIB ECP card 2 (first) ECP card 2 (second) Main board IIB Main board IIB, bubble card Main board, bubble card, main card 6, BE board

Address * 1 Addresses of main cards are those when they are mounted on ECP board II. *2 Addresses of IJP cards and ECP cards are those when they are mounted on main board II. *3 Two digits from the left are ignored. Six digits from the right are effective.

Rev. 8-21-01

FF0000 - FF003F FF0040 - FF6FFF FF7000 - FF77FF FF7800 - FF78FF FF7900 - FF79FF FF7A00 - FF7AFF FF7B00 - FF7BFF FF7C00 - FF7CFF FF7D00 - FF7DFF FF7E00 - FF7E0C FF7E10 - FF7E1F FF7E20 - FF7E2F

Board and card CRT board (for 300 panel for OH) Not-used area ECBUS board RS board (sixth) RS BOARD (fifth) RS BOARD (fourth) RS BOARD (third) RS BOARD (second) RS BOARD (first) EC BOARD ( E0 ) EC BOARD ( E1 ) or EC Card EC BOARD ( E2 ) or EC Card

FF7E30 - FF7E3F

EC BOARD ( E3 ) or EC CARD

FF7E40 - FF7E7F FF7E80- FF7EBF FF7EC0 - FF7EDF FF7EE0 - FF7EFF FF7F00 - FF7F1F FF7F20 - FF7F3F FF7F40 - FF7F5F FF7F60 - FF7F7F FF7F80 - FF7F9F FF7FA0 - FF7FBF FF7FC0 - FF7FDF FF7FE0 - FF7FFF

HC BOARD (MOP unit) DATA BOARD (RS-232C 1ch.) DATA BOARD (RS-232C 2ch.) DATA BOARD or FDC BOARD DATA BOARD (printer: centronics) Graphic board IG or graphic board HDC board OSP500 CRP board Not-used area Not-used area (for DNC) OSP5 (remote display unit)


DIAGNOSTICS

Access Address (MB II, MB II A) Address

Board and Card

Address

Board and Card *1

000000 - 07FFFF 080000 - 0FFFFF 100000 - 1FFFFF 200000 - AFFFFF B00000 -B00007 B00008 - B03FFF B04000 - B07FFF B08000 - BFFFFF C00000 - E77FFF E78000 - E7FFFF E80000 - EFFFFF F00000 - F7FFFF F80000 - F87FFF F88000 - F8FFFF F90000 - F97FFF F98000 - F9FFFF FA0000 - FA7FFF

Main board II Main card 1-II or 5-II Main card 5-II Use-inhibited area Main board II Main board II Not-used area User inhibited area Not-used area OSP5 CRP board (RX-CRP board) ECP board II (second) ECP board II (first) or IJP board SVP board II (first) SVP board II (second) SVP board II (third) SVP board II (fourth) SVP board II (fifth)

F00000 - F1FFFF F20000 - F77FFF F78000 - F7BFFF F7C000 - F7CFFF F7D000 - F7DE3F F7DE40 - F7DE5F F7DE60 - F7DEF7 F7DE80 - F7DEBF F7DECO - F7DEDF F7DEE0 - F7DEFF F7DF00 - F7DF3F F7DF40 - F7DF5F F7DF60 - F7DF9F F7DFA0 - F7DFBF F7DFCO - F7DFFF F7E000 - F7FCFF F7FD00 - F7FFFF

ECP board II and Card 1-II (volatile RAM) Not-used area ECP board II and card 1-II (non-volatile RAM) Main card 2 (panel 1F) Not-used area ECP card 4-II ECP card 3 (PG, EC I/O) Main card 3 (RS232C) Main card 3 (puncher, centronics) ECP card 2 (EC I/O) Not-used area ECP card 4-II Not-used area Main card 2-II of main card 2, 4 Not-used area Use-inhibited area ECP board II(D/A, R1C, encoder, ECBUS)

FA8000 - FAFFFF FB0000 - FCFFFF

Timing board CRP board II

FD0000 - FEFFFF FF0000 - FF7FFF FF8000 - FFBFFF FFC000 - FFCFFF FFD000 - FFDFFF FFE000 - FFFFFF

Not-used area System I/O area AXIS board Operation panel for OSP5000M-G Local I/O area Not-used area

* 1 Addresses of main cards are those when they are mounted on ECP board II. *2 Addresses of IJP cards and ECP cards are those when they are mounted on main board II. *3 Two digits from the left are ignored. Six digits from the right are effective.

Address FF0000 - FF003F FF0040 - FF6FFF FF7000 - FF77FF FF7800 - FF78FF FF7900 - FF79FF FF7A00 - FF7AFF FF7B00 - FF7BFF FF7C00 - FF7CFF FF7D00 - FF7DFF FF7E00 - FF7E0C FF7E10 - FF7E1F FF7E20 - FF7E2F

Address

Board and Card *2

FFD000 - FFD05F FFD060 - FFDO7F FFD080 - FFD09F FFD0A0 - FFDCFF FFDD00 - FFDE1F FFDE20 - FFDE5F FFDE60 -FFDE7F FFDE80 - FFDEBF FFDEC0 - FFDEDF FFDEE0 - FFDEFF FFDF00 - FFDE1F FFDF20 - FFDF5F FFDF60 - FFDF9F FFDFA0 - FFDFBF FFDFCO - FFDFCF FFDFD0 - FFDFDF FFDFEO - FFDFEF FFDFF0 - FFDFFF

Board and Card CRT board (for 300 panel for OH) Not-used area ECBUS board RS board (sixth) RS BOARD (fifth) RS BOARD (fourth) RS BOARD (third) RS BOARD (second) RS BOARD (first) EC BOARD (first) EC BOARD (second) or EC Card EC BOARD (third) or EC Card

IJP card 3 (AD) IJP card 5 (DA, PHP, FEED-P) IJP card 6 (differential transformer) Not-used area Main board II (DMA) Main card (RS-422) Main board 2-II (general purpose switch) Main board 3 (RS232C) Main board 3 (FACIT punch) ECP card 2 Main board II (Main board) Main board II (RTC, PTM,DIA) Main card 2-II (PTR) or (Main card 2,4) Main board II (bubble card (first)) Main board II (bubble card (common)) Main board II (bubble card (second)) Main board II, Main card 6, BE board (bubble card) FF7E30 - FF7E3F EC BOARD (fourth) or EC CARD FF7E40 - FF7E7F HC BOARD (MOP unit) FF7E80- FF7EBF DATA BOARD (RS-232C 1ch.) FF7EC0 - FF7EDF DATA BOARD (RS-232C 2ch.) FF7EE0 - FF7EFF DATA BOARD or FDC BOARD FF7F00 - FF7F1F DATA BOARD (printer: centronics) FF7F20 - FF7F3F Graphic board IG or graphic board FF7F40 - FF7F5F HDC board FF7F60 - FF7F7F OSP500 CRP board FF7F80 - FF7F9F Not-used area FF7FA0 - FF7FBF Not-used area FF7FC0 - FF7FDF (for DNC) FF7FE0 - FF7FFF OSP5 (remote display unit)


Rev. 8-21-01

DIAGNOSTICS

Access Address (MB) (OSP5000) Address

Board and Card

Address

Board and Card *1

000000 - 07FFFF 020000 - 03FFFF 040000 - 07FFFF 080000 - EFFFFF F00000 - F3FFFF F40000 - F7FFFF F80000 - F87FFF F88000 - F8FFFF F90000 - F97FFF F98000 - F9FFFF FA0000 - FA7FFF FA8000 - FAFFFF FB0000 - FCFFFF FD0000 - FEFFFF FF0000 - FF7FFF FF8000 - FFBFFF FFC000 - FFCFFF

F40000 - F5FFFF F60000 - F77FFF F78000 - F79FFF F7A000 - F7BFFF F7C000 - F7CFFF F7D000 - F7DE3F F7DE40 - F7DE4F F7DE50 - F7DE5F F7DE60 - F7DEF7 F7DE80 - F7DEDF F7DEE0 - F7DEEF F7DEF0 - F7DEFF F7DF00 - F7DF9F F7DFA0 - F7DFBF F7DFCO - F7FCFF F7FD00 - F7FFFF

ECP board, ECP Card 1 Not-used area ECP board and ECP card 1 Not-used area Main card 2 Not-used area ECP card 4 Not used area ECP card 3 Main card 3 ECP card 2 (first) ECP card 2 (second) Not-used area Main card 2 Not-used area ECP board

FFD000 - FFDFFF

Main board Main card 1 or 5 Main card 5 User-inhibited area ECP board (second) ECP board (first) SVP board (first) SVP board (second) SVP board (third) SVP board II (fourth) SVP board II (fifth) Timing board CRP board (OSP500L)I Not-used area System I/O area AXIS board Main card 2 or main card 4 (OSP5000) Local I/O area

FFE000 - FFFFFF

Main board

Address FF8000 - FF9FFF FFA000 - FFBCFF FFBD00 - FFBD3F FFB040 - FFBD4F FFBD50 - FFBD5F FFBD60 - FFBD7F FFBD8F - FFBD9F FFBDA0 - FFBDBF FFBDC0 - FFBDDF FFBDE0 - FFBDFF FFBE00 - FFBFFF

Board and Card *2 AXIS board Not-used area AXIS board AXIS card 3 AXIS card 4 Not-used area AXIS card 6 AXIS card 1 AXIS board, Axis card, Axis card 4 AXIS board AXIS board, AXIS card 1

Board and Card *2 IJP card 3 IJP card 5 IJP card 6 Not-used area Main board Main card 7 Not-used area Main card 3 ECP card 2 (first) ECP card 2 (second) Main board Main card 2 or 4 Main board, bubble card Main board, Bubble card, Main card 6, BE board

Address

Board and Card

FF7E30 - FF7E3F

EC BOARD (fourth) or EC CARD

FF0000 - FF003F

CRT board (for 300 panel for OH) Not-used area ECBUS board RS board (sixth) RS BOARD (fifth) RS BOARD (fourth) RS BOARD (third) RS BOARD (second) EC BOARD (first) RS BOARD (first) EC BOARD (second) or EC Card EC BOARD (third) or EC Card

FF7E40 - FF7E7F

HC BOARD (MOP unit)

FF7E80- FF7EBF FF7EC0 - FF7EDF FF7EE0 - FF7EFF FF7F00 - FF7F1F FF7F20 - FF7F3F FF7F40 - FF7F5F FF7F60 - FF7F7F FF7F80 - FF7F9F FF7FA0 - FF7FBF FF7FC0 - FF7FDF

DATA BOARD (RS-232C 1ch.) DATA BOARD (RS-232C 2ch.) DATA BOARD or FDC BOARD DATA BOARD (printer: centronics) Graphic board IG or graphic board HDC board OSP500 CRP board Not-used area Not-used area (for DNC)

FF7FE0 - FF7FFF

OSP5 (remote display unit)

FF0040 - FF6FFF FF7000 - FF77FF FF7800 - FF78FF FF7900 - FF79FF FF7A00 - FF7AFF FF7B00 - FF7BFF FF7C00 - FF7CFF FF7D00 - FF7DFF FF7E00 - FF7EOF FF7E10 - FF7E1F FF7E20 - FF7E2F

Rev. 8-21-01

Address FFD000 - FFD05F FFD060 - FFDO7F FFD080 - FFD09F FFD0A0 - FFDCFF FFDD00 - FFDE1F FFDE20 - FFDE5F FFDE60 -FFDE7F FFDE80 - FFDEBF FFDEE0 - FFDEEF FFDEF0 - FFDEFF FFDF00 - FFDF9F FFDFA0 - FFDFBF FFDFC0 - FFDFEF FFDFF0 - FFDFFF


1 Addresses of main cards are those when they are mounted on ECP board. *2 Two digits from the left are ignored. Six digits from the right are effective.

DIAGNOSTICS The following is an example of how an alarm is displayed on the 2nd line of the CRT when an alarm occurs. The 1st group of asterisk on the left display the alarm number and axis code. This axis code indicates which axis the alarm is being generated 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 needs to be converted to a binary format to decipher the source of the problem. Look up the alarm in the Alarm & Error List manual for an explanation of the alarm.

MDI OPERATION ****-**

DATA INPUT

F1

ALARM-*

N Alarm Message

Alarm Code

XA ZA XB

20.0378 45.0496 25.0267

ZB

40.0845

ACTUAL POSIT

F2

Part Program

F3

0

BLOCK DATA

F4

CHECK DATA

SEARCH

F5


F6

F7

EXTEND

F8

Rev. 8-21-01

DIAGNOSTICS

Rev. 8-21-01


DIAGNOSTICS


Rev. 8-21-01

DIAGNOSTICS

MDI OPERATION 260- 1

DATA INPUT

F1

Rev. 8-21-01

Alarm-A

N Turret index control abnormal

A-turret

2

XA ZA XB

20.0378 45.0496 25.0267

ZB

40.0845

ACTUAL POSIT

F2

Part Program

F3

BLOCK DATA

SEARCH

F4

F5


0

CHECK DATA

F6

F7

EXTEND

F8

Lathe


Rev. 8-21-01

Lathe

Rev. 8-21-01


Lathe


Rev. 8-21-01

Lathe

Rev. 8-21-01


Lathe


Rev. 8-21-01

Lathe

Rev. 8-21-01


Lathe


Rev. 8-21-01

Lathe

Rev. 8-21-01


Machining Center


Rev. 8-21-01

Machining Center

Rev. 8-21-01


Machining Center


Rev. 8-21-01

Machining Center

Rev. 8-21-01


Machining Center


Rev. 8-21-01

Machining Center

Rev. 8-21-01


Machining Center


Rev. 8-21-01

Machining Center

Rev. 8-21-01


Machining Center


Rev. 8-21-01

Notes

EL501

Notes

EL501

OSP 5000/5020 CONTROL PARAMETERS ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501

CH .

Lathe Parameters are specific values that define the limits and capabilities of a machine. The control needs parameters to control the machine efficiently and safely. The parameter settings dictate the characteristics of a particular machine. Most of the parameters are factory set and should not be changed. However, some parameters do need to be changed from time to time and a record of parameters changed should be logged. An updated copy of all parameters should be copied to a diskette or other peripheral device. Parameters are accessed by pressing the Parameter mode button. The different parameter menus are accessed by pressing the Item up or Item down function keys. To access the next page of a particular menu press the Page up or Page down buttons. The following are the different types of parameters on Okuma lathes with the OSP 5000/5020L series controls. User Parameter User parameters contain the variable soft limits 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). The variable soft limits are designed to protect the chuck and tailstock from collision. The variable soft limits cannot be set outside the stroke end limits. When a stroke end limit is set, the corresponding variable soft limit is set to the same value and must be reset if need be. The actual tool path will not agree with the programmed tool path when cutting sharp corners. Droop data is used to eliminate or reduce these path tracing errors. Droop amount can be set from 0 to 1.000 mm.

Programed tool path Actual tool path Droop

Chuck/Tailstock These parameters tell the control whether chucking is ID or OD and whether the control is in chuck or tailstock work mode. If the tailstock is being used, it is referred to as center work. The chuck and tailstock can have a barrier built around them to further protect them from collisions. Parameter long word #s 18 to 23 are used along with these parameters to provide further protection. This chuck barrier data is ignored

during manual operation!!

Rev. 9-06-02


Lathe Common variable Common variables are programming variables that can be used from one program to another. They can be used in sub and main programs. System Parameter The system parameters are different for every machine. They define the characteristics of the individual axes. STROKE END LIMIT The stroke end limits (SELs) define the limits of the axis travel. With SELs the ballscrews are protected from overrun. SELs are also referred to as the machines soft limits. The machines are also protected with stroke end limit switches (hard limits). If any of these limit switches are actuated, the power to the machine, with exception of the control, is shut off and machine operation is brought to a complete stop.

SETTING STROKE END LIMITS Any time an Absolute Position Encoder is replaced, a belt is broken, or a motor is removed for inspection, the Stroke End Limits in the System 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. Press the MANUAL Mode key 2. Press F7 (CHECK DATA). If F7 does not show CHECK DATA, press F8 (EXTEND) until it does. 3. Press the CURSOR DOWN key until AXIS DATA is displayed. 4. Record the RAPA value for the axis under repair. 5. Press the PARAMETER Mode key. 6. Press the ITEM DOWN key until SYSTEM Parameter page 1 is displayed. 7. Use the CURSOR keys to highlight + STROKE END LIMIT for correct axis. 8. Add 20 inches (508 mm) to the number that was recorded in step 4. 9. Press F1 (SET), type the value calculated in step 8, and press the WRITE key. This will allow the axis to move far enough to trip the over travel switch in the positive direction. Okuma America Corporation 7-2

Rev. 9-06-02

Lathe

SETTING STROKE END LIMITS continued 10. Subtract 20 inches (508 mm) from the number that was recorded in step 4. 11. Use the CURSOR keys to highlight - STROKE END LIMIT for correct axis. 12. Press F1 (SET) key, type the value calculated in step 8, and press the WRITE key. This will allow the axis to move far enough to trip the over travel switch in the negative direction. 13. Press the MANUAL Mode key. 14. Press the axis button on the machine operation panel and Pulse Handle the axis in the positive direction until alarm 123 Stroke End Limit appears. 15. Record the RAPA signal for the present position and subtract .2 inches (5.08 mm) from this value. 16. Press the PARAMETER Mode key. 17. On page one of SYSTEM Parameter press F1 (SET) and enter this new value into the + Stroke End Limit in the System Parameters. This will allow you to jog the axis to the outer limit just before tripping the hard limit switch. 18. Turn the STROKE END LIMIT CANCEL switch on and move the axis off of the hard limit switch by using the Pulse Handle. 19. Turn the STROKE END LIMIT CANCEL switch off and repeat the above steps for the negative limit. Remember to add .2 inches (5.08 mm) to the RAPA value to set the SEL. 20. Select ZERO OFFSET Mode key, move the axis to the zero position, highlight the correct axis and press the CAL function key then the WRITE key. 21. Press the PARAMETER Mode key and note the value in the upper left corner of the screen next to BC. This is the backup counter, when the number that was noted reappears.backup is complete. NOTE: When the Stroke End Limits are reset the USER Parameters are assigned the same dimensions. The operator needs to reset the User Parameters.

