Okuma OSP 5000 - MACHINE OPERATION

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OSP 5000/5020 CONTROL

MACHINE OPERATION

ELECTRICAL MAINTENANCE

TRAINING MANUAL EL 501

Main Page

Terms and Acronyms9
Table of Contents13
Safety Precautions17
Checks before Turning on Power17
Precautions to Observe When Using a Chuck17
Checkup Around the Machine18
Precautions for Machine Operations18
Setup19
Workpiece Loading and Unloading19
Machine Centers19
At the End of the Day20
When a Problem Occurs20
Other General Precautions20
Machine Definition33
Machine Tool35
Numerical Control Machine35
Computerized Numerical Control Machine35
Microprocessor36
Memory36
Permanent Storage36
Long-Term Storage37
Temporary Storage37
Servo System38
I/O Devices38
Tape Reader38
Disk Drives39
RS-232 Interface39
External Switches39
Lathe40
Machining Center41
Vertical Machining Center41
Horizontal Machining Center42
Travelling Column Type Horizontal Machining Center43
Double Column Machining Center44
Grinder45
Work Coordinate System for OD Grinding46
Wheel Coordinate System for OD Grinding47
Wheel Coordinate System for ID Grinding47
Machine Operation48
Basic Construction of the Operation Panels50
NC Operation Panel50
Functions Available When the AUTO Mode Key Is Pressed51
MDI53
Manual53
Actual Position54
Part Program54
Block Data55
Check Data55
Tool Data56
Edit AUX57
Zero Set58
Parameter59
Auto Mode60
Functions Available When the MDI Mode Key Is Pressed63
Functions Available When the MANUAL Mode Key Is Pressed63
Actual Posit, Part Program, Block Data and Check Data Menus64
Data Setting Mode Keys (Tool Data, Edit Aux, Zero Set and Parameter)66
NC Status Display Lamps70
Mode Selection Keys70
Data Setting Mode70
Operation Mode71
Character Keys71
Numeric Keypad71
LATHE Machine Operation Panel72
Cursor Keys72
Page Keys72
Turret Keys72
Pulse Handle73
Spindle73
Spindle Override73
Coolant73
Spindle Gear74
Load Monitor74
Tool Index74
Rev.74
Lighting75
Single Block75
Block Delete75
Individual Mode75
Stroke End Limit Cancel/Load Mode Panel76
Inter Lock76
CRT Display76
Sequence Restart76
Machining Center Machine Operation Panel77
Orientation77
Cw77
Release77
Rev. 8-21-0177
Jog Speed78
Freedrate78
Oil Mist78
Oil Hose78
NC Panel79
NC Operation79
ATC Operation80
APC Operation81
Pendant Operation Panel82
Optional Panel82
Hour Meter82
Operation End Mode82
Control On/Off83
Operational Panel above Tape Reader View87
ATC Magazine Operation Panel View88
Manual Tool Change Operation88
Check Panel View88
MDI Operation89
Rev.89
Construction90
Power Supplies92
If the Power Source Inductance Is too High92
Rev.94
OPUS 5000/5020 Power Supply Unit96
Alarm and CPU Status Led’s Located on the Control Rack98
Printed Circuit Boards98
Rev. 8-21-0198
Main Processor Board99
Bubble Memory99
Ram100
Different Board Configurations102
Main Card 13 (A911-1521) RS-232 Card103
Main Card 15 (A911-1526)103
Main Card 16 (A911-1516)/Main Card 17 (A911-1517)103
CRP-IIC (A911-1692) or (A911-1693)103
Serial if104
CRP 9 (A911-1580) - CRT Processor Board104
SVP-IID - Servo Processor Board104
SPC1 (A911-1534) - Additional 1 Axis Card105
SPC2 (A911-1535) - Additional Pulse Handle Card105
EC Board (A911-1120) - Electrical Control Board105
ECP Board IIA - Electrical Control Processor Board105
ECP Card 2 (A911-1142) - Expansion Card106
ECP Card 3 (A911-1143) - Expansion Card106
ECP Card 4-II (A911-1544) - Expansion Card106
FDC II BOARD (A911-1703) - Floppy Disk Control Board106
RS Board (A911-125) - RS-232C Interface Board107
CCP Board (A911-1594) - Communication Control Processor Board107
CCPC2 Card (A911-1596) - Signal Converter Card107
TCC-A (A911-1598)/TCC-B (A911-1599) - Turret Control Card107
EC I/O Rack108
Fieldnet I/O Unit109
Fiber Opitic Cable Part Numbers110
How to Troubleshoot a Fiber Optic Cable111
Servo Systems112
Axis Drives112
Ldu 600112
Ldu Tr113
Bdu114
Description of Led’s on BDU Style DCPS114
Led’s on the SVC Board of a BDU-A Type Drive Amplifier115
Description of Led’s on SVC-1 Board of a BDU-D Drive Amplifier116
Bld117
Description of Led’s on BLD-A Type Drive Amplifier117
Bliid119
Description of Led’s on BLIID-A Type Drive Amplifier119
Speed and Position Feedback119
Led’s on Lower Right Side of the SVC-1Board on BL-IID Type D Drive121
Spindle Drives123
Diagnosing a Spindle Drive Alarm126
Feedback Devices127
Tachometer127
Absolute Position Encoder128
Procedure for Replacing Absolute Position Encoders128
Removing Encoder from Motor128
Removing the Encoder from the Motor Shaft129
Installing the Encoder to the Motor Shaft129
