CNC SYSTEMS SP-U100M OSP-U10M MX-V/MD-V/MA-V/ MB-V/MF-V SERIES MAINTENANCE MANUAL (5th Edition) Pub. No. 4194-E-R4 (ME34-040-R5) Jan. 2002 OKUMAME00-001-R1P-(i) SAFETY PRECAUTIONS SAFETY PRECAUTIONS ‘The machine is equipped with safety devices which serve to protect personnel and the machine itself from hazards arising from unforeseen accidents. However, operators must not rely exolusively on these safety devices: they must also become fully familiar with the safety guidelines presented below to ensure accident-free operation. This instruction manual and the warning signs attached to the machine cover only those hezards which ‘Okuma can predict. Be aware that they do not cover all possible hazards. 1 Precautions Relating to Machine Installation (1) Install the machine ata site where the following conditions (the conditions for achievement of the guaranteed accuracy) apply. - Ambient temperature: 17 10 25°C (62.6 10 77°F) ~ Ambient humidity: 40% to 75% at 20°C (68°F) (no condensation) Site not subject to direct sunlight or excessive vibration; environment as free of dust, acid, corrosive gases, and salt spray as possible. (2) Prepare a primary power supply that complies with the following requirements. - Voltage: 200 = Voltage fluctuation: 10% max. Power supply frequency: 50/60 Hz Do not draw the primary power supply from a distribution panel that also supplies a major noise source (for example an electric welder or electric discharge machine) since this could cause matfunction of the CNC unit. - lf possible connect the machine to.a ground not used by any other equipment. If thereis no choice but to use a common ground, the other equipment must not generate a large amount of noise (such as an electric welder or electric discharge machine). (8) Installation Environment Observe the following points when installing the control enclosure. ~ Make sure that the CNC unit will not be subject to direct sunlight Make sure that the control enclosure will not be splashed with chips, water, or oil Make sure that the control enclosure and operation panel are not subject to excessive vibrations or shook. The permissible ambient temperature range for the control enclosure is Oo 40°C (22 to 104°F) The permissible ambient humidity range for the control enclosure is 30 to 95% (no condensation), ~ The maximum altitude at which the control enclosure can be used is 1000 m (3281 ft).‘ME00-001-R1_P-(i) ‘SAFETY PRECAUTIONS Points to Check before Turning on the Power (1) Close all the doors of the control enclosure and operation panel to prevent the entry of water, chips, and dust. (2) Make absolutely sure that there is nobody near the moving parts of the machine, and that there are no obstacles around the machine, before starting machine operation. (3) When turning on the power, turn on the main power disconnect switch first, then the CONTROL ON switch on the operation panel. Precautions Relating to Operation (1). After turning on the power, carry out inspection and adjustment in accordance with the daily inspection procedure described in this instruction manual. (2) Use tools whose dimensions and type are appropriate for the work undertaken and the machine specifications. Do not use badly worn tools since they can cause accidents, (8) Donot for any reason touch the spindle or tool while spindle indexing is in progress since the spindle could rotate: this is dangerous. (4) Check that the workpiece and tool are properly secured. (6) Never touch a workpiece or tool while it is rotating: this is extremely dangerous. (©) Do not remove chips by hand while machining is in progress since this is dangerous. Always ‘stop the machine first, then remove the chips with a brush or broom, (7) Donot operate the machine with any of the safely devices removed. Do not operate the machine with any of the covers removed unless itis necessary to do so. (8) Always stop the machine before mounting or removing 4 tool (@) Donot approach or touch any moving part of the machine while it is operating, (10) Do not touch any switch or button with wet hands. This is extremely dangerous. (11) Before using any switch or button on the operation panel, check that its the one intended.ME00-001-R1_P-(ii) SAFETY PRECAUTIONS Precautions Relating to the ATC (1). The tool clamps of the magazine, spindle, etc., are designed for reliability, but itis possible that ‘a lool could be released and fall in the event of an unforeseen accident, expasing you to danger: do not touch or approach the ATC mechanism during ATC operation. (2) Always inspect and change tools in the magazine in the manual magazine interrupt mode. (8) Remove chips adhering to the magazine at appropriate intervals since they can cause misoperation. Do not use compressed air to remove these chips since it will only push the chips further in. (4) It the ATC stops during operation for some reason and it has to be inspected without turning the power off, do not touch the ATC since it may start moving suddenly. On Finishing Work (1) On finishing work, clean the vicinity of the machine. (2) Return the ATC, APC and other equipment to the predetermined retraction position. (3) Always turn off the power to the machine before leaving It (4) Totum off the power, turn off the CONTROL ON switch on the operation panel first, then the main power disconnect switch.ME00-001-A1.P-(iv) ‘SAFETY PRECAUTIONS 6. Precautions during Maintenance Inspection and When Trouble Occurs In order to prevent unforeseen accidents, damage to the