Rev. 9-06-02


Lathe BACKLASH The backlash compensates for the lost motion on each axis when the axis feed direction is reversed. The set backlash value is subtracted from the value read by the absolute position encoder when the axis motion is reversed. Typically if the backlash setting is higher than .0015 inches, the ballscrew assembly needs to inspected for mechanical lost motion problems. PR ZERO OFFSET This is the zero offset for the absolute position encoder. This parameter can be used as the difference in position between the previously and currently mounted encoder. This parameter is usually set to zero. STROKE COMP Stroke compensation makes up for axis positioning error. The tolerance for every 100 mm of travel is 3 µm. If the positioning error is greater, the error is compensated by this parameter. The system parameters are factory set and recorded on the OSP control card that is sent out with every machine. If an encoder has to be changed, then these SELs and zero offsets will have to be reset. Rapid This parameter is on the second page of the system parameter menu. It is accessed by pressing the Page down button on the NC operation panel after accessing the system parameter menu. The control calculates RCON every 12.8 msec. The amount of travel it calculates is determined by this parameter. This Rapid parameter is referred to as the feed unit amount. The feed unit amount is expressed as µm/12.8 msec. Setting this value too high will generate alarm 101 CON velocity. Accel Rapid This parameter is referred to as the acceleration unit amount. The acceleration/ deceleration time is set by this parameter. When the axis starts moving, initially the feed unit amount is 0. The amount calculated is increased by the acceleration unit amount every 12.8 msec until the feed unit amount (Rapid) is reached. The same happens in reverse when an axis is commanded to stop. Every 12.8 msec the feed unit amount (Rapid) is reduced by the acceleration unit amount (Accel Rapid) until RCON reaches 0.


Rev. 9-06-02

Lathe CAUTION

If the acceleration unit amount (Accel Rapid) is changed to a value larger than the preset one, it could adversely affect motor and machine performance. Therefore, be sure to contact your Okuma distributor when a change of the acceleration unit amount is desired. Jog Feed This parameters sets the amount of travel calculated when the axis is moved manually. This parameter determines the axis travel speed in jog mode. Accel Jog Feed This parameter sets the amount of travel calculated when the axis accelerates and decelerates in jog mode. Torque This is the NC torque limiter parameter. The control will send out an alarm if the current level in the drive amplifier exceeds the level set in this parameter. The number in this parameter is 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 operator to move a tool from one station to another without having to change the tool offset. T This page shows the system parameters for the NC turret (T axis). The following parameters are shown on this page. Rapid Jog Feed

Rev. 9-06-02

Accel Rapid Accel Jog Feed

Torque Droop Data

PR Zero Offset Unclamp Timer


Lathe PR ZERO OFFSET This is the zero offset of the NC turret axis. If the encoder on a NC turret is changed, the PR ZERO OFFSET has to be reset. 1. With the machine on, verify at which station the turret in question is clamped. If the turret is not clamped, turn on the parameter which allows movement of the turret with the pulse handle.(OPB 40.2 for A turret, OPB 40.3 for B turret) Position the turret so it will clamp. 2. Press the PARAMETER key, item to the Turret Angle page. Note the angle that corresponds to the clamped station. 3. Press the item key until SYSTEM PARAMETERS can be viewed. Press the page key until T-AXIS can be viewed. 4. Make sure the correct turret is selected and move the cursor to PR ZERO OFFSET. 5. Press {F1}(SET) function key and press the WRITE key (this sets PR ZERO OFF SET to zero). 6. Press the {F5}(BACKUP) function key. 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} (BACKUP) function key. 10. Turn the power OFF and back ON. 11. Manualy index the turret, then index the turret to each position with MDI or AUTO. (the positions will be fine tuned if indexed in Auto mode ) Optional Parameter (long word) Optional parameter long words are parameters whose value can be higher than the decimal equivalent of a 16 bit word which can be 5 digits or higher in length. An example of this type of parameter would be for chuck and tailstock barrier dimensions. Optional Parameter (Word) Optional parameter word parameters are used to control miscellaneous operations such as chuck open/close and spindle start/stop. These parameter values can be up to 5 digits in length. Optional Parameter (Bit) These parameters control the turning on and off of functions needed for proper program operations. Inch/metric mode would be an example of this parameter. These parameter values are either a 1 or a 0. Spindle Control Parameter Okuma America Corporation 7-6

Rev. 9-06-02

Lathe

These parameters are used on high precision VACs (VACII & VACIII). The optimal values for these parameters are factory set and should not have to be changed. A description of these parameters can be found in the 10th edition of the operation manual. Some parameters are looked at only once when the control is powered 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 set. When this alarm occurs, check the number at the backup counter (BC=00) on the 4th line of the CRT and wait until this number appears again (approx. 3 min) before turning off the power. After powering up again, check that the parameters have been changed to the new settings. The alarm is cleared after the machine is powered up again. The backup counter counts in Hexadecimal from 00 to 4F on a continuous basis. The following are the different types of parameters on Okuma machining centers with OSP

Rev. 9-06-02


Machining Center 5000/5020M series controls. Common Variable These programming variables have the same function as the common variables on lathes, they are common to all programs. There are 128 on machining center controls and they are labeled VC1 to VC128. User Parameter PROG LIMIT These parameters contain the adjustable soft limits of the individual axes. In this menu, the Work Coordinate value (WRK) and the Machine Coordinate value (MC) can be seen. G60 OVERRUN AMT The G60 overrun amount is the amount of travel the axis will overshoot when unidirectional positioning is active. BACKLASH The backlash compensates for the lost motion on each axis when the axis feed direction is reversed. The set backlash value is subtracted from the value read by the absolute position encoder when the axis motion is reversed. CLAMP IN-P This parameter shows the clamp in-position width for each axis. If this parameter is set to 0, clamp in-position check is not carried out. If the axis moves out of this window an alarm will be displayed on the CRT. G/M Code Macro These parameters allow the programmer to call up macros which contain sub-programs that have specific functions. MC User Parameter (long word) These parameters are mostly positioning information about the APC or ATC. Up to 8 digits can be entered in these parameters. The decimal equivalent of these parameters can be 5 digits or higher.


Rev. 9-6-02

Machining Center MC User Parameter (word) These parameters are mostly for setting up the on/off time of the various functions that are required to be activated for some length of time. Parameter # 40 set to one will allow the operator to move an axis with the Pulse Handle in an alarm condition. MC User Parameter (bit) These parameters turn on or off various machining functions. For example, with parameter 9 bit 2 set to a 1, the operation end warning buzzer will not be turned off by the timer. MC System Parameter (long word) These parameters are used to control the various EC controlled axes. These parameters are used to control the ATC magazine and APC shifter arm positioning. The following MC System Parameter (long word) parameters are looked at often when troubleshooting an ATC or APC. 9 41 48

Shows the zero offset of the ATC magazine. Shows the zero offset of the APC shifter arm. Shows the orientation offset for high precision spindle drives ( VAC II & III )

MC System Parameter (Word) These parameters are mostly for the ATC and APC operation. The following parameters should be looked at and recorded whenever repairs or maintenance is being performed on the machine. 1 2 5 6 21

Sequence number the ATC is presently positioned at. Sequence number the APC is presently positioned at. Tool changer arm (TA) A. B. mode Pallet A.B. mode Spindle orientation offset for VACI.

NC Optional Parameter (long word) These parameters are CNC related parameters that the control needs to look at when machining parts. These parameters check for programming errors when certain functions are performed, i.e. cutter radius compensation. NC Optional Parameter (word)

Rev. 9-6-02


Machining Center

These parameters can use up to 5 digit values. Some of these parameters are used to set up the control for proper data transfer or file handling. NC Optional Parameter (bit) These parameters turn on or off various functions. The value setting on these parameters are 1 or 0. NC optional parameter bit No. 16 bit 7 has to be set to a 1 when checking the following parameters. System Parameters Pitch Error Compensation Machine System Parameter (long word) Machine System Parameter (word) NC Optional Parameter long word number 33 and up NC Optional Parameter word number 33 and 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 the NC optional parameter bit No. 3 bit 0 to bit 7 and No. 9 bit 0 and 1 can be confirmed on this display page. Although it is possible to change the unit system settings from this page, it is recommended that the changes be made at the NC optional parameter bit page. These settings are determined by a combination of data bits, changing the unit systems from the Input Unit System page might unexpectedly change other unit system settings. System Parameter TRAVEL LIMIT These parameters set the travel limits of the individual axes. These limits are very similar to the SELs on lathes. PITCH ERROR COMP These parameters specify the range for which pitch error compensation is used within the total travel range of the axis.


Rev. 9-6-02

Machining Center IN POSITION This parameter sets up the window of allowable positioning when executing exact stop checks. Once the axis is inside this window, the control moves on to the next block in the program. Setting this parameter to zero can cause the machine to hang up without an alarm indication. ZERO OFFSET This parameter sets the zero offset of the machine coordinate system for each axis. Figure 2 shows a description the zero offsets on machining centers.

Y axis (Z axis on horizontal m/c)

Machine Zero

Machine Table X axis

Zero Offset

Program Zero

Z axis

(Y axis on horizontal m/c)

Machine Table Fig. 2

Rev. 9-6-02


Machining Center

Setting Zero Offset

1. 2.

3. 4. 5. 6. 7.

Summary: When X,Y or Z axis motors are removed or encoders are changed, the Zero Offset Parameter must be reset first. Vertical Machining Center Press the MANUAL mode key. Move the machine to its Zero position on the table. The X and Y-axis Zero Position is at the center of the table. The Z-axis zero position is at the T value above the tabletop. Refer to Figure No. 39 on page 13 for some Machine Models. Press the Parameter key. Press the function key F6 or F7 ITEM until the NC Optional Parameter Bit screen appears. Press the cursor key to position the cursor at Bit 7 of Parameter No. 16. Press the function key F1 SET and key in 1 on the keyboard. Press the Write key. This enables the setting of the System Parameters.

PARAMETER SET

NC OPTIONAL PARAMETER (BIT)

NO. 1 2 3 4 5 6 7 8 9 10

7 0 0 0 0 1 0 0 0 0 0

6 1 1 1 0 0 0 0 0 0 0

5 0 0 0 0 0 0 0 0 0 0

ACT POSIT (WORK)

4 0 0 0 0 0 0 0 0 0 0

3 0 0 0 1 0 0 0 0 0 0

2 0 0 0 1 0 0 1 0 0 0

1 1 0 1 1 0 0 0 1 1 0

0 1 0 1 0 0 0 0 0 1 0

X 000.000

NO. 11 12 13 14 15 16

Y 000.000

7 0 0 0 0 0 0

6 0 0 0 0 0 0

5 0 0 0 0 0 0

4 0 0 0 0 0 0

3 0 0 0 0 0 0

Z 000.000

2 0 0 0 0 0 0

1 0 0 0 0 0 0

0 0 0 0 0 0 0

B 000.000

= SET

F1

SEARCH

F2

F3

F4

F5

ITEM

ITEM

EXTEND

F6

F7

F8


Rev. 9-6-02

Machining Center

Setting Zero Offset continued 8.

Press the function key F6 or F7 ITEM until the System Parameter page is displayed. Then PAGE down until the Parameter Set page is displayed. Ref Fig 38

9.

While the spindle is centered on the table for X and/or Y: (Z axis will need to be positioned the specific distance from the table as indicated in the chart of Fig 39) cursor down and over to the Zero Offset of the axis to be calculated, press the function key F3 CAL. Type 0 and press Write.

10.

Press the function key F8 EXTEND until BACKUP is diplayed and then press F7 BACKUP. Wait for the equal sign to appear.

11.

After the Zero Offset has been established for the Z axis, set the Tool Change Position for the Z axis. Follow the procedure on page 14.

PARAMETER SET * SYSTEM PARAMETER *

X P TRAVEL LIMIT 284.611 N TRAVEL LIMIT -284.611 P PITCH ERROR COMP. 281.000 N PITCH ERROR COMP. -281.000 IN POSITION 0.003 0.000 ZERO OFFSET 8036.726 IN POSITION (H) 0.020 ACT POSIT (MC)

X -48.844

1mm

Y 231.000 -231.000 231.000 -231.000 0.003 0.000 11675.278 0.020 Y 2.126

Z 452.270 -1.000 51.000 -1.000 0.003 0.000 6465.770 0.020 Z 448.125

=IF =IF =IF =

SET

F1

ADD

F2

CAL

F3

SEARCH

F4

ITEM

F5

F6

Figure 38

Rev. 9-6-02


ITEM

F7

[EXTEND]

F8

Machining Center Vertical Machining Center

P

N T X - AXIS N

Z - AXIS Y - AXIS N P

P

S t r o k e L im it S e t t in g s M A C H IN E T Y P E M C -4 V A M C -4 V A E M C -5 V A M C -5 V A H IG H C O L U M N M C -5 V A E M C -6 V M C -6 V H IG H C O L U M N M C -6 V E M C -6 V A M C -6 V A E M X- 4 5 V A E V A /V B M X 5 5 -V A B

L IM IT P O S IT IV E N E G A T IV E P O S IT IV E N E G A T IV E P O S IT IV E N E G A T IV E P O S IT IV E N E G A T IV E P O S IT IV E N E G A T IV E P O S IT IV E N E G A T IV E P O S IT IV E N E G A T IV E P O S IT IV E N E G A T IV E P O S IT IV E N E G A T IV E P O S IT IV E N E G A T IV E P O S IT IV E N E G A T IV E P O S IT IV E N E G A T IV E

X - A X IS 326 326 326 326 526 526 526 526 601 601 536 536 536 536 751 751 626 626 626 626 380 380 525 525

Y - A X IS 206 206 206 206 256 256 256 256 306 306 306 306 306 306 306 306 316 316 316 316 230 230 280 280

Z - A X IS 452 0 452 0 562 0 562 0 612 0 612 0 612 0 612 0 612 0 751 0 452 0 442 0

S P IN D L E D IS T A N C E ’ T ’ 200 385 200 415 200 440 440 170 230 230 160 160

Figure No.39


Rev. 9-6-02

Machining Center

Set Z axis ATC Home Position on Vertical Machining Center 1.

Select a tool with a flat on the bottom so you can indicate off the bottom of tool.

2.

Single step the ATC cycle and stop when the magazine pot moves to the down position.

3.

Set up an indicator and zero it to the bottom of the tool.

4.

Move the table and indicator away from the tool and single step the ATC back to sequence No. 1.

5.

Remove this tool and put it into the spindle.

6.

Move the Z-axis to the upper most position.

7.

Move the indicator to a position below the tool.

8.

With the pulse handle bring the Z-axis down so the indicator reads zero.

9.

Press the Parameter Push Button

10.

Item down with the F6 Item Down key to the SYSTEM PARAMETER screen.

11.

Page down to HOME POSITION screen 1 through 8.

12.

Highlight the Home Position No. 1 Z location.

13.

Press CAL F3 push button.

14.

Press Extend until the Back Up function is displayed.

SPINDLE MAGAZINE TOOL POT

0. 0

Rev. 9-6-02


0.0

Machining Center

Zero Offset Setting Procedure for Horizontal Machining Center Summary: When a axis motor is removed from the machine the Zero Offset Parameter must be reset. Press the Manual Mode button. Move the Axis to its Zero position. Y Axis is 50mm or 1.9685 from the top of the table. Z Axis is the face of the spindle to the face of the pallet.

Y Axis Travel

Y Axis Zero Offset

50 mm

Y = Zero

250 mm

100 mm Test Bar

Calculate Zero Offset to -200.00 mm This will be Actual Position of 200.000 mm 200 mm Actual Position of Y = 000.000


Rev. 9-6-02

Machining Center

Z Axis Zero Offset

Z= Zero

Z Axis Travel

PRECISION SQUARE

Rev. 9-6-02


Machining Center IN POSITION (H) Sets the in-position width used in positioning the individual axes when executing a tool change, pallet change, etc. When the axes are moving towards their individual home positions, the next block of data will be processed when the axes only have the amount specified in this parameter left to travel to reach their home position. SWL HD These four parameters set the position of the horizontal spindle when it is swiveled and becomes a vertical spindle. This type of spindle head is used on double column machines. (MCM) BARRIER (Y,Z) On horizontal machining centers, if both the Y and Z axes enter a certain area at the same time, they will interfere with each other. To prevent this, a barrier zone is set up so an alarm will occur if this happens. ENCODER OFFSET This parameter offsets the zero-cross point of the position encoder. HOME POSITION These parameters allow the user to machine multiple workpieces on a pallet or table. No. 1, 3, and 4 home positions are reserved for the ATC and APC. No. 1 shows the home position of the axes when a tool change is performed. No. 3 shows the home positions when the A pallet is being changed. No. 4 shows the home positions when the B pallet is being changed. HOME POSITION MOVEMENT ORDER Sets up the order in which the axes will move. For example, when a tool change is performed on a vertical machining center, the Z axis has to move to position first. The setting range is 0 to 3 with 0 meaning no movement and 1st, 2nd, and 3rd setting the order in which the axes will move. INDUCTOSYN OFFSET This parameter data is used to align the phase of the feedback signal of the inductosyn or MPR feedback device with the absolute position encoder signal.