Mpr130
Inductosyn130
Connecting the Encoder Input/Output (Ribbon Cable) Connector130
VAC Resolver131
Pulse Generators131
TCC Resolver132
Diagnostics133
Actual Position135
Machining Center Data136
Block Data Soft Key137
Check Data Soft Key140
Axis140
EC I/O’s141
EC Extend I/O’s141
Panel I/O’s142
Spec Code142
Machine Code142
Alarm Message List142
NC I/O’s143
Machine I/O’s143
NC Spec Table143
MC Spec Table143
NC Axis Data144
Machine Axis Data144
Alarm List144
System Variables144
Alarms145
Chart Showing the Different Numbering Systems146
Description of the Different Types of Alarms the Control Can Gener-Ate147
What Appears on the Screen When a CPU Level Alarm Occurs148
Display Format of CPU Alarms (Bus Error)149
BUS Error150
Access Address (MB II B)151
Access Address (MB II, MB II A)152
Access Address (MB) (OSP5000)153
Display Format of Alarm P, A, B, C and D155
Alarm Codes156
How to Check Alarm Contents156
Peripheral Processor Start159
SVP Start159
Timing Generator Stop161
Tool Number Input162
Servo Amp164
Collete Unclamp165
Turret Index Control Abnormal165
Alarm Table - Alarm a166
Spindle Rotation Interlock167
Probable Faulty Locations171
Travel Limit over172
Axis Drive Unit173
Sequence Count over173
ATC System Condition174
Parameters175
User Parameter Overview177
Chuck/Tailstock177
Setting Stroke End Limits178
Common Variable Info178
System Parameter Overview178
Backlash179
PR Zero Offset Overview179
Stroke Comp179
Rapid/Accel Rapid179
Jog Feed180
Accel Jog Feed180
Torque180
Turret Offset180
PR Zero Offset181
Optional Parameter (Long Word)181
Optional Parameter (Word)181
Optional Parameter (Bit)181
Spindle Control Parameter182
Common Variable183
User Parameter183
G/M Code Macro183
MC User Parameter (Long Word)183
MC User Parameter (Word)184
MC User Parameter (Bit)184
MC System Parameter (Long Word)184
MC System Parameter (Word)/Nc Optional Parameter (Long Word)184
NC Optional Parameter (Word)185
NC Optional Parameter (Bit)185
Input Unit System185
System Parameter185
Setting Zero Offset186
In Position186
Zero Offset186
In Position (H)/SWL HD187
Barrier (Y,Z)187
Encoder Offset187
Home Position Movement Order187
Inductosyn Offset/Pitch Comp Span/Pitch Point188
Pitch Error Compensation188
NC Hour Meter/Power on Time/Nc Running Time188
Spindle Revolution Time/Cutting Time188
NC Work Counter189
Spindle Control Parameter Info189
External Input Time189
Software190
OSP Data Management Card192
Option Features192
Option Specification192
Type of Control Software193
OSP Management Data Card194
Type of Control Soft (NC Software)194
Type of Control Soft (EC Software)194
Optional Features (NC Software)194
Optional Features (EC Software)195
NC-EC Options195
System195
Motor/Drive Unit/Position Encoder195
NC/EC Options196
Different Methods of Saving Files on Lathes197
Initializing a Diskette198
Backing up Part Programs199
Lathes199
Special Notes for W-Axis and LT Machines200
W-Axis Machines200
To Backup Parameters through Centers with Software 709BF and Higher201
Reloading the Parameters202
Tape Format Table203
Machining Centers213
Loading Software213
5020M D-Disk Procedure215
Schematic Symbols218
Lathe Schematics231
Machining Center Schematics233
Table of Composition Drawings237
Internal Layout of Control Enclosure240
External View or Pendant Box241
Internal Layout of Pendant Box242
General System Figure of Machine Mounted243
I/O Card and Gray Code List244
OSP 502OM CNC System Configuration245
Power Supply System Diagram246
Power Supply Circuit Diagram247
Control Power Circuit250
Circuit Diagram of NC Control Power253
Circuit Diagram of Power between Unit254
Circuit Diagram of Spindle Motor255
Motors Circuit256
Circuit Diagram of Axis Drive Unit257
Servo System Diagram258
Circuit Diagram of X-Axis Drive Unit259
Circuit Diagram of Y-Axis Drive Unit260
Circuit Diagram of Z-Axis Drive Unit261
Circuit Diagram of A-Axis Drive Unit262
Circuit Diagram of SVP II-1 Control263
Circuit Diagram of SVP II-2 Control264
Circuit Diagram of NC Operation Panel265
Panel Control Input Circuit Diagram of Manual Operation Panel266
Panel Control Output Circuit Diagram of Manual Operation Panel271
Circuit Diagram of Panex Bus Line273
Panex Bus Line Circuit274
Circuit Diagram of Operation Panel275
ECP Bus Line Circuit Diagram276
EC Control Input277
EC Control Output280
ECP Control Circuit (MG Axis)284
Tape Reader/Winder Loading Circuit285
PG PHD SP Control Circuit Diagram286

Okuma OSP 5000 - MACHINE OPERATION

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