machine, etc., it is essential to observe the following points when performing maintenance inspections or during checking when trouble has ‘occurred. (1) When trouble occurs, press the emergency stop button on the operation panel to stop the machine, (2) Consult the person responsible for maintenance to determine what corrective measures need to be taken. (8) If two or more persons must work together, establish signals so that they can communicate to confirm safety before proceeding to each new step. (4) Use only the specified replacement parts and fuses. (5) Always tum the power off before starting inspection or changing parts. (©) When parts are removed during inspection or repair work, always replace them as they were and secure them properly with their screws, ete. (7) When carrying out inspections in which measuring instruments are used ~ for example voltage checks — make sure the instrument is properly calibrated. (8) Do not keep combustible materials or metals inside the control enclosure or terminal box. (9) Check that cables and wites are free of damage: damaged cables and wires will cause current leakage and electric shocks. (10) Maintenance inside the Control Enclosure. a) Switch the main power disconnect switch OFF before opening the control enclosure door. b) Even when the main power disconnect switch is OFF, there may some residual charge in the servo amplifier and spindle drive unit, and for this reason only service personnel are permitted to perform any work on these units. Even then, they must observe the following precautions. = Servo amplifier Discharge the residual voltage one minute after tuning off the breaker Inside tne unit + Spindle drive unit Discharge the residual voltage one minute after turning off the main power disconnect switch. ©) The control enclosure contains the NC unit, and the NC unit has a printed circuit board whose memory stores the machining programs, parameters, etc. In order to ensure that the contents of this memory will be retained even when the power is switched off, the memory is supplied with power by a battery. Depending on how the printed circuit boards. are handled, the contents of the memory may be destroyed and for this reason only service personnel should handle these boards.ME00-001-R1P-(v) ‘SAFETY PRECAUTIONS (11) Periodic Inspection of the Control Enclosure a) Cleaning the cooling unit ‘The cooling unitin the door of the control enclosure serves to prevent excessive temperature rise inside the control enclosure and increase the reliability of the NC unit. Inspect the following points every three months. - Is the fan motor inside the cooling unit working? ‘The motor is normal if there is a strong draft from the unit. - Is the external air inlet blocked? Ifitis blocked, clean it with compressed air General Precautions (1) Keep the vicinity of the machine clean and tidy. (2) Wear appropriate clothing while working, and follow the instructions of someone with sufficient training (9) Make sure that your clothes and hair cannot become entangled in the machine, Machine operators must wear safety equipment such as safety shoes and safety goggles. (4) Machine operators must read the Instruction manual carefully and make sure of the correct procedure before operating the machine. (5) Memorize the position of the emergency stop button so that you can press it immediately at any time and from any position. (6) Do not access the inside of the control panel, transformer, motor, etc., since they contain high-voltage terminals and other components which are extremely dangerous. (7) Iftwo or more persons must work together, establish signals so that they can communicate to confirm safety before proceeding to each new step.ME00-001-A1.P-(vi) ‘SAFETY PRECAUTIONS 8. Symbols Used in This Manual ‘The following warning indications are used in this manual to draw attention to information of particular importance. Read the instructions marked with these symbols carefully and follow them, PTET] [: indicates an imminent hazard which, if not avoided, will result in death or serious injury. [AAWARNING).[:_!ndicates hazards which not avoided, could result in death or serious injury. AACAUTION] |: tpdeates hazarés which, itrot avoided, could result in minor injuries or damage to devices] or equipment NOTICE | [: indicates precautions relating to operation or use.4194-E P-() TABLE OF CONTENTS SECTION 1 OUTLINE OF OSP... 1 2 3 SECTION 2 MAINTENANCE AND INSPECTION... 1 W +2, 13. 14, 15. 31 8-2, 3-3, 3-4, 3-5, 3-6. 3-7, 3-8, 3-9. ‘TABLE OF CONTENTS System Configuration VO Link and Servo Link . Construction and Outline of Units CPU Unit NC Rack NC PCB's Power Supply Unit FieldNet Unit (0 Unit). Servo Unit Motors and Position Encoders Floppy Disk Drive Unit . Operation Panel 3-10. Gooling Unit att Control Enclosure . Inspection during Installation . Installation Site Environmental Requirements Primary Power Supply Input Voltage Range Including Voltage Vatiation .. Momentary Voltage Variation Rate and Power Source Inductance Daily Inspection Daily Inspection . .. 7 Every Three-month Inspection Cleaning the Floppy Disk Drive 18 18 18 19 19 19 20 20 20 20 at at 22 24 24 24 244194-E P-(i) ‘TABLE OF CONTENTS PAGE SECTION3 TROUBLES AND TROUBLESHOOTING 26 1, General Check Procedure When Trouble Occurs .. 26 2, Trouble Analysis, ar 3. Checking the Inpuy/Output Signals : ee etree 28 3-1. Checking the Input/Output Signals at the CHECK DATA Screen... esseeees 28 4. CPU Status Indication 31 5, Power