Rev. 9-6-02

Machining Center

PITCH COMP SPAN. This data specifies the distance between sets of pitch points for setting the pitch error compensation data. PITCH POINT This parameter sets the total number of pitch points for each axis. PITCH ERROR COMPENSATION The ball screws each have their own pitch-to-pitch errors. This set of parameters compensate for those errors. To see the pitch error compensation data for the other axes, press the axis change function key (F5). NC HOUR METER The NC Hour Meter parameter accumulates the following hours and displays them on the CRT screen. POWER ON TIME Accumulates the amount of time that power is supplied to the NC NC RUNNING TIME Records the amount of time the NC is running (RUN light is on). SPINDLE REVOLUTION TIME Records the amount of time the spindle has been rotating. CUTTING TIME Records the amount of time the cutting feedrates are fed to the axes. The last three parameters mentioned will not record the time when the Machine Lock mode is on.

Rev. 9-6-02


Machining Center

EXTERNAL INPUT TIME Records the amount of time the external input signal is on. These timers can be preset so when the COUNT data exceeds the SET value, a C level alarm will show up on the CRT. NC WORK COUNTER Pressing the PAGE key will display this screen (when at NC Hour Meter parameter 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 related data that are set at the factory. These parameters should not be changed unless requested by Okuma. On machining centers, the backup counter is not shown. Data can be backed up immediately by pressing the extend key (F8) then the backup key (F7). It is recommended that this procedure be done every time a parameter is changed. Incidentally on Okuma Grinders, the backup occurs as soon as the WRITE key is pressed.


Rev. 9-6-02

Notes

EL501

Notes

EL501

OSP 5000/5020 CONTROL SOFTWARE ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501

CH .

SOFTWARE This section will cover software related functions. In this section ∅ refers to the number zero and O or o refers to the letter O. The Management Data Card will be discussed in this section. The software loading procedures will also be discussed along with parameter backup procedures. Every Okuma machine comes with its own Management Data Card (MDC). This sheet of paper is very useful when troubleshooting or diagnosing a problem. The MDC shows which software files should be in the memory of the machine. The specification codes on the MDC show which options have been purchased with the machine. The hardware for the machine is also shown. The drawing numbers for the electrical schematics are also shown on most MDCs. Japanese built lathes, some grinders, and the American built Cadet (LNC 8) do not show the drawing number for the machines electrical schematics. The drawing number for the schematics of these machines can be found on the machines identification plate (nameplate). Every machines memory is divided into two sections (directories): BB∅ and BB1. The BB0 directory is for the system software files and the BB1 directory is for part programs. Most 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: The A1 diskette (NC software), the A2 diskette (EC software), and the B diskette (parameter data). All the software files in the BB∅ directory have to match what is on the diskette label and the MDC. The only two exceptions are the BIN file and the MEU file (M/C). The BIN file is used to initialize the memory in the machine. It is erased from memory after it has initialized the memory. The data in the MEU file on machining centers is stored in the RAM of the ECP board. This file is not seen in the BB0: directory. The following describes the different methods of saving files on lathes. PIP

This function is accessed by going into EDIT AUX mode. This function is used to transfer Part Programs. (BB1 files)

DATA PIP

This function is used to transfer Parameters, Offsets, and Tool Data etc. It is also accessed by going into EDIT AUX mode.

Both use the CN0 (RS - 232C) and/or FD∅ (Floppy Disk Drive) ports. All parameter data is backed up to a file named A.TOP. The FDC (Floppy Disk Controller) board and the disk drive is needed to load the system software files.

The following describes the different methods of saving files on Machining Centers. PIP

Rev. 8-21-01

This function is accessed by going into EDIT AUX mode. This function is only used to transfer Part Programs. (BB1 files) Okuma America Corporation 8-1

SOFTWARE The utility disk (D Disk) is needed to back up(save to a diskette) Parameter, Offsets, and Tool Data etc. The D diskette is not needed to reload data. With software version 709BF and higher, the Punch/Read function can be used to reload Parameter, Offsets, and Tool Data etc. To find out what software version the machine has, look at the MAA file in the BB∅ Directory. With this version (709BF) and higher, all parameter data can be transferred through a default file named A.TOP. PUNCH /READ

on machining centers the Punch/Read function is accessed by going into Parameter mode.

The FDC (Floppy Disk Drive) is needed to load 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 to be reloaded. It is possible to load just the B diskette if faulty parameter data is suspected.

Initializing a diskette When the Okuma disk drive is used, the diskette has to be formatted (initialized) to the OSP format. To initialize a diskette do the following: 1. Insert a new diskette into the floppy disk drive. 2. Press EDIT AUX mode key. 3. Press the EXTEND function key (F8) once. 4. Press the INIT function key (F2), the CRT will display: =IN 5. Type in FDÆ: press the WRITE key, the CRT will display: initialize OK (Y/N)! If nothing is typed in and the WRITE key is pressed the memory for the part programs will be erased because BB1 is the default! 6. Type in Y and press WRITE , the CRT will display: formatting (Y/N)! Okuma America Corporation 8-2

Rev. 8-21-01

SOFTWARE 7. Type in Y and press Write , the CRT will display: format (2DD-72∅K=∅,2HD-1.44M=1)! 8. Type in a 1 or ∅ depending on the type of diskette you have and press the Write key. In most cases, the 1.44M is used. When the equal (=) sign appears, formatting is completed.

Backing Up Part Programs 9. The control should be put in metric mode (NC optional parameter bit number three bit zero set to a zero) Go into EDIT/AUX mode and press F3 to access the PIP function. Press the COPY function key and key in BB1:*.*,FDÆ: and press the WRITE key. This copies all the files in BB1: to the diskette.(@ > Press PIP 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 know how old the data is on the diskette. When the parameters are copied to a peripheral device the control automatically names the file A.TOP. The following is a procedure on how to back up the parameters (A.TOP file) on a lathe. 1. Go into Edit Aux mode. 2. Go into Data Pip menu. (Press F8 twice then F5) 3. Go into Output. (Press F2) 4. At the cursor (> op), {See NOTE}. type CNÆ: if using the RS 232 port or type FDÆ: if using a floppy disk drive then press Write (enter) The CRT will display: output data is? ! 5. If the Write key is pressed at this time, the file automatically gets named A.TOP. When the cursor (>) appears at the bottom of the screen, the backup is complete.Press D-PIP Quit.

Rev. 8-21-01


Lathe NOTE: The A.TOP file can be named something else by inputting a new name before pressing the Write key in STEP 4. The file extension (.TOP) will automatically get added to the new file name. For two turret machines, it is suggested that the parameters for each turret be saved separately. For example, typing in FDÆ:UP.TOP;A, will save all parameters pertaining to the upper turret to a file called UP.TOP. If ;B is entered after the filename, all parameters pertaining to the lower turret would be sent to the output device.(Be sure tochange the file name.) Special Notes for W-axis and LT machines. There are two parameters that relate to interference distances on LT and W-axis 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 machines Optional Parameter Long Word # 53 How to manually set this data. 1. Measure the physical distance between the spindle interference points. (spindle nose B to spindle nose R). i.e. 500 mm is measured 2. SET 500,000 as the data for O.P.L.W. # 53. (Can only set one time.) 3. Add -460,000 to this value to bring it down to 40,000. At this point the spindles should be moveable. 4. Add small positive values until the desired interference distance is reached. (i.e. 200000 = 2.000) (Setting range is 40000 - 9999999) W-axis machines Do the same procedure for the W-axis interference distance with the exceptions of set 100,000 at step #2 and add 100,000 at step #3(on W-axis this value can be brought to zero). The data for the W-axis interference is entered in O.P.L.W. # 45.


Rev. 8-21-01

Machining Center The following describes how to backup parameters through the A.TOP file on machining centers with software version 709BF and higher: MAKE SURE ATC & APC ARE AT SEQUENCE # 1. 1. Go into Parameter mode. 2. Set NC optional parameter bit number 16.7 to a 1 and 3.∅ & 9.∅ to a ∅. 3. Press Extend. (F8) then press Punch (F2). 4. At the cursor (=PU), type CNÆ: if using the RS 232 port or type FDÆ: if using a floppy disk drive then press Write (enter). The CRT will display: Please input message! At this point you can type in a message, i.e. machine and serial number this parameter file belongs to or name of the particular parameters being backed up. Press the Write key. (It 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 files. The following table displays the menu shown. The individual files can be saved or all of them at once. To save one particular file type in the number and press the Write key. To save all the files type in the first file number (1∅∅) then a dash (-) and then the last file number and press the Write key.

1∅∅ 2∅∅ 21∅ 22∅ 23∅ 3∅∅ 4∅∅ 41∅ 6∅∅

Zero Offsets Tool Length Offsets Cutter Radius Compensation Tool Management No. Tool Management Data Common Variable System Parameters User Parameters Pitch Error Compensation

7∅∅ 71∅ 72∅ 8∅∅ 81∅ 82∅ 83∅ 84∅

Optional Parameter Long Word Optional Parameter Word Optional Parameter Bit MC User Parameter Long Word MC System Parameter Long Word MC User Parameter Word MC System Parameter Word MC User Parameter Bit

(Press Page Down to view all of the menu.)

Rev. 8-21-01


Lathe 6. When the equal sign (=) appears at the bottom of the screen, the backup procedure is complete.

Reloading The Parameters LATHES To reload the parameters on a lathe do the following: 1. Go into Edit Aux mode. 2. Go into Data Pip menu. (Press F8 twice then F5) 3. Go into Input. (Press F1) 4. At the cursor (> IN), type CNÆ: if using the RS 232 port or type FDÆ: if using a floppy disk drive; type the file name if A.TOP is not used, then press the WRITE key(enter). When the cursor (>) reappears at the bottom of the CRT, press Back Up key or wait for BC to count around, turn power off. Then reload part programs by using the COPY key and type FD∅:*.MIN,BB1: WRITE , when the = sign appears, the loading procedure is completed. If an alarm occurs when reloading the A.TOP file, it will show which line in the A.TOP file is causing the alarm. Make a note of this data, i.e. [P1/A]N1X250.000Z250.00. In this example, the P1 represents a group of parameters. The A represents 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 above and type in UP.TOP instead of *.MIN. Press PIP QUIT (F4) to get out of the PIP function. To edit the file, press the Edit function key (F4) and enter *.*. Cursor down to the file UP.TOP and press the WRITE key. You can cursor down to the line in question or use the FIND command to locate the line to be edited. To locate the line via the FIND command for the example above, press the FIND (F1) function key and type in /P1/ and press WRITE. Position the cursor on the line in question and press the LINE DELETE function key. Once the line is located delete all the characters on that line. Once this is done, re-copy the file back to the diskette. Rename the file when you copy it back to the floppy and keep the original file. To do this, type in BB1:UP.TOP,FDÆ:U.TOP when the file is copied back to the diskette. This will rename the file U.TOP. Once this is done, repeat the procedure to reload the parameters to see if everything loads up properly. Remember to reload the edited file and not the original ?.TOP.


Rev. 8-21-01

Lathe

Rev. 8-21-01

Ref. 3290-E Special Functions


Lathe



Rev. 8-21-01

Lathe

Rev. 8-21-01



Lathe



Rev. 8-21-01

Lathe

Rev. 8-21-01



Lathe



Rev. 8-21-01

Lathe

Rev. 8-21-01



Lathe



Rev. 8-21-01

Lathe

Rev. 8-21-01



Lathe



Rev. 8-21-01

Lathe

MACHINING CENTERS To reload the parameters on a machining center with software file 709BF and higher do the following with the machine in E STOP: 1. Go into Parameter mode. Set NC Optional Parameter Bit number 16.7 to 1and, 3. ∅ and 9. ∅ to ∅. 2. Go into Extend. (Press F8) 3. Go into Read. (Press F1) 4. At the cursor (R _), type CNÆ: if using the RS 232 port or type FDÆ: if using a floppy disk drive then press Write (enter). The CRT will display: Message (***********) Read Continuing?(Y/N) 5. Type in Y and press the Write key. When the cursor(>) appears, the load procedure is finished. v Check MC System Parameter Long Word 9,41 & 48 v Check MC System Parameter Word 1,2,5,6,21 The cable configuration from the OSP control to various peripherals is shown in the Special Functions Manual.

Loading Software The following is a procedure on how to load the system software files on an Okuma lathe or machining center. 1. Compare the software files in the BB∅ directory with the files on the A diskette. This will insure that the correct software files for the machine in question are about to be loaded. 2. Compare the spec codes in the machine to the spec codes in the Management Data Card. 3. Load Mode On (1). This switch is located in the control cabinet or in the Tape Reader Box. 4. Press System Reset, CRT displays:

Rev. 8-21-01


SOFTWARE Control Floppy Loading Wait 5. Insert A diskette into floppy disk drive. 6. Press Load Start The CRT will display: Control Floppy Loading Start The files being loaded will be displayed. 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 diskette, load it at this time. When the following appears again move on the step 8. Control Floppy Loading Finish (or End) Control Floppy Loading Wait 8. Turn the Load Mode switch Off. 9. Press the System Reset switch. 10. Re-load the parameters using the parameter loading procedure.


Rev. 8-21-01

Machining Center 5020M D-Disk Procedure The following is a step by step procedure to back up the B diskette using the utility (D) diskette. All parameter backup files (.PBU) should be saved except for the MSU and MVU files. These two files contain servo data. With software version 709BF and higher the MCU file does not need to be backed up either. The customer should back up all the part programs for the machine before this procedure is done. If the system software files have to be loaded, 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 (1) 4. Push System Reset, CRT will display: Control Floppy Loading Wait

5. Press upper case and D ($), CRT displays: FDOS Load Wait

6. Insert utility (D) diskette into the floppy disk drive (FD0). 7. Press Load Start, CRT displays: Operating System Program II-A**.*** Okuma 19**.*.** =

8. Type in BPIP and press the write key, CRT displays: Load:SYS >AAddress set for Dump >DDump MPB file >BBackup PBU file >CCopy >UUpdate PBU file >RRecover(floppy B) 9. Remove D diskette and load B diskette into floppy disk drive. 10. Type in B and press the write key, CRT displays: MAU Backup OK(Y/N)!

Rev. 8-21-01


SOFTWARE

11. Type in Y and press the write key, CRT displays: Next PBU file search (Y/N)! 12. Type in Y and press the write key, CRT displays: MDU Backup OK (Y/N)! 13. Type in Y and press the write key, CRT displays: Search next (Y/N)! 14. Type in Y and press the write key, CRT displays: MGU Backup OK (Y/N)! 15. Type in 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 in N and press the write key, CRT displays: PBU file not found > Files that need to be backed up might vary from machine to machine because of options. The important thing is NOT TO BACK UP the MSU and MVU files (and MCU). It is Very Important to save the MAU (user parameters) and the MDU (system parameters). The MGU file should be saved if the customer has the MOP Tool or IGF function.


Rev. 8-21-01

SOFTWARE

19. Type in D and press the write key, CRT displays: F78000-F7BFFF Dump OK (Y/N)! 20. Type in Y and press the write key, CRT displays: MEU 03 Overwrite (Y/N)! 21. Type in Y 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 appears, the task is finished. Typing in the following data, will show all the data that has been backed up on the upper part of the CRT: DIR(space)FD0: , PN: 23. LOAD MODE OFF 24. Remove B disk from floppy disk drive. 25. Press SYSTEM RESET. 26. Power OFF 27. Power ON

Rev. 8-21-01


SOFTWARE


Rev. 8-21-01

SOFTWARE

Rev. 8-21-01


SOFTWARE


Rev. 8-21-01

SOFTWARE

Rev. 8-21-01


SOFTWARE


Rev. 8-21-01

SOFTWARE

Tape/Disk Part Numbers ·

D-Disk for 5000L Contrlos with 8floppy

A911-DDISK5020MG8

·

Tape # 0 for 5000L Controls

A911-TAPE-ZERO

·

CMOS Clear Tape for OSP 3000

A911-CLEAR-TAPE

·

D-Disk Graphics Functions(CRP-II)

A911-DDISK-5020MG

·

D-Disk without Graphics Functions(CRP-9)

A911-DDISK-5020MN

·

D-Disk for OSP7000M Controls

A911-DDISK-7000M

·

Battery Connection Floppy for 7000 L/M

A911-BATTERY-CONN

Rev. 8-21-01


.

Notes

EL501

Notes

EL501

OSP 5000/5020 CONTROL SCHEMATIC SYMBOLS ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501

CH .

9- 1

Okuma America Corporation

No. 1

Name Conductor

Old Symbol

Abrev

New Symbol

Abrev

Remarks 1-1 One conductor (wire)

Example

QF52 30A

1-2 Two conductors

-3

1-3 Three conductors 1-4 n equals number of conductors in cable 1-5 Shielded cable

-3 -36 -15 -20 -9

2

2-1 Connected Node 2-2 Connected 2-3 Not connected

Not Node

3

Terminal

TB

XT XJ

Terminal Block Test Jack

CN8 TB1

IC1

4

Coil

MS CR TR CTR

KM KA KL KP KR KT

Contact (Motor Starter) Instantaneous Latching relay Polarized relay Reed relay Time-Delay

KA1

AS TR 0N CR 31

AS

Schematic Symbols

120

C7 NA-25

PL

Rev. 8-13-01

Okuma America Corporation No. 5

6

Name Relay Contact

Solenoid

Old Symbol

Abrev MS CR

SOL MB MC CH

New Symbol

Abrev KM KA KL KP KR KT

Remarks Contact (Motor Starter) Instantaneous Contact Latching Relay Polarized relay Reed relay Time-Delay

YV YB YC YH YA

Solenoid Valve Magnetic Brake Magnetic Clutch Magnetic Chuck Electromagnet

Example RPL1 KA2

15

KA1

KA6

2

X14

A107 -18

PSB (B9)

HO8A (B7) C01

6

5

3

4

K614

SOL12A

YV4

7

8

Overload

Transformer

OL

T PT

OL FR

TA TC TM TS TV

TC

Rev. 8-13-01

Thermal overload relay Current threshold protective device with time-lag action.

Current Transformer Transformer for Control circuit supply Power transformer Magnetic Stabilizer Voltage Transformer 7-2 Iron core transformer 7-3 Fixed or Tap transformer 7-4 Variable transformer

B12 5

12 H1 P1

W12

8

X6

TC1 200V

X7 X4

110V 100A 18A

X5

0V X1 H2 P1 H3 P1

P1 9V

X2 P1 X3 P1

1KVA TC1

R4. S4 AC100/110V

7-5 Step down transformer

Schematic Symbols

9- 2

9- 3


No. 9

Name Choke coil

Old Symbol 8-1

Abrev X CH

New Symbol

Abrev X CH

Remarks Reactor Choke Coil 8-1 Fixed 8-2 Adjustable 8-3 Iron core

REC

9-1 Diode

8-2 8-3

10

Rectifiers

REC

Example

9-2 Full wave rectifier

CR9 6

MY

9-3 Bridge rectifier

11

Motor

M G MG TG

M

Motor (M DC Motor) Generator (G DC Gen) Motor Generator Tacho Generator 10-1 Field on DC 10-2 Armature on DC

AS

M14

L ub ricatio n o il 9pump motion for head stock 60 HZ

Setting 0.83A

Schematic Symbols

3

Rev. 8-13-01

Okuma America Corporation no. 12

13

Name Resistor

Fuse

Old Symbol

Abrev R

New Symbol

F

Abrev R

FU

Remarks 11-1 Fixed resistor 11-2 Tap resistor Variable resistors 11-3 Linear 11-4 Rotary 11-5 Dial Type

12-1 General 12-2 Enclosed

Example

K102

K102A

SCM

F1

F1

CN2

CN2

-1.2.3 2A

14

Bell

BL

BL

Bell

15

Buzzer

BZ

BZ

Buzzer

5

R

2A

HA XBOP4

16

Connector

CN

Socket Pin

XB XP XS

Connector Plug Socket Receptacle

17

Shunt connection

SH

SH

16-1 Shunt

18

Current Transform er

CT

MLT CT

16-2 Multiplier Current Transformer

Rev. 8-13-01

Schematic Symbols

A109 3

4 (AD501)

XBM51 -24

-12

9- 4

9- 5


No. 19

Name Meter

Old Symbol

Abrev

Measuring Instrument

20

Lamp Color description is shown with the symbol.

21

Ground

22

Circuit Breaker

23

Circuit Breaker Contact

New Symbol

Abrev A V W S N HM PC

Remarks Ampere meter Volt meter Watt meter Speedometer Tachometer 18-1 Hour Meter Parts Counter

LED L PL FL HL

19-1 Light Emitting Diode 19-2 Lamp Pilot Lamp 19-3 Fluorescent LED

Example

PC XBOP5 -B4

XBOP5 -B3

LETCP

HLON

R XBOP1 -R1

PLAL AL

T1

W

XE

R

FL1

CB

CB

E FG

Earth Frame or Chassis

QF QM

23-1 Circuit Interrupter 23-2 Magnetic CB 23-3 Thermal Magnetic CB

QF

OF11 CB2 P

IF

30A

CB1 21 QF1

4 20

AL1 20

CB2

21

AL2 20

20

CB3

21

QF2

A303 21 (AB401)

Schematic Symbols

5A

S OF52

36-1 Breaker has to be manually reset. 36-2 Breaker resets automatically.

5A

1FO

AL3 20

A302 21

(AB402)

QF3 21

20 (AB403)

Rev. 8-13-01


A: Normally Open No. Name 24 Limit Switch

B: Normally Closed Old Symbol Abrev LS

New Symbol

Abrev SQ

Remarks Limit Switch Micro Switch

Example DS2

TB1

LS1S C

25

Proximity Switch

LS

SQ

Position sensor

SQ9

TB1

SQ18

NO

LS1C RD NPN SQ21A

25-1 Magnetic Prox Switch 26

Float Switch

FS

SL

BK

WH

Liquid level sensor

SL1 (FSIL) -4

TBCON -5

X11 C

27

Pressure Switch

PS

NO

Pressure sensor SP

SPIP PSIC TBOU C

28

Thermal Switch

THS

NO TBOU

Auto Reset Manual Reset A312 A311 XT2 TH1H

Rev. 8-13-01

Schematic Symbols

XT2

TP1

9- 6

9- 7

Okuma America Corporation A: Normally Open No. Name 29 Temperature

30

B: Normally Closed Old Symbol Abrev ST

New Symbol

Abrev ST

Remarks Temperature Switch

Example ST1H

ST1 60 C

Flow Switch

FS

Flow switch for air, water, oil, etc. TBCON

(FS2L)

TBCON

-6

31

Foot Switch

FTS

TP1

-8

Also labeled Pedal Switch SF1

FTS10 NO C

32

Push Button Switch

PB

NO

PB 32-1 Push Button

TB2

PBON

PBOFF

ACN22

ACN22 1

-5

3

PBOFF

32-2 Mushroom Head AXB22 XT2

XT1

ACN22 3 2 -5

4

-3

PBON

1

ACN22 161 4 -3

3

32-3 Push Button Switch with a light 1

32-4 Push Pull Switch 32-5 Pull Switch 32-6 Turn Switch

1

EM2

2 2 SADIL

1

2

2

159

1

2

ON OFF 1

Schematic Symbols

2

AXBDIL

Rev. 8-13-01


A: Normally Open No. Name 33 Switch

B: Normally Closed Old Symbol Abrev

New Symbol

Abrev SW

Remarks 33-1 Single-pole, Singlethrow (Flat panel switch) 33-2 Toggle Switch

Example TOGGLE SWITCH SW1

33-3 Single-pole, Doublethrow

SASIL

1

34

Timer Relay Contact

TR

35

Arc Suppressor

AS

Z

34-1 Instantaneous operation in the direction of the arrow. Time delay in the opposite direction. 34-2 Instant operation Time delay reset Arc Suppressor KA34 A2

A1 Z

36

37

Rev. 8-13-01

C

C VC C

22-1 Fixed Capacitor 22-2 Variable Capacitor 22-3 Electrolytic Capacitor

B

GB

If more than one battery.

Capacitor

Battery

2

Schematic Symbols

XT4

O5 A1 MSIL A2 AS

9- 8

9- 9

Okuma America Corporation Indicates which page to look in Check Data Menu PAGE LOCATION

C1

56N TB10 C1

EC. IN. 01

PIN NO.

ISO24V 3-19 COM 3-20

54N TB10

CPU TEMP ALARM

CN1H

CPU-OL

CN1H A306

-5

-6

3-6

BIT 4

TMA/

NO. 8

60 C

CN-E0-3 LINE NO. Signal Name

Name of the EC board

Schematic Symbols

Rev. 8-13-01

Okuma America Corporation A2

DC24V

6

A2

Push Button

RELAY NAME

C7

C9

TB2

PBON ACN22 PBOFF

CN8 -H

-5

2

1

3

A2 NA-2

1

ACN22 4

-3

CN8

A3 NA-3

-F

6

CN8 -G

C11

160

C5 8

A6

S1 1

NA-6

ON A

G6E OFF A

OFF B

G6C

A4

1

C1 C3

Location of N.O. Contacts Normally Open Location of N.C. Contacts Normally Closed

1 C2

G6E

JUMPER -4

CONTROL ON

G6C

6 C10

ON B

RCM

5

C8

CN1 - 1, 2, 3

A1 NA-1

8 C5 CONTROL OFF

NA-4 C12

TBPT

A5 NA-5

3

24 VOLT DC RELAY RU1

C13

C14

RELAY UNIT Indicates line number

Rev. 8-13-01

Schematic Symbols

9- 10

Notes

EL501

Notes

EL501

OSP 5000/5020 CONTROL LATHE SCHEMATICS A40003 ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501

CH .

DRAWING NO .

DESCRIPTION

PAGE

B40017

CIRCUIT DIAGRAMS (1)

B40009


B40010


B40007

ELECTRICAL PARTS LAYOUT

D40016

CONTROL CABINET PARTS LIST

D40017

MACHINE WIRING PARTS LIST

T40015

CONTROL CABINET WIRING TABLE

T40008

MACHINE WIRING TABLE

1

REMARKS

f

c

OSP502OLM ELECT . DRAWINGS SPC

9-30-91

Drawing No . :

A40003

DRAWING NO.

DESCRIPTION

PAGE

C40009

SYSTEM CONFIGURATION

C40028A

POWER LINE BRANCH

Al

C10003

CONTROL POWER SUPPLY

A2

C40010

CHIP CONVEYOR

A3

C10005A

COOLING UNIT

A4

C40032

MOTOR CONTROL (1)

B1

C40033

MOTOR CONTROL (2)

B2

C40034

MOTOR CONTROL (3)

83

C10009

OPUS 5020 POWER SUPPLY

Cl

C40035

POWER SEQUENCE

C2

C40012

EMERGENCY LIMIT

C3

C10069

SPINDLE DRIVE UNIT (1)

Dl

C10070


D2

C40013


D3

C10015

SPINDLE ORIENTATION

D4

C10016A

FEED AXIS CONTROL (1)

El

C10017


E2

C40036


E3

C10019


E4

C10020

X-AXIS POSITION ENCODER

E5

C10021

Z-AXIS POSITION ENCODER

E6

C40014

CHUCK CONTROL (1)

Fl

C40015

CHUCK CONTROL (2)

F2

C40002A

SMW AIR CHUCK

F3

C40016

CHUCK PRESSURE CHANGE

F4

C40017

SPINDLE GEAR CHANGE

G

C10027A

TURRET SELECT

H

C40003A

TAILSTOCK CONTROL (1)

Il

REMARKS

CIRCUIT DIAGRAMS (1) SPC

9-30-91

Drawing No . :

B40017

DRAWING NO .

DESCRIPTION

PAGE

C40004A


12

C40018

TAILSTOCK PRESSURE CHANGE

13

C40019

MANUAL FRONT DOOR

J1

C40020

AUTOMATIC FRONT DOOR (1)

J2

C10033


J3

C10034

AIR BLOW

J4

C10035

SPARE AIR BLOW

J5

C40029

WORK COUNTER

K1

C40030

HOUR METER

K2

C40021

INDICATION LAMP

K3

C40031

LUBRICATION MONITOR

L

C10040

NC-EXTERNAL INPUT

M

C40022

SYSTEM CONTROL

Nl

C40023

TAPE READER PTR

N2

C10042

CRT PANEL

Pi

C10043A

OPERATION PANEL INPUT (1)

P2

C10044


P3

C10045A

OPERATION PANEL OUTPUT (1)

P4

C10046


P5

C10047

PANEX CARD 4

P6

C40024

M-CODES (1)

Rl

C40025

M-CODES (2)

R2

C40026

USER M-CODES (1)

R3

C40027

USER M-CODES (2)

R4

C10052

TOUCH SETTER

Sl

C10071A

LOAD MONITOR B

S2

C10054

PANEX CARD 2A (1)

S3

C10055

PANEX CARD 2A (2)

S4

REMARKS

I,

CIRCUIT DIAGRAMS (2) TH

103 .26 .91

Drawing No . :

B40009

DRAWING NO .

I

DESCRIPTION

IPAGEI

C10079

I RECEPTACLE

I Tl

C10080

I PUNCHER RS-232-C INTERFACE

I T2

REMARKS

CIRCUIT DIAGRAMS (3) 103 TH .26 .911 Drawing No . : 1

B40010

A

H

000

00

C

F1

i

q~llllllllll

H

H < 7

O

WR 15n

< THIS WAVING IS EXCLUSIVELY OUR PROPERTY AND DWI NOT aE COPIED OR PASSED ON TO A THIRD PARTY WTTW OUT OUR PRIOR VRITTEN APPROVAL VE VIIl RETAIN All RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN,

DOTE

R

S

T

E

C81

I

H

A

-

.

-C

CUSTOMER'S POWER SUPPLY AC220V 60Hz

60A

2

f I

I I I I I I

I

I

i I

I I I I I I I I I I I L_~1

I

i I

3

I

4

I

I I

I I

5

I I OPTION

6 TERMINALS SCREWED TOGETHER . REMOVE SCREW CONNECTION IF TRANSFORMER IS ADDED .

TRANSFORMER THERMAL PROTECTION

THIS DRAWING IS EXCLUSIVELY MR PROPERTY AND SHALL NOT HE CRIED OR PASSED ON TO A THIRD PARTY VITHOUT OUR PRIOR WRITTEN APPROVAL VE VIII RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN. NOTE

TITLE

rP

AGE

Al

REVISION

OKUMA MACHINE TOOLS INC.

7

O

POWER LINE BRANCH

FT -

I

I

0

I

DRAWING CHANGE FOR CLARITY 3-28-91 DRAWING NO.

C40028

SPC

9-25-91

0

Telo P1 ACT00/120Y COMMON ACIOOV

2

3

4

CIRCUIT TRIP

BREAKER

5

8

7

PAGE

TIUS DRAWING IS EXCLUSIVELY OUR PROPERTY ANDSHALL NOT BE COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIORWRITTEN APPROVAL. WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN.

OKUMA MACHINE TOOLS INC. TITLE

A2

REVISION


~NpTE

C10003 r .a ..~.rur .we..s..www s r~r "nr " rrw

SHALL. VITHPRIOR VRITTEN APPROVAL VE VILL RETAM ALL RIGHTS FOR PATENT ISSUE OR REGISTRATIIN Or KSIGTI THIS

DRAVDIG IS EXCLUSIVELY OUR PROPERTY AND COPIED OR PASSED ON TO A THIRD PARTY

NOT 1E

OUT IA1R

THIS DRAWING IS EXCLUSIVELYOUR PROPERTY ANDSHALL NOT of COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL. WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DES".

H

A

C

AC220V 30 R1

S1

ITI

MS1L (1315)

R17

01-11(B18) LUBRICATION OIL PUMP MOTOR BOHZ .025KW SETTING

.24A

2

B2 LUBRICATION OIL PUMP MOTOR FOR HEAD STOCK 60HZ SETTING

83

OLIC (1314)

SETTING ~ 8 .5A

OL6 (818) r1

MS6 (1313) 1

2

3"4 5 1 ~6

S6 TB

r'I

-

3

U9 HYDRAULIC OIL PUMP MOTOR 60HZ 2.WW 1 .5KW

Y

B4

0.53A

5

2 4 6

U6

4

TSCON

VB

COOLANT MOTOR SOHZ 40DW

W6

SETTING

5

2.tA

85

AC100V

T2 B6

B-10

F ,

7L (1311) 4

3

6

j 07

ILI B-11

PLIL

TBI

~o-

RUt

S _2L-50

WORK LIGHT

(u-so

TBI 97

PAGE THIS DRAWING IS EXCLUSIVELY DUR PROPERTY AND SHALL NOT HE COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL VE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE DR REGISTRATION 13F DESIGN. NOTE


MOTOR

CONTROL

REVISION

(1) OVERLOAD SETTING CHANGE DRAWING NIL

5-31-91

SPC

C40032

COOLANT ON

B7

88

POWER SAVE ON

89

2

BIO

LUBRICATION MOTOR ON

t

3

ILLUMINATING LAMP ON

Bit

v.

4

COOLANT MOTOR

5

OIL PUMP MOTOR

LUBRICATION MOTOR 6

COOLANT SOLENOID VALVE

7

PAGE

OUR PROPERTY AND SHALL THIS DRAWING IS EXCLUSIVELY NOT !E COPIED OR PASSED ON TO A THIRD PARTY VITNOUT OUR PRIOR WRITTEN APPROVAL VE WILL RETAIN ALL RIGITS FOR PATENT ISSUE OR REGISTRATION OF DESIGN, NOTE

I

OKUMA MACHINE TOOIS INC . TITLE

B2

REVISION

p p p

MOTOR CONTROL (2)

p TH

5-31-91

DRAWING NO.

C40033

8

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F 3-23-91 DRAVING IH.

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THIS DRAWDIG IS EXCLUSIVELY MR PROPERTY AND SMALL NOI DE COPIED L3R PASSED ON TO A THIRD PARTY VITHDUl MM PRIOR VRITTEN APPROVAL VE VIOL RETAIN ALL RIGIITS FOR PATENT ISSUE Lit REGISTRATIM DF DESIOI NOTE

OICUMA MACHINE TOOLS INC . TITLE

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LOW PRESS


CHUCK PRESS CHANGE 3-23-Y1 DRAWING

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THIS DRAVIIIG IS EXCLUSIVELY OUR PROPERTY AND VKL OKUMA MACHINE TOOLS INC . NOT )E COPIED OR PASSED TIN TO A THIRD PARTY V00IIUT OUR PRIOt VRITTEN APPRQVAL VE VILL RETAIN All RIWS FEW PATENT ISSUE 11R REQSTRATIM Or DESIGN, TITLE TAILSTOCK CONTROL (2) NOTE

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THIS DRAVING IS EXCLUSIVELY DR PROPERTY AND SHALL IdiY DE CUPID OR PASSED ON TD A THIRD PARTY VITHDJT DJR PRIOR VRITTEN APPROVAL. VE VDl RETAIN ALL RIGHTS FOR PATDT ISSUE OR REGISTRATIQI OF DESIGN. NOTE

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0 3-25-91 DRAWING ND,

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THIS DRAW Wq IS EXCLUSIVELY OUR PROPERI Y AND SNAIL NOT DE COPI10 OR PASSED ON TO A THIRD PARTY WRH. OUT OUR PRIOR WRITTEN APPROVAL. WE WILL RETAIN ALL RIGHIS FOR PATENT ISSUE OR REGISTRATION OF DESIGN.

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PAGE 7145 DRAWING tS EXCPASSED ON 10 11DPERTY AND BItAII IIOT BE ( OPTED OR 70 A TNIRp PARTY WR14 OUT OUR PRIOR WRITTEN APPROVAL. WE WILL TAW ALL Ilv'.NTS Tf)R PATENT ISSUE OR REGISTRATION OF DESIGN.

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WORK COUNTER FULL COUNT

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REVISION

WORK COUNTER 3-28-a1 DRAWING NCL

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PAGE THIS DRAWING IS EXCLUSIVELY OUR PROPERTY AND SHALL NOT BE COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN NOTE


REVISION

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REVISION

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DESCRIPTION

C40057

HIGH SPEED, SPINDLE DRIVE UNIT

E40029

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REVISION

LIJC-8HS MOTOR CONNECTIOIJS SRIA

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OKUMA MACHINE TOOIS INC .

REVISION

7000RPM SDU PCB SWITCH SETTING

TITLE

SRM

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11-25-91 DRAWING NO.

E40178

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OSP 5000/5020 CONTROL MACHINING CENTER SCHEMATICS ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501

CH .

DRAWING NO .

DESCRIPTION

PAGE

820036


820037


820038

CONTROL CABINET PART LOCATION (1)

820039

CONTROL CABINET PART LOCATION (2)

820040

MACHINE WIRING PARTS LOCATIONS

D20053


D20060


T20053

CONTROL CABINET WIRING TABLE

T20052

MACHINE WIRING TABLE

REMARKS

MC4VA OSP5020M ELECT . DRAWINGS SPC

11-14-91

Drawing No . :

A20004

DRAWING NO .

DESCRIPTION

PAGE

C20064

SYSTEM CONFIGURATION

C20002A

POWER LINE BRANCH

Al

C20003A


A2

C20004

CONTROL POWER CIRCUIT (1)

A3

C20134

CONTROL POWER CIRCUIT (2)

A4

C20006

OPUS 5020M POWER SUPPLY

Bl

C20007

SPINDLE CONTROL (1)

Dl

C20008

SPINDLE CONTROL (2)

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C20009B

MOTOR CONTROL (1)

D3

C20010

MOTOR CONTROL (2)

D4

C20135

FEED-AXIS CONTROL (1)

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E2

C20013


E3

C20014


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C20015


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C20016

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C20017

Y-AXIS POSITION ENCODER

E7

C20018

Z-AXIS POSITION ENCODER

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C20019

A-AXIS CONTROL (1)

E9

C20020

A-AXIS CONTROL (2)

E10

C20021

A-AXIS POSITION ENCODER

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CRT PANEL

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C20023


F2

C20024


F3

C20025


F4

C20026


F5

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REMARKS

CIRCUIT DIAGRAMS (1) SPC

11-14-91

Drawing No . :

B20036

DRAWING NO .

DESCRIPTION

PAGE

C20030


F8

C20031

PANEX CARD 5A (1)

F9

C20032

PANEX CARD 5A (2)

F10

C20032

PANEX CARD SA (3)

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C20033

OPERATION PANEL

F12

C20034

ECP BUS LINE

G1

C20035

EC 1/0 RACK

G2

C20136

EC INPUT (1)

H1

C20037

EC INPUT (2)

H2

C20038

EC INPUT (3)

H3

C20039

EC INPUT (4)

H4

C20040

EC OUTPUT (1)

J1

C20137

EC OUTPUT (2)

J2

C20042

EC OUTPUT (3)

J3

C20043

EC OUTPUT (4)

J4

C20044

EC OUTPUT (5)

J5

C20045

EC OUTPUT (6)

J6

C20046

EC OUTPUT (7)

J7

C20047

WORK LIGHT

Kl

C20048

4, 8-M CODES

K2

C20049

MG-AXIS

Ll

C20050

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L2

C20140

PTR

Ml

C20065

FLOPPY DISK

M4

C20056

PG, PH, DA CONTROL

M6

C20066

RECEPTACLE

Tl

C10080

PUNCHER RS232C INTERFACE

T2

REMARKS

CIRCUIT DAGRAMS (2) SPC

11-14-91

Drawing No . :

B20037

THIS DRAWING IS EXCLUSIVELYOUR PROPERTYANDSMALL NOT BE COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIORWRITTENAPPROVAL . WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESNN.

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THIS DRAWING IS EXCLUSIVELY OUR

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NOTE

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FEED - AXIS CONTROL (1) . 6-3-91 1 DRAWING N0

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REVISION

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THIS DRAWING IS EXCLUSIVELY OUR PROPERLY AND SNAIL NOT BE COPIED OR PASSED ON 70 A TNtgD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL. WE WXl RETAIN All RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESON.

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THIS DRAWING IS EXCLUSIVELYOURPROPERTY AND SHALL NOT BE COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL . WE WILL RETAIN All RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN . NOTE


REVISION

TITLE

EC

I/0 RACK CODY

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ORAWINO No .

C20035

BIT 0

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CHIP CONVEYOR MOTOR OVERLOAD

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THIS WAVING IS MUSIVO.Y OUR PROPERTT AND SHALL NOT BE COPIED OR PASSED ON TO A THIRD PARTY VITHOUT OUR PRIOR VRITTEN APPROVAL VE VOl RETAIN ALL RIGHTS F13R PATENT ISSUE OR REGISTRATION 1TF BESIGK

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REVISION

EC INPUT (1)

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71

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1 1

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THIS DRAWING IS EXCLUSIVELYOUR PROPERTYANDSHALL NOT BE COPIED OR PASSED ON TO A THIRD PARTY WITH OUT OUR PRIORWRITTEN APPROVAL. WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN.

1 23 < 24

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7

PAGE

H2

E12 REVISION


EC INPUT (2) CODY

5

SPINDLE TOOL CHANGE PREPARATION

H227

H237

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1 1I

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THIS DRAWING IS EXCLUSIVELY OUR PROPERTY MIDSMALL NOT BE COPIED OR PASSED ON TO ATHIRD PARTY WITH OUT OUR PRIORWRITTEN APPROVAL. WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN.

CHANGE ARM POSITION 'ES' (A-GR PPER ON MAGAZINE SIDE)

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H4 THIS DRAWING IS EXCLUSIVELY OUR PROPERTY AND SHALL NOT BE COPIED OR PASSED ON TO A THIRD PARTYWITH. OUT OUR PRIOR WRITTEN APPROVAL . WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF OESpN. NOTE


EC INPUT (4)

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THIS DRAWING IS EXCLUSIVELY OUR PROPERTY ANDSMALL NOT BE COPIED OR PASSED ON TO ATHIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL. WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN. NOTE

OKUMA MACHINE TOOLS INC. [= TITLE EC OUTPUT (1)

CODY . ....... . ...... . .. . ...., . . . . ... . .. . ., .. . . ..

pRAWINGNO .

C20040

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E02 ,! -A C) THIS DRAVPK 1S EXCLUSIVELY OUR PROPERTY MID SIIALL 1101 8E COPIED 1R PASSED ON TO A TIIIRD PARTY VITHOUT OUR PRIOR VRITTEN APPROVAL VE WILL RETAIN ALL RIC447S FOR PATENT ISSUE OR REGISTRATION OF DESIGN.

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THIS DRAWING IS EXCLUSIVELY OUR PROPERTY ANDSMALL NOT BE COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL. WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN. NOTE


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EC OUTPUT (3) CODY

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J3

REVISION

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C20042

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PAGE J4 THIS DRAWING IS EXCLUSIVELY OURPROPERTY ANDSHALL NOT BE COPIED OR PASSED ON TO A THIRD PAR" WITH . OUT OUR PRIOR WRITTEN APPROVAL WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESKIN . NOTE

E3


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EC OUTPUT (4)

0 1

13-2r-99 DRA"nao NO

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STANDBY ON MAGAZINE SIDE

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O

X

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THIS DRAWING IS EXCLUSIVELY OUR PROPERTY AND SHALL NOT BE COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL. WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN.

m

PAGE THIS DRAWING IS EXCLUSIVELY OUR PROPERTY AND SMALL NOT BE COPIED OR PASSED ON TO A THIRD PARTYWITH. OUT OUR PRIOR WRITTEN APPROVAL. WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN . NOTE


J6

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EC OUTPUT (6) CODY

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a-»-o'I

C20045

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PAGE

THIS DRAWING IS EXCLUSIVELY OUR PROPERTYANDSMALL NOT SE COPIED OR PASSED ON TO ATHIRD PARTY WITH. OUT OUR PRIOR WRITTEN APPROVAL. WE MALL RETAIN ALL RIGHTS FOR PATENT -SSUE OR REGISTRATION OF DESIGN. NOTE

OKUMA MACHINE TOOLS INC,.

J7

REVISION

TITLE

EC OUTPUT (7) CODY

~-=!-ES

wuwPgND

C20046

THIS DRAWING IS EXCLUSIVELYOURPROPERTY AND SMALL NOT BE COPIED OR PASSED ON TO A THIRD PARTY WITMOUT OUR PRI0RWRITTENAPPROVAL . WE WILL RETAIN ALL RIGMTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN . NOT


REVISION

WORK LIGHT

CODY

C20047

CN21 K201

(~21)

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(RESISTIVE LOAD)

AC220V:2A . DC24V:2A

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MAXIMUM CURRENT :

SA

OPTION

6

7

DRAWING IS EXCLUSIVELY OUR PROPERTY AND SHALL NOT BE COPIED OR PASSED ON TO A THIRD PARTY WITH OUT OUR PRIOR WRITTEN APPROVAL WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN . THIS

NOTE

OKUMA MACHINE TOOLS INC,. TITLE

PAGE K2

PENSION

4 . 8 M-CODES CODY

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K015 X 45 THIS DRAWING IS EXCLUSIVELY OURPROPERTY AND SHALL NOT BE COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL . WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESMIN . NOTE


REVISION

TITLE

TB1,TB7 CODY

19341 - (OSP5020) change ]-29-59

DRAWING NO .

E20038

CODY

9-9-e9

2 X1 H1

X2 XS

H2

72

X4 X5

H3

XG X7

3

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TRANSFORMER HAS LEAD WIRES.

5

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Cl detail W

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W rc THIS DRAWING IS EXCLUSIVELY OUR PROPERTY ANDSHALL NOT BE COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIORWRITTEN APPROVAL. WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN. NOTE

REVISION OKUMA MACHINE TOOLS INC. TITLE

PT PANEL CODY

Add cl /9229 oRAwu+o No .

E20039

CODY

9-25-59

R3 I S3

T3

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1,2

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A14

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CNS2-F

CNS3-F

-0-_-__-_____ _--____ CNS1-M

CNS2-M

CN53-M

CNS4-F

CNS5-F

CNS4-M

CNS5-M

___-_-_--____- .-,

PAGE OUR PROPERTY AND SHALL THIS WAVING Is EXCLUSIVELY NOT BE COPIED OR PASSED ON TO A THIRD PARTY VITFF OUT OUR PRIM VRITTEN APPROVAL VE VILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIQL NOTE


REVISION

PS PANEL SPC

Na

E20198

THIS DRAWING IS EXCLUSIVELYOUR PROPERTY AND SNAIL NOT BE COrIED OR FASSED ON TO A THIRD PARTY VAIN OUT OV< «" OR WRITTEN APPnOVAL. WE WILL RETAIN All RIG-41S FOR PATENT ISSUE OR REGISTRATION OF DESIGN.

ORAWB4 NO

L10110

A

2

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H111

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SS24

SS21

NM2

2

3

4

5

6

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LEFT DOOR REAR VIEW

PAC£ THIS DRAVING IS EXCLUSIVELY OUR PROPERTY AND SHALL NOT BE COPIED DR PASSED ON TO A THIRD PARTY VITHOUT OUR PRIOR VRITTEN APPROVAL VE VILL RETAIN ALL RIGHTS FOR PATENT ISSUE 13R REGISTRATION OF KSIGK NOTE


REVISION D

LEFT DOOR

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vw Na

rDRA

E20202

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2 CN2

CN1

CN-FT2

CN-FT1

CN3 CN-PT3 3

4

LEFT DOOR

5

6

SIDE VIEW

7

PAGE THIS DRAVING IS EXCLUSIVELY OUR PROPERTY NO SHALL NOT DE COPIED (R PASSED ON TO A THDID PARTY VITIF OUT OUR PRIOR VRITTEN APPROVAL VE VIII RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION IF DESIOL NOTE

OKUMA TITLE

MACHINE TOOLS INC . FDD

REVISIORN

1

In

UNIT

D

VC

1-14-07 DRAVM NO .

E20203

0 o 0 X

Y

Z

4

5

TOUCH SENSOR

FRONT VIEW

REAR VIEW

PUS DRAVING Is EXCLUSIVELY OUR PRUPERTY AND SHALL NOT PE COPIED OR PASSED ON TO A THIRD PARTY VRNDUT OUR PRIOR VRITTEN APPROVAL VE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATILIN IF DESIGt NOTE


REVISMN

SYSTEM PANEL 11-14-91

DRAVM Na

E20204

2

FITTING M

CN-P-I

CNP-

CN-P-2

CNP-2

CN-P-3

CNP-3

CN-P-4

CNP-4

CN-P-S

CNP-5

CN-P-6

CNP-6

CN-P-7

CNP-7

CN-P-B

CNP-8

E

3

TBCRT

CNOP

4

0 w a FLAT PANEL

c 3 Z

U

T95

FITTING L BACKSIDE VIEW

THIS DRAWING IS EXCLUSIVELYOUR PROPERTY AND SHALL NOT BE COPIED OR PASSED ON TO A THIRD PARTYWITH OUT OUR PRIOR WRITTEN APPROVAL. WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN .

IMP

relsi CNFPS

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zT 1

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PAGE THIS DRAWING IS EXCLUSIVELY OVA PROPERTYAND SHALL NOT BE COPIED Of'. PASSED ON TO A THIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL. WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN. NOTE


REVISION

FLAT PANEL CODY

3-2s-es DRAWINGNO .

E20047

THIS DRAWING IS EXCLUSIVELY OUR PROPERTY AND SHALL NOT BE COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL . WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN .

t

704P

71 OP

OPERATION BOX

2 SSGN 711P

3

PHDI

4

4

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PHD1

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5

6

7

PULSE HANDLE

PAGE THIS DRAWING IS EXCLUSIVELY OUR PROPERTYAND SHALL NOT BE COPIED OR PASSED ON TO A THIRD PARTYWITHOUT OUR PRIOR WRITTEN APPROVAL. WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN .


PULSE HANDLE

REVISION

DRAWING NO.

DESCRIPTION

PAGE

E20001

AXIS MOTOR

E20199

PARTS LOCATION, MAIN BREAKER BOX

E20200

MAIN BREAKER BOX

E20004

DETAIL "A" TB2

E20005

DETAIL "B" TB2A, TB2B, TB2C

E20007

LUBE OIL UNIT

E20009A

DETAIL "D" X-AXIS SERVO

E20010

TB3 PARTS LOCATIONS

E20011

TB3

E20012

DETAIL "A" OPERATION BOX

E20013

M-CODE OPTION

E20014

A-AXIS OPTION

E20015

ATC / TB10M LOCATION

E20201

TB10M

E20197

MG PANEL

E20017

PARTS LOCATION FOR TB11M

E20018

DETAIL "A" TB11M

REMARKS

MACHINE WIRING PARTS LOCATIONS SPC

11-14-91

Drawing No . :

B20040

THIS DRAW1NG IS EXCLUSIVELY OUR PROPERTY AND SHALL NOT HE COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN.

A

B

C

2

3

4

5

V

6

1. 2. 3. 4. S.

MAIN BREAKER BOX FS1 (FLOAT SWITCH, OIL UNIT) OIL UNIT MOTOR TRANSFORMER MG PANEL BOX

E. 7. 6.

MAGAZINE SOLENOIDS TERMINAL BOX LURE MOTOR COOLANT PUMP MOTOR _

7

PAGE THIS WAVING IS EXCLUSIVELY OUR PROPERTY AND SMALL NOT BE COPIED OR PASSED ON TO A THIRD PARTY VITHOUT OUR PRIM VRITTEN APPROVAL VE VOl RETAIN ALL RIGHTS FAR PATENT ISSUE IR REGISTRATION IF DESIGN. NOTE

OKUMA MACHINE

TOOLS

INC .

REVISION

D D

PARTS LOCATION FOR MAIN BREAKER BOX

TITLE

D

11-1s-+a1

nwAVn+~ Nn

E20199

O

C

A VFUZ2 V2

Z-AXIS MOTOR

Z-AXIS FB MG FB

2

3

4

5

VFU42

VFM2E VFM26

TRANSFORMER T1

6

SPINDLE MOTOR TB11M

VFA12B

LSX/LSY

VFM22

VFM22

NOTE

Y-AXIS ENCODER TB10M

Y-AXIS MOTOR

THIS BRAVING IS EXCLUSIVELY IIUR PROPERTY AND 9411 fXrT X COPIED Qt PASSED ON TO A THIRD PARTY VIT}OIT IxR PRMR VRITTEN APPRDVAL VE VDl RETAIN ALL RIGHTS FUt PATENT ISSUE DR REGISTRATION OF DESICJI

7

PAGE

OKUMA MACIUNE TOOIS INC . TITLE

REVISION

A A A

MAIN BREAKER BOX

rTli-

A A 11-14-91

BRAVING Na

E2 0200

T02

TD2

4

KG15x71

U I S,~

AS

AS

tJ S023150N1'

501315007

vI4

6

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m

S0231503F

PAGE Till S DRAWING IS EXCLUSIVELY OUR PROPERTY AND SHALL NOI BE COPIED OR PASSED ON TO A THIRD PARTY VITHUU7 OUR PRIOR WRITTEN APPROVAL WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE 1X2 REGISTRATION OF DESIGN. NOTE


T141S PRAVING IS EXCLUSIVELY OUR PROPERTY AND SHALL 1401 DE COPIED OR PASSED ON 10 A THIRD PARTY WITHOUT OUR PRIOR VRITTEN APPROVAL . VE VILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN. NOTE

THIS DRAVIIIG IS EXCLUSIVELY OUR PROPERTY AND SHALL HOT HE COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN.

H

THIS DRAWING IS EXCLUSIVELY OUR PROPERTY AND SHALL NOT HE COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL. WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN.

C

THIS DRAVING IS EXCLUSIVELY OUR PROPERTY AND SMALL NOT HE COPIED OR PASSED ON TO A THIRD PARTY VITHOUT OUR PRIOR VRITTEN APPROVAL VE VILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN.

MOM

U11 `JfAAWUII

Y-1i-C

cal NOIt1ABU

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OUR THIS DRAWING IS EXCLUSIVELY PROPERTY AND SHALL NOT HE COPIED CTR PASSED ON TO A THIRD PARTY WITHOUR OUT PRIOR WRITTEN APPROVAL WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN.

CN-P-1

CNP-1

CN-P-Z

CNP-2

CN-P-3

CNP-7

CN-P-4

CNP-4

CN-P-5

CNP-5

CN-P-6

CNP-6

CN-P-7

CNP -7

CN-P-8

CNP-8

E E

TBCRT

CHOP

FLAT PANEL

uz

u

RaS DRAWING IS EXCLUSIVELYOUR PROPERTYAND SIIALL WIT SF COPIED On PASSED ON TO A TT11R0 PARTY WITHOUT OUR Pnion WRITTEN APPROVAL WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE On REGISTRATION OF DESIGN. NOTE

TB5

A

H

C

2 CN-EA-J1-F

CN"I-F

3

4

5

6

7

PAGE

THIS DRAWING IS EXCLUSIVELY OUR PROPERTY AND SHALL NOT HE COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN. NOTE

OKUMA

TITLE

MACHINE

TOOLS

I INC. i

n

REVISION

--

G

A-AXIS OPTION

FRAM

6-27-90 DRAWING NIL

E20014

THIS DRAVIIlG IS EXCLUSIVELY OUR PROPERTY AND SHALL HOT HE COPIED OR PASSED ON TU A THIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL . WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN.

000 000 SOL2

SOL19 SOL18

SOLO SOL9 SOL10 000

000 SOLB

SOLIS SOL17

LS15

LS18

SOL14

LS17

LS12

LS13

LS14

LS9

L510

LS11

LS6

LS7

P24

772

P24

773

P24

774

P24

775

P24

sO112

777

000 000 000 000 SOL3

P24

771

776

SOL11 SOL13 SOL16 000 SOLE

770

LS8

781

861

782

862

783

885

784

B88

SOV

865

107

867

108

871

750

872

752

873

753

874

805

875

P24

876

SPIMG

en

SP2MG

$78

SP3MG

882

SP4MG

883 864

SOV SOV

E

SOV

E

SOV

E

SOV

E

so' l

E

KGI5x31

KG15x31

TO O41 m TO MG PANEL THIS BRAVING IS EXCLUSIVELY OUR PROPERTY AND STwLL NOT BE COPIED OR PASSED ON TO A THIRD PARTY VITHOUT OUR PRIOR VRITTEN APPROVAL . VE VILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGSTRATION OF DESIEK NOTE


REVISION

TB10M BRAVING In

E20201

a

FRONT VIEW H 0 0

1E128 FP81 9A

O+

4

3(D

O+

3

4O+

FSS11A

N

v c0

BACK VIEW D

D

D

IA

V

P

a

f0

N

Symbol No .

Nomenclature

LS1

Spindle speed range change

LS2

Spindle speed range change limit switch, release

LS3

Spindle speed range change

LS4

Tool in spindle unclamp limit switch

LSS

Tool in spindle clamp limit switch

PB16

Manual tool change cycle pushbutton switch

PB17

Manual tool clamp pushbutton switch

PB18

Manual tool unclamp pushbutton switch

Ml

Spindle drive motor

MS

Spindlehead cooling and lubricating pump motor

PC1

Spindle speed encoder

COOLER

Spindlehead lubricating and cooling unit EHIci--j vo 1

I

ic w ,-I 4oR beAKP-

t ,mlot

TI IIS DRAWINGIS EXCLUSIVELY OUR PROPERTY AND SHALL NOT BE COPIED OR PASSED ON TO A THIRD PARTY WITHOUT OUR PRIOR WRITTEN APPROVAL. WE WILL RETAIN ALL 11ICNTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN .

limit switch, high limit switch, low

Z-AY15

'tFAVEL

A

in

0 M1

ruFM28

lm

C

B

z N N 0 V U

v

a

A zn

n

a

N

N M N

~i N a0

P1316 P017 PO18 LSZ M5

VFM28

MAIN BREAKER BOX VFM28 VFM28 THIS DRAWING IS EXCLUSIVELY OUR PROPERTY AND SHALL NOT BE COPIED OR PASSED OI TO A THIRD PARTY WITHUUT OUR PRIOR WRITTEN APPROVAL WE WILL RETAIN ALL RIGHTS FOR PATENT ISSUE OR REGISTRATION OF DESIGN. 1107E

MAIN BREAKER BOX

Page No . 11/18/91

1 MC4VA


N :\EENG\D20053 PART NAME

OMT PART NUMBER

DESCRIPTION

MANUFACTURER

CONNECTOR

HONDA

CONNECTOR, AT CONNECTOR, AT

OCJ HONDA

OKT20 CABLE CLAMP FOR NRP20

CONNECTOR

HONDA

MCP-20F01

1006-0200

PCB UNIT

OCJ

BDU DRIVE UNIT, SVC-A

E3702-HOO-003

CONNECTOR

HONDA

CONNECTOR NRP-20FOI

** UNIT NAME : BDU-A CN-SAA-1 E3702-HOO-003 CN-SAA-1 CN-SAA-1

E3708-578-001

CN-SAA-10

E3702-HOO-002

*w UNIT NAME

CN-SAX-1 CN-SAX-1

CN-SAX-10 CN-SAX-10

** UNIT NAME

E3708-HOO-002

: BDU-X

1006-0211

E3708-578-001

E3702-HOO-002 E3708-HOO-002 : BDU-Y

POWER UNIT

OCJ

CONNECTOR, AT

OCJ

CONNECTOR, AT

HONDA

CONNECTOR

HONDA

MANUFACTURER'S PART NUMBER

CONNECTOR MRP-20FOI

MC-20-LS2

BDU POWER UNIT, BLD 30A OKT20 CABLE CLAMP FOR MRP20 MCP-20FOI MC20-LS2

1006-0200

PCB UNIT

OCJ


CN-SAY-1

E3702-HOO-003

CONNECTOR

HONDA

CONNECTOR MRP-20FOI

CM-SAY-10

E3702-HOO-002

CN-SAY-1

CN-SAY-10 ** UNIT NAME

CN-SAZ-1 CN-SAZ-1

CN-SAZ-10 CN-SAZ-10 ** UNIT NAME

1006-0211

E3708-578-001

E3708-HOO-002 : BDU-Z

1006-0200

POWER UNIT

OCJ

CONNECTOR,

AT

OCJ

CONNECTOR,

AT

HONDA

CONNECTOR

HONDA

BDU POWER UNIT, BLD 30A OKT20 CABLE CLAMP FOR MRP20 MCP-20F01 MC20-LS2

1006-0211

PCB UNIT POWER UNIT

E3708-578-001

CONNECTOR,

AT

OCJ

OKT20 CABLE CLAMP FOR MRP20

E3708-HOO-002

CONNECTOR,

AT

HONDA

MC20-LS2

E3702-HOO-003 E3702-HOO-002

: CONTROL CABINET


HONDA

CONNECTOR MRP-20F01

OCJ

CONNECTOR CONNECTOR

OCJ

HONDA

BDU POWER UNIT, BLD 30A

MCP-20FOI

1098-9050

CASE

OCJ

3 .5" FLOPPY DISC CASE

E5400-ZZZ-003

NAME PLATE

TMI

CAUTION DISCONNECT

NAME PLATE

TMI

E3520-FOO-001 E5400-ZZZ-005-1

E5410-ZZZ-002-2 E5506-L01-001

LAMP

NAME PLATE FUSE

FUJI

TMI LITTLE FUSE

AHX130

INCANDESCENT

SPARE PARTS LABEL

MACHINE NAME PLATE 218 .100

LAMP

Page No . 11/18/91

2 MC4VA CONTROL CABINET PARTS LIST N :\EENG\D20053

PART NAME

OMT PART NUMBER

DESCRIPTION

MANUFACTURER


FUSE TOOL,PIN REMOVER CABINET PANELS AND FITTINGS PANEL PANEL PANEL COVER COOLING UNIT TERMINAL BLOCK END PLATE JUMPER BAR JUMPER BAR TERMINAL BLOCK END PLATE JUMPER BAR SWITCH

LITTLE FUSE JAE

COOL UNIT TB1 TB1 TB1 T67 T87 T87 T87 TH1

E5506-LO1-002 E5689-JOO-001 E7300-ZZZ-012 E7310-ZZZ-003-2 E8029-ZZZ-003 E8029-ZZZ-004 E8029-ZZZ-005 E8030-ZZZ-004 E7391-090-485-1 E5514-909-001 E5514-909-002 E5514-909-003 E5511-909-002 E5514-909-001 E5514-909-002 E5514-909-003 E3043-POI-001

YOSHIDA YOSHIDA YOSHIDA YOSHIDA YOSHIDA YOSHIDA YOSHIDA PEPI

218 .100 JIET-DBC-20 CONTROL CABINET MC-4VA PANEL PANEL PANEL MC-4VA PANEL BDU COVER, SMALL HEAT EXCHANGER 45OW TERMINAL BLOCK KG15 END PLATE KG30, KG15 JUMPER BAR KG15 JUMPER BAR KG30 TERMINAL BLOCK KG15 END PLATE KG30, KG15 JUMPER BAR KG15 SWITCH, NC 0000+060H

: CPU RACK' 1911-1516 1911-1545 1911-1547 1911-1703 E0201-AOI-005 E3702-HOO-004 E3708-578-002 E3702-HOO-003 E3708-578-001 E3702-HOO-004 E3708-578-002 E3702-HOO-003 E3708-578-001 E3702-HOO-003 E3708-578-001 E3702-HOO-003 E3708-578-001 E3702-HOO-003

PCB UNIT BATTERY UNIT PCB UNIT PCB UNIT OSP UNIT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR

OCJ OCJ OCJ OCJ A-B HONDA OCJ HONDA OCJ HONDA OCJ HONDA OCJ HONDA OCJ HONDA OC' I 1

MAIN CARD 16 BATTERY FOR ECP2A ECP2A DA1 PCB UNIT FDC BOAR02 OSP5020H MC4VA CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR CONNECTOR MRP-20FOI OKT20 CABLE CLAMP FOR CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR CONNECTOR MRP-20FOI OKT20 CABLE CLAMP FOR CONNECTOR MRP-20FOI OKT20 CABLE CLAMP FOR CONNECTOR MRP-20FOI OKT20 CABLE CLAMP FOR CONNECTOR MRP-20FOI

** UNIT NAME

CN-CRP-6 CN-CRP-6 CN-EPO-5 CN-EPO-5 CN-EPO-7 CN-EPO-7 CN-EPO-8 CN-EPO-8 CN-EP3-2 CN-EP3-2 CN-EP3-3 CN-EP3-3 CN-EF

OTY UOM

MRP34 MRP20 MRP34 MRP20 MRP20 MRP20

1 1 1 1 1 2 1 1 1 51 29 1 2 43 1 16 1

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

EA EA EA EA ST EA EA EA EA EA EA EA EA EA EA EA EA EA

Page No . 11/18/91


PART NAME

OMT PART NUMBER

DESCRIPTION

CN-EP3-4 CN-MO-1 CM-MO-1 CN-MO-3 CN-MO-3 CN-SO-1 CN-SO-1 CN-SO-2 CN-SO-2 CN-SO-3 CN-SO-3 CN-SO-4 CN-SO-4 CN-S1-1 CN-S1-1 CN-S1-2 CN-S1-2 CHI CN1 CN2 CN2 CNLK2 CNLK2

E3708-578-001 E3702-HOO-004 E3708-578-002 E3702-HOO-004 E3708-578-002 E3702-HOO-005 E3708-578-003 E3702-HOO-005 E3708-578-003 E3702-HOO-003 E3708-578-001 E3702-HOO-003 E3708-578-001 E3702-HOO-005 E3708-578-003 E3702-HOO-005 E3708-578-003 E3702-AOI-010 E3708-A01-006 E3702-AOI-009 E3708-AOI-006 E3702-AOI-004 E3708-AOI-004

CONNECTOR, CONNECTOR CONNECTOR, CONNECTOR CONNECTOR, CONNECTOR CONNECTOR, CONNECTOR CONNECTOR, CONNECTOR CONNECTOR, CONNECTOR CONNECTOR, CONNECTOR CONNECTOR, CONNECTOR CONNECTOR, CONNECTOR CONNECTOR, CONNECTOR CONNECTOR, CONNECTOR CONNECTOR,

: DC-PS 1006-0031 E5001-501-003 E3702-HOO-001 E3708-HOO-001 E3702-AOI-012 E3702-AOI-012 E3702-AOI-012 E3702-AOI-012

PCB UNIT RING CORE CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR CONNECTOR CONNECTOR

: E10 RACK 1911-1268 1911-1269

PCB UNIT POWER SUPPLY

** UNIT NAME

CN-DP-4 CN-DP-4 CN-DP-5 CN-DP-6 CN-DP-7 CN-DP-8 ** UNIT NAME

MANUFACTURER


AT

OCJ

AT

OCJ

AT

OCJ

AT

OCJ

AT

OCJ

OKT20 CABLE CLAMP FOR MRP20 CONNECTOR MRP-34FO1 OKT34 CABLE CLAMP FOR MRP34 CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR MRP34 CONNECTOR MRP-50F01 OKT50 CABLE CLAMP FOR MRP50 CONNECTOR MRP-50F01 OKT50 CABLE CLAMP FOR MRP50 CONNECTOR, MRP-20 F01 OKT20 CABLE CLAMP FOR MRP20 CONNECTOR MRP-20FOI OKT20 CABLE CLAMP FOR MRP20 CONNECTOR MRP-50F01 OKT50 CABLE CLAMP FOR MRP50 CONNECTOR MRP-50F01 OKT50 CABLE CLAMP FOR MRP50 CONNECTOR - F 206037-2 206070-1 206030-1 206070-1 CONNECTOR 206060-1 CONNECTOR AT 206062-1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA

OCJ

PCB UNIT, POWER SUPPLY MAGNETIC CORE FR68X44X15 4000H MCP-8F01 MC-8LS2 CONNECTOR, 207396-1 CONNECTOR, 207396-1 CONNECTOR, 207396-1 CONNECTOR, 207396-1

1 1 1 1 1 1 1 1

EA EA EA EA EA EA EA EA

OCJ

EIO TRP POWER SUPPLY, MS

2 EA 1 EA

AT AT AT AT AT AT AT

HONDA HONDA HONDA HONDA

HONDA OCJ HONDA OCJ HONDA OCJ HONDA OCJ

AMP AMP AMP AMP AMP AMP

TOKIN HONDA HONDA AMP AMP AMP AMP

OCJ

OTY UOM

Page No . 11/18/91


PART NAME

OMT PART NUMBER

DESCRIPTION

MANUFACTURER


PCB UNIT PCB UNIT PCB UNIT PCB UNIT NAME PLATE CONNECTOR CONNECTOR, CONNECTOR CONNECTOR CONNECTOR, CONNECTOR CONNECTOR, CONNECTOR CONNECTOR, CONNECTOR CONNECTOR, CONNECTOR CONNECTOR CONNECTOR

OCJ OCJ OCJ OCJ

CN-DR-1 CN-DR-1 CNE02 CNE11 CNEI1 CNE12 CME12 CNE13 CNE13 CRE01 CNE01 CNE03 CNE04 CRE05

1911-1270 1911-1271 1911-1275 1911-1278 E5400-ZZZ-004 E3702-HOO-004 E3708-578-002 E3703-AOI-006 E3702-HOO-004 E3708-578-002 E3702-HOO-004 E3708-578-002 E3702-HOO-004 E3708-578-002 E3702-HOO-004 E3708-578-002 E3703-AOI-006 E3703-AOI-007 E3703-A01-007

HONDA OCJ AMP HONDA OCJ HONDA OCJ HONDA OCJ HONDA OCJ AMP AMP AMP

EIO DRR EIO ACSSR EIO PC EIO TRH NAMEPLATE, EIO RACK 481X12 CONNECTOR MRP-34F01 OKT34 CABLE CLAMP FOR NRP34 171315-3 CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR NRP34 CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR MRP34 CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR MRP34 CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR MRP34 CONNECTOR - M 171315-3 CONNECTOR - M 171319-5 CONNECTOR - M 171319-5

: FAN MOTOR 1 E8020-ZZZ-017 E5501-578-001-A E1310-528-013 E1318-528-007 E5514-909-001 E5514-909-002

BRACKET ARC SUPPRESSOR . FAN MOTOR FAN MOTOR, AT TERMINAL BLOCK KG15 END PLATE

OCJ TOBISHI TOBISHI YOSHIDA YOSHIDA

FAN BRACKET MC-4VA S023150NF FAN MOTOR,4715PS-20W-830-15 FAN MOTOR ATA-30F TERMINAL BLOCK KG15 END PLATE KG30, KG15

** UNIT NAME AS FM1 FM1 TBFM1 TBFM1 ** UNIT NAME

CN-P-1 CN-P-1 CN-P-2 CN-P-2 CN-P-l CN-F

: FLAT PANEL 1098-0002 1911-1555 E3702-HOO-005 E3708-578-003 E3702-HOO-004 - E3708-578-002 E3702-HOO-004 E3708-578-002

AT

AT AT AT AT

NAME PLATE PCB UNIT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT

OCJ OCJ HONDA OCJ HONDA OCJ P^4DA

NAME PLATE, FLAT PANEL PCB UNIT, PANEX CARD CONNECTOR MRP-50FOI OKT50 CABLE CLAMP FOR MRP50 CONNECTOR MRP-34F01 OKT34 CABLE CLAMP FOR MRP34 CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR MRP34

Page No . 11/18/91


PART NAME

OMT PART NUMBER

DESCRIPTION

MANUFACTURER


CN-P-4 CN-P-4 CN-P-5 CN-P-5 CN-P-6 CN-P-6 CN-P-7 CN-P-7 CN-PA5-0 CN-PA5-0 CN-PA5-1 CN-PA5-1 CN-PA5-2 CN-PA5-2 CN-PA5-3 CN-PA5-3 CN-PA5-5 CN-PA5-5 CNFP1 CNFP1 CNFP2 CNFP2 CNFP3 CNFP3 CNFP4 CNFP4 CNFP5-F CNFP5-M CNPA5-3 CNPA5-3 PBip PB2P PBEN SSIN SSIN SS2N SS2N

E3702-HOO-004 E3708-578-002 E3702-HOO-004 E3708-578-002 E3702-000-004 E3708-578-002 E3702-HOO-004 E3708-578-002 E3702-HOO-004 E3708-578-002 E3702-HOO-004 E3708-578-002 E3702-HOO-005 E3708-578-003 E3702-HOO-004 E3708-578-002 E3702-HOO-004 E3708-578-002 E3702-HOO-404 E3708-578-002 E3702-HOO-004 E3708-578-002 E3702-HOO-004 E3708-578-002 E3702-HOO-004 E3708-578-002 E3701-082-004 E3703-AOI-005 E3702-HOO-004 E3708-578-002 E2800-722-096 E2800-722-096 E2803-722-048 E2830-917-005 E5545-721-002 E2830-917-005 E5545-721-002

CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR CONNECTOR CONNECTOR, AT SWITCH SWITCH SWITCH SWITCH, ROTARY KNOB SWITCH, ROTARY KNOB

HONDA OCJ HONDA OCJ HONDA OCJ HONDA OCJ HONDA OCJ HONDA OCJ HONDA OCJ HONDA OCJ HONDA OCJ HONDA OCJ HONDA OCJ HONDA OCJ HONDA OCJ AMP AMP HONDA OCJ FUJI FUJI FUJI

CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR MRP34 CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR MRP34 CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR MRP34 CONNECTOR NRP-34FOI OKT34 CABLE CLAMP FOR MRP34 CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR MRP34 CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR MRP34 CONNECTOR MRP-50FOI OKT50 CABLE CLAMP FOR NRP50 CONNECTOR, MRP-34FOI OK34 CABLE CLAMP FOR MRP34 CONNECTOR, MRP-34FOI OK34 CABLE CLAMP FOR MRP34 CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR MRP34 CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR MRP34 CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR MRP34 CONNECTOR MRP-34FOI OKT34 CABLE CLAMP FOR MRP34 CONNECTOR, 171267-1 CONNECTOR, 171268-1 CONNECTOR, MRP-34FOI OKT34 CABLE CLAMP FOR MRP34 SWITCH, PUSH BUTTON AH22-FG20SWITCH, PUSH BUTTON AH22-VR02SWITCH, PUSH BUTTON AH22-VR02RS-500P1-1-22P20L-22R U .ANTR2A RS-500P1-1-22P20L U .ANTR2A

FUJITSU FUJITSU

QTY UOM

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA

Page No . 11/18/91


PART NAME

OMT PART NUMBER

DESCRIPTION

MANUFACTURER


SS3N SS3N SS4N SS4N SS5N

E2830-014-001 E5545-721-002 E2830-917-004 E5545-721-002 E2811-722-029

SWITCH, ROTARY KNOB SWITCH, ROTARY KNOB SWITCH

TOKYO SOKUTEI FUJITSU FUJITSU FUJI

LA240 U .ANTR2A RS-500 P1-1-22P15L-22 U .ANTR2A SWITCH, SELECTOR AH22-J3C11A

: HOUR METER E5420-ZZZ-004 E5501-090-001 E3702-AOI-011 E3703-AOI-003 E3300-AO2-002 E3300-AO2-001

NAME PLATE PWR METER ARC SUPPRESSOR CONNECTOR CONNECTOR HOUR METER HOUR METER

AMP AMP AT&C CO . AT&C CO .

NAMEPLATE HOUR METER 99X249 S0131506F ZC150V 0 .3MF CONNECTOR-F 170894-1 CONNECTOR-M 170895-1 HOUR METER 57036102000XX HOUR METER 5704BI09000XX

: LEFT DOOR 1911-1705 E8050-ZZZ-017 E3702-782-079 E3702-782-087 1911-1415

PCB UNIT SHEET METAL CABLE CABLE FLOPPY DISK DRIVE

OCJ OCJ OCJ

BRACKET, FDD FDD COVER CONNECTOR CABLE FT-FDD CONNECTOR CABLE FDC-FDD FDD412A

** UNIT NAME AS CNP3E-F CNP3E-M HMI 142 ** UNIT NAME

CABLE CABLE FDD ** UNIT NAME

AS AS (MI5) AS (MI5) AS (MI6) AS(M3) AS(M6) AS(M7) C850 CB50 CB50 C857 C85

: MAIN BREAKER BOX E5400-ZZZ-002 NAME PLATE MACHINE NAME PLATE E5410-ZZZ-002-2 E7310-ZZZ-012 BOX E5501-090-001 ARC SUPPRESSOR E5501-090-001 ARC SUPPRESSOR E5501-578-001-A ARC SUPPRESSOR E5501-578-011 ARC SUPPRESSOR E5501-578-011 ARC SUPPRESSOR E5501-578-011 ARC SUPPRESSOR E5501-578-011 ARC SUPPRESSOR E2410-722-009 CIRCUIT BREAKER E2418-722-001 CIRCUIT BREAKER, AT E2418-722-004 CIRCUIT BREAKER, AT E2410-722-011 CIRCUIT BREAKER E2410-722-036 CIRCUIT BREAKER

TMI

OCJ OCJ NISSHIN NISSHIN NISSHIN FUJI FUJI FUJI "jJ I il

480V CAUTION LABEL NAMEPLATE, MACHINE 125X155 MAIN BREAKER BOX SQ13150OF ZC150V 0 .3MF S0131506F ZC150V 0 .3MF S02315ONF AC250V 0 .3MF S023150-3F 0 .3MF S023150-3F 5023150-3F S023150-3F BREAKER, EA103A75ATSHT N6A A1-53 3 POLE BREAKER EA33 30AT 3 POLE BREAKER EA33 20AT

Page No .

7

11/18/91

MC4VA



OMT PART NUMBER

DESCRIPTION

CLAIM-F

E3702-HOO-019

CONNECTOR

CLAIM-F CN2M-F CN2M-F

CN3M-F CN3M-F

CNEMGA-F CNEMGA-F CNEXA-F CNEXA-F CNEXA-F CNEXA-F CNEZA-F CNEZA-F TB2 TB2 T02 T62A T828 T62C ** UNIT NAME

MANUFACTURER

MANUFACTURER'S

HONDA

MCP-60FOI

HONDA

MCP-34FOI

HONDA

MCP-34FOI

HONDA

HONDA

MCP-60S

HONDA

MCP-34S

HONDA

MCP-34S

CONNECTOR,

AT

E3702-HOO-017 E3708-HOO-006

CONNECTOR CONNECTOR,

AT

E3702-HOO-017 E3708-HOO-006

CONNECTOR

CONNECTOR,

AT

CONNECTOR,

AT

HONDA

MCP-20FOI MCP-205

CONNECTOR, AT

HONDA

MCP-20S

CONNECTOR, AT

HONDA

CONNECTOR, AT

HONDA

MCP-20S

END PLATE

YOSHIDA

KG15 END PLATE

TERMINAL BLOCK

FUJI

TERMINAL BLOCK

FUJI

TERMINAL BLOCK AYBN104-5 TERMINAL BLOCK KG15

E3708-HOO-007

E3702-HOO-002 E3708-HOO-005 E3702-HOO-002

E3708-HOO-007 E3702-HOO-002 E3708-HOO-005 E3702-HOO-002 E3708-HOO-005 E5514-909-001 E5514-909-002 E5514-909-003

E5511-722-006 E5514-909-001 E5511-295-012

CONNECTOR

HONDA

MCP-20FOI

CONNECTOR

HONDA

MCP-20FOI

CONNECTOR

HONDA

MCP-20S MCP-20FOI

TERMINAL BLOCK

YOSHIDA

KG15

JUMPER BAR

YOSHIDA

JUMPER BAR

TERMINAL BLOCK

YOSHIDA

CONNECTOR

: OPERATION BOX E7305-ZZZ-002-2

BOX

CHOP CHOP

E3702-AOI-004 E3708-AOI-004

CONNECTOR, AT

AMP

CN5MA-M CN5MA-M

E3703-HOO-008 E3708-HOO-004

CONNECTOR, AT

HONDA

E8000-ZZZ-011

BRACKET

CNPHDI-F

FITTING L FITTING M

T65 TB5 ** UNIT NAME

CNP2E-F

PART NUMBER

E3703-AOI-003 E8020-ZZZ-019 E5514-909-001

E5514-909-002

CONNECTOR CONNECTOR CONNECTOR FITTING

TERMINAL BLOCK END PLATE

: OPERATION END MODE E5420-ZZZ-003 NAME PLATE E5601-762-007 E3702-AO1-011

BUSHING

CONNECTOR

AMP

HONDA AMP

KG15

TERMINAL BLOCK TG860

OPERATION BOX

CONNECTOR 206060-1

CONNECTOR AT 206062-1 MCP-16HOI MCP-16S

170895-1

CONNECTOR BRACKET FITTING - L FITTING "M", MC-4VA

YOSHIDA YOSHIDA

TERMINAL BLOCK KG15 END PLATE KG30, KG15

NAMEPLATE HEYCO AMP

END MODE 99X249

P-500 CONNECTOR-F 170894-1

Page No . 11/18/91


PART NAME

OMT PART NUMBER

DESCRIPTION

MANUFACTURER


CNP2E-M SS21 SS23 SS24

E3703-A01-003 E2840-728-006 E2840-728-006 E2840-728-006

CONNECTOR TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH

AMP FUJISOKU FUJISOKU FUJISOKU

CONNECTOR-M 170895-1 ET115D-1 ET115D-1 ET115D-1

PLUG CONNECTOR CONNECTOR NAME PLATE, POWER LAMP, RED LAMP, GREEN SWITCH SWITCH SWITCH

HEYCO AMP AMP

P-375 CONNECTOR-F 170894-1 COMMECTOR-14 170895-1 NAMEPLATE POWER ON/OFF 99X249 NEON LAMP NO5665P RED NEON LAMP N05665P GREEN AH30-L2W10L AN30 ER01 AN30 VR01

DIN RAIL END PIECE ARC SUPPRESSOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR RELAY RELAY, AT RELAY, AT

OMRON OMRON

** UNIT NAME

: POWER ON/OFF E5601-762-007 E3702-AOI-011 CNPIE-F CNPIE-M E3703-AO1-003 NAME PLATE E5420-ZZZ-005 NLEMR E3510-290-001 E3510-290-006 NLSIN E2851-722-094 PB1 P92 E2801-722-009 P63 E2803-722-014

** UNIT NAME

AS CNS1-F CNS1-M CNS2-F CNS2-M CNS3-F CNS3-M CNS4-F CNS4-M CNS5-F CNS5-M CR31 CR32 CR33 CR35 CRWL CRWL CRWL

: PS PANEL E3208-000-007 E3208-000-008 E5501-090-001 E3702-A01-011 E3703-AOI-003 E3702-AOI-011 E3703-AOI-003 E3702-AOI-011 E3703-AOI-003 E3702-A01-011 E3703-AOI-003 E3702-AOI-011 E3703-AO1-003 E3100-FOO-007 E3100-FOO-007 E3100-FOO-007 E3217-FOO-001 E3200-000-004 E3208-000-003 E3208-000-005

SATO PARTS SATO PARTS FUJI FUJI FUJI

AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP FUJI FUJI FUJI FUJI OMRON

SQ13150OF ZC150V 0 .3MF CONNECTOR-F 170894-1 CONNECTOR-M 170895-1 CONNECTOR-F 170894-1 CONNECTOR-M 170895-1 CONNECTOR-F 170894-1 CONNECTOR-M 170895-1 CONNECTOR-F 170894-1 CONNECTOR-M 170895-1 CONNECTOR-F 170894-1 CONNECTOR-M 170895-1 SC-0, 4A, 4N0000111 SC-0, 4A, 4N0000111 SC-0, 4A, 4N0000111 SH-4, 8A, 4SH8801 RELAY, MY2N 24VDC RELAY ACCESSORY PYC-A1 RELAY, AT PYF08A

Page No . 11/18/91


PART NAME

OMT PART NUMBER

DESCRIPTION

MANUFACTURER


DIODE FITTING MS2 MS3 MS6 MS7 Ol2 OL3 Ol5 OL5, AT OL6 OL7 PS PANEL TB4 T64 TB4, AT TB4, AT TB4, AT T84, AT

E4400-H02-001 E8020-ZZZ-016-1 E3100-FOO-009 E3100-FOO-008 E3100-FOO-008 E3100-FOO-008 E3110-FOO-019 E3110-FOO-015 E3110-FOO-020 E3118-FOO-002 E3110-FOO-020 E3110-FOO-022 E8000-ZZZ-049 E5511-909-001 E5514-909-001 E5511-909-002 E5511-909-003 E5514-909-002 E5514-909-003

DIODE BRACKET CONTACTOR CONTACTOR CONTACTOR CONTACTOR OVERLOAD RELAY OVERLOAD RELAY OVERLOAD RELAY OVERLOAD RELAY, AT OVERLOAD RELAY OVERLOAD RELAY PANEL TERMINAL BLOCK TERMINAL BLOCK JUMPER BAR COVER END PLATE JUMPER BAR

HITACHI

YOSHIDA YOSHIDA YOSHIDA YOSHIDA YOSHIDA YOSHIDA

DIODE, V06C PS PANEL FITTING SC-5-1, 4NCOH0111 SC-05, 4N0000111 SC-05, 4N0000111 SC-05, 4N0000111 TK-5-1N, 5-8A, 4NKOHP TK-ON, .24- .36A, 4NKOAC TK-ON, .95-1 .45A, 4NKOAH SZ-HB, OVERLOAD BASE UNIT TK-ON, .95-1 .45A, 4NKOAH TK-ON, 1 .7-2 .6A, 4NKOAK PS-PANEL MC-4VA TERMINAL BLOCK KG30 TERMINAL BLOCK KG15 JUMPER BAR KG30 COVER PLATE KG30 END PLATE KG15 JUMPER BAR KG15

: PSC PANEL E8005-ZZZ-023-2 E8020-ZZZ-023-1 E2410-722-036 E0901-EOO-002

PANEL BRACKET CIRCUIT BREAKER POWER SUPPLY

FUJI ELCO

PSC PANEL, MC4VA PSC BRACKET, MC4VA BREAKER, EA33 20AT K100AU-24N

** UNIT NAME : PT PANEL C1 E4343-M04-001 CB1 E2400-722-002 CB2 E2400-722-003 C83 E2400-722-001 C84 E2400-722-001 C85 E2400-722-111 E2400-722-112 CB6 PT E8020-ZZZ-021-3 REC1 E2714-569-004 REC2 E2714-569-008

CAPACITOR CIRCUIT BREAKER CIRCUIT BREAKER CIRCUIT BREAKER CIRCUIT BREAKER CIRCUIT BREAKER CIRCUIT BREAKER PANEL RECTIFIER RECTIFIER

** UNIT NAME

C854 PSC1

FUJI FUJI FUJI FUJI FUJI FUJI FUJI FUJI FUJI FUJI

MALLORY FUJI FUJI FUJI FUJI FUJI FUJI NINON INTER NIHON INTER

VTH10M100 10MF 100V BREAKER CP31/3W AC250V CIRCUIT BREAKER CP31/5W AC250V CP31/2W AC250V CP31/2W AC250V CP311/5W DC50V CP311/30W DC50V PT-PANEL, MC4VA PT768 75A PT102 6F 10A

Page No . 11/18/91


PART NAME

OMT PART NUMBER

DESCRIPTION

MANUFACTURER


T2 TB TB TB

E2510-DOI-001-1 E5511-909-001 E5511-909-002 E5514-909-002-2

TRANSFORMER TERMINAL BLOCK JUMPER BAR END PLATE

DONGAN YOSHIDA YOSHIDA YOSHIDA

TRANSFORMER-3 83-2-136CC TERMINAL BLOCK KG30 JUMPER BAR KG30 END PLATE KG30, KG15

: PTR 1099-9010 1911-0532

PTR BOX PUNCHER TAPE READER

OCJ OCJ

CONNECTOR-F CONNECTOR, AT

AMP AMP

206306-1 23-37 REV . 207446-1 23 CAP

: PULSE HANDLE E4926-782-014 E5409-183-349 E5589-090-111 E5601-192-020 EBOOO-ZZZ-013 E8047-090-788 E8125-882-158 E3702-AOI-011 E3703-AOI-003 E3702-A01-011 E3703-AOI-003 1911-0429 E2830-917-006 E5545-721-003 E2841-728-002

COIL CORD NAME PLATE, PHD PACKING CABLE CLAMP PANEL PHD CABLE CLAM BOX BRACKET CONNECTOR CONNECTOR , CONNECTOR CONNECTOR PULSE HANDLE ROTARY SWITCH KNOB TOGGLE SWITCH

OCJ

CABLE 0 .2 SOR NAME PLATE PLATE FOR PHD PULSE HANDLE PACKING CG-16SN PHD CABLE CLAMP MC-4VA PULSE HANDLE BOX FITTING PH PANEL CONNECTOR-F 170894-1 CONNECTOR-M 170895-1 CONNECTOR, 170894-1 CONNECTOR-M 170895-1 PULSE HANDLE SWITCH RS-500P1-11P30*L-22R KNOB R .ANTR60A SWITCH ET115E-1 L9 .5

: PUNCHER PANEL E5420-ZZZ-001-1 E8029-ZZZ-021 E5525-H03-001 E5526-HO3-001 E3702-JOO-012 E3708-JOO-008

NAME PLATE COVER RECEPTACLE RECEPTACLE, CONNECTOR CONNECTOR,

** UNIT NAME

** UNIT NAME : PTR i/F CNP-12 E3702-AOI-008 CNP-12 E3708-AOI-007 ** UNIT NAME

CNPHDI-F CNPHDI-M CNPHD2-F CNPHD2-M PHD1 SS37N SS37N SS6N ** UNIT NAME

ACM100 ACM100 CN31 CN31

PUNCHER 5261 AT AT

KINJYO

OCJ AMP AMP AMP AMP OCJ FUJITSU FUJISOKU

JAE HUBBEL HUBBEL jAF

NAMEPLATE, PUNCHER COVER 15X55 5261 224-VAL DBU-25S-FO DB-59-J2

Page No . 11/18/91


PART NAME

OMT PART NUMBER

DESCRIPTION

MANUFACTURER


CN31

E3708-JOO-013

CONNECTOR, AT

JAE

D20418-J

2 EA

: RELAY CARD EBOOO-ZZZ-020 E3702-HOO-016 E3708-HOO-008 E3702-HOO-018 E3708-HOO-009 E3702-HOO-016 E3708-HOO-008 E3702-HOO-018 E3708-HOO-009 E3200-000-003 E3208-000-004 E3200-000-003 E3208-000-004 E3200-000-003 E3208-000-004 E3200-000-003 E3208-000-004 E3200-000-003 E3208-000-004 E3200-000-003 E3208-000-004 E3200-000-003 E3208-000-004 E3200-000-003 E3208-000-004 E3200-000-003 E3208-000-004 E3200-000-003 E3208-000-004 E3900-596-001-B E3900-596-002

PANEL CONNECTOR CONNECTOR, CONNECTOR CONNECTOR, CONNECTOR CONNECTOR, CONNECTOR CONNECTOR, RELAY RELAY, AT RELAY RELAY, AT RELAY RELAY, AT RELAY RELAY, AT RELAY RELAY, AT RELAY RELAY, AT RELAY RELAY, AT RELAY RELAY, AT RELAY RELAY, AT RELAY RELAY, AT PCB UNIT PCB UNIT

HONDA HONDA HONDA HONDA HONDA HONDA HONDA HONDA OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OMRON OCJ OCJ

PANEL, RELAY MCP-16FOI CONNECTOR NC-16LS2 MCP-24FOI CONNECTOR, HOUSING MC-24LS2 MCP-16FOI CONNECTOR MC-16LS2 MCP-24FOI CONNECTOR, HOUSING MC-24LS2 MY2 DC24V RELAY AT, CLIP, PYC-P MY2 DC24V RELAY AT, CLIP, PYC-P MY2 DC24V RELAY AT, CLIP, PYC-P MY2 DC24V RELAY AT, CLIP, PYC-P MY2 DC24V RELAY AT, CLIP, PYC-P MY2 DC24V RELAY AT, CLIP, PYC-P MY2 DC24V RELAY AT, CLIP, PYC-P MY2 DC24V RELAY AT, CLIP, PYC-P MY2 DC24V RELAY AT, CLIP, PYC-P MY2 DC24V RELAY AT, CLIP, PYC-P PCB UNIT MC POWER SEG . RELAY CARD 2 TOV M CODE

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

HONDA

CONNECTOR MRP-50FOI

1 EA

w* UNIT NAME CNIR CNIR CN2R CN21t CN3R CN3R CN4R CN4R CR1 CR1 CR10 CR10 CR2 CR2 CR3 CR3 CR4 CR4 CR5 CR5 CR6 CR6 CR7 CR7 CR8 CR8 CR9 CR9 RPL1 RPL2

** UNIT NAME : SDU CNVAC-1 E3702-HOO-005

CONNECTOR

AT AT AT AT

QTY UOM

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA

Page No . 11/18/91

12 MC4VA



OMT PART NUMBER

DESCRIPTION

CNVAC-1

E3708-578-003

CONNECTOR,

CNVAC-3

E3708-578-001

CONNECTOR,

CNVAC-3 SDU SDU SDU

** UNIT NAME

E3702-HOO-003

CONNECTOR

1006-1102

PCB UNIT

1006-1216 1006-1250 : SYSTEM PANEL

CNP11E-F

CNP11E-M NLEMX NLEMY NLEMZ PB28

w* UNIT NAME

AS

CN21-F CN21-F CN5M-F CN5M-F

MANUFACTURER'S

AT

OCJ

OKT50 CABLE CLAMP FOR MRP50 CONNECTOR MRP-20F01

AT

OCJ OCJ

OKT20 CABLE CLAMP FOR MRP20 SVC-A

OCJ OCJ

MSA

COVER FOR MSA

POWER UNIT COVER

E5410-ZZZ-012

NAMEPLATE

E8020-ZZZ-049

SHEET METAL

E5410-ZZZ-013

MANUFACTURER

HONDA

PART NUMBER

DECAL, STROKE END LIMIT CANCEL DECAL, X Y Z 4 5 TOUCH SENSOR

NAMEPLATE

SYSTEM PANEL

CONNECTOR CONNECTOR

AMP AMP

CONNECTOR-F 170894-1 CONNECTOR-M 170895-1

E3510-290-001

LAMP, RED LAMP, RED

SATO PARTS

NEON LAMP N05665P RED

E2800-722-016

SWITCH

FUJI

AN30-FYIO

E3702-AO1-011

E3703-A01-003 E3510-290-001 E3510-290-001

: TB3 BOX'

LAMP, RED

E8020-ZZZ-008

BRACKET

E5501-090-001

ARC SUPPRESSOR

E8020-ZZZ-025 E3702-HOO-002 E3708-HOO-005 E3702-HOO-016 E3708-HOO-004

SATO PARTS


SATO PARTS


CONNECTOR BRACKET MC-4VA A-AXIS BRACKET MC-4VA

BRACKET, A-AXIS

SQ1315OBF ZC150V 0.3MF

CONNECTOR

HONDA

MCP-20FO1

CONNECTOR

HONDA

MCP-16F01

CONNECTOR

HONDA

CONNECTOR, AT

HONDA

MCP-20S

CONNECTOR, AT

HONDA

MCP-16S

CONNECTOR, AT

HONDA

CONNECTOR, AT

HONDA

NCP-20S

HONDA

MCP-205

MCP-34F01

CN614 CN6M

E3702-HOO-017 E3708-HOO-006

CNA-F

CONNECTOR

HONDA

MCP-20FOI

CNA-F

E3702-HOO-002

CNEAA

E3708-HOO-005 E3702-HOO-002

CONNECTOR

HONDA

MCP-20FOI

YOSHIDA

TERMINAL BLOCK

YOSHIDA

JUMPER BAR

CNEAA T83

T83 TB3

TB3A TB3A

MCP-345

E3708-HOO-005

CONNECTOR, AT TERMINAL BLOCK

E5514-909-002

END PLATE JUMPER BAR

YOSHIDA

END PLATE

TERMINAL BLOCK

JUMPER BAR

Yf'QNIDA

IDA

E5514-909-001 E5514-909-003 E5514-909-001 E5514-909-002

TERM .BLOCK

END PLATE

KG15

KG30, KG15 KG15

KG15

KG30, KG15

Page No .

1

11/18/91

MC4VA



** UNIT NAME

CLAIM-N

OMT PART NUMBER

: ATC MAGAZINE

DESCRIPTION

HONDA

NCP-60NOI

SOLENOID CON" & CBL

MURRELEKTRONIK

MSUD-24952 WITH 90900

SOLENOID CON" & CBL

NURRELEKTRONIK

E2208-MO2-003 E2208-M02-003 E2208-M02-003

SOLENOID CONN & CBL

E2208-M02-003

E2208-MO2-003 E2208-M02-003

SOL15

E2208-M02-003

SOL3

E2208-M02-003

SOLS

E2208-M02-003

SOL7

E2208-M02-003

SOL9

E2208-M02-003

SOL2

E2208-M02-003

SOLO

E2208-M02-003

SOLE

E2208-M02-003

** UNIT NAME

E2208-M02-003

: AXIS MOTOR

CONNECTOR AT

SOLENOID CON" & CBL SOLENOID CON" & CBL SOLENOID CON" & CBL SOLENOID CON" & CBL SOLENOID CON" & CBL SOLENOID CONN & CBL SOLENOID CON" & CBL SOLENOID CON" & COL SOLENOID CON" & CBL SOLENOID CON" & CBL SOLENOID CON" & CBL

MURRELEKTRONIK

NSUD-24952 WITH 90900 MSUD-24952 WITH 90900

1 EA

MURRELEKTRONIK

MSUD-24952

MURRELEKTRONIK MURRELEKTRONIK

MURRELEKTRONIK

NSUD-24952 WITH 90900

MURRELEKTRONIK

MSUD-24952

: CN2M CABLE

E3708-HOO-010

90900 90900 90900

1 EA 1 EA 1 EA

1 EA 1 EA

1 EA

1 EA

ENCODER

OMY

FB TYPE ENCODER

1 EA

MOTOR

OMY

BLMHIOIE-12SB

1 EA 1 EA

1 EA

BLMH101E-12S

1 EA

Y-AXIS MOTOR CABLE

1 EA

OMW

FB TYPE ENCODER

Z-AXIS MOTOR CABLE

1 EA

OMW

CONDUIT

KINJYO

VFM28 L1750 SG28/SG28 CONNECTOR, HOUSING MCP-34MOI

1 EA 1 EA

CONNECTOR, AT

HONDA

ENCODER

E5552-192-159 E3703-HOO-009

90900

1 EA

X-AXIS MOTOR CABLE

OMW

E3702-782-066

90900

FB TYPE ENCODER

OMW

CABLE

Z-AXIS

1 EA

1 EA

NSUD-24952

MSUD-24952

1 EA

90900

MURRELEKTRONIK

MURRELEKTRONIK

1 EA

1 EA

NSUD-24952

MSUD-24952

1 EA

90900 90900

MURRELEKTRONIK

MURRELEKTRONIK

OMY

1005-1101 1005-8004

WITH WITH WITH WITH WITH WITH WITH WITH

MURRELEKTRONIK

MOTOR

1005-8004

MSUD-24952 WITH 90900

MSUD-24952 MSUD-24952

1005-1001

Z-AXIS

CN2M

1 EA

ENCODER

E3702-782-065

CN2M

NSUD-24952 WITH 90900 MSUD-24952 WITH 90900

OMY

E3702-782-064

** UNIT NAME

MURRELEKTRONIK MURRELEKTRONIK

1 EA

CABLE

X-AXIS

Z-AXIS

MC-60LS2

1005-8004

Y-AXIS

1 EA

HONDA

1 EA

MOTOR

Y-AXIS

1500 MM

BLNHIOIE-12S

1005-1001

Y-AXIS

VFN22

OMW

X-AXIS X-AXIS

2 EA

CONNECTOR

SOLID

SOLE

SG22

E3703-HOO-011

CONDUIT

SOLENOID CON" & CBL

SOL13 SOL14

QTY UOM

PART NUMBER

FITTING

E5552-192-007 E3708-"00-011

SOL12

MANUFACTURER'S

E3710-192-002

CNIM-M SOL1 SOL11

MANUFACTURER

CABLE

CONNECTOR

HONDA

CONNECTOR, AT MC-34LS2

1 EA

Page No . 11/18/91

2 MC4VA MACHINE WIRING PARTS LIST N :\EENG\D20060 OMT PART NUMBER

DESCRIPTION

MANUFACTURER


: CON CABLE E5552-192-159 E3703-HOO-009 E3708-HOO-010

FLEXIBLE TUBING CONNECTOR CONNECTOR, AT

OMW HONDA HONDA

VFN28 L1750 SG28/SG28 CONNECTOR, HOUSING MCP-34M01 CONNECTOR, AT MC-34LS2

** UNIT NAME : CON CABLE CNSM-F E3708-HOO-008 CNSM-M E3703-HOO-008 E3708-HOO-008 CN5M-M CN5MA-F E3702-HOO-016

CONNECTOR AT CONNECTOR CONNECTOR, AT CONNECTOR

HONDA HONDA HONDA HONDA

MC-16LS2 MCP-16M01 CONNECTOR MC-16LS2 MCP-16FOI

** UNIT NAME : CN6M CABLE E3702-HOO-004 CN-P-8 E3708-578-002 CN-P-8 E3703-HOO-009 CN6M-M E3708-HOO-010 CN6M-M

CONNECTOR CONNECTOR, AT CONNECTOR CONNECTOR, AT

HONDA OMW HONDA HONDA

CONNECTOR NRP-34FOI OKT34 CABLE CLAMP FOR NRP34 CONNECTOR, HOUSING MCP-34M01 CONNECTOR, AT MC-34LS2

CONDUIT CONNECTOR CONNECTOR CONNECTOR, AT

KINJYO JAE HONDA HONDA

VFM22 L3000 SG22/MS22-22 JL02-8B-22-B14SC-FO MCP-20MOI MC-20LS2

PART NAME

** UNIT NAME CN314 CON

** UNIT NAME CNEMG CNEMGA CNEMGA

: CNEMG CABLE E5552-192-155 E3702-JOO-001 E3703-HOO-010 E3708-HOO-002

** UNIT NAME

: COOLANT MOTOR CABLE CONDUIT E5552-192-154

KINJTO

VFN12 L2600 SG12/AG12

** UNIT NAME

: LSX LS1t CABLE E5552-192-156

CONDUIT

KINJYO

VFM22 L2700 SG22/SG22

** UNIT NAME

: LUBE MOTOR CABLE E5552-192-153 CONDUIT

KINJYO

VFN12 L1700 SG12/SG12

** UNIT NAME

: TRANSFORMER E3710-192-004 E5552-192-009 E2510-DOI-004

DnNGAN

SG42 VFM42 83-XXX-4-5372 EK

T1

FITTING CONDUIT TRANSFORMER, 30KVA

Page No . 11/18/91

3 MC4VA



+* UNIT NAME

OMT PART NUMBER

: WARNING LIGHTS

WARNING LIGHT,

E3600-TOO-002-1

WARNING LIGHT, AMBER

E3702-AOI-007

CNPA1-M

E3703-AO1-002

CNPA2-M

E3703-AOI-002

CNPA2-F

RED

E3600-TOO-001-1 E3600-TOO-002

CNPA1-F

DESCRIPTION

E3702-AOI-007

MANUFACTURER

MANUFACTURER'S

TONEMASTER ELEC

MF400 RED

PART NUMBER

AC115V WARN LIGHT

TONEMASTER ELEC

MF400 AMBER AC115V WARN LIGHT MF400 AMBER AC115V WARN LIGHT

CONNECTOR

AMP

CONNECTOR-F 170923-1 170924-1

CONNECTOR

AMP

CONNECTOR-F 170923-1 170924-1

WARNING LIGHT, AMBER

CONNECTOR CONNECTOR

TONEMASTER ELEC

AMP AMP

EL 501 OSP 5020 Electrical Maintenance RevD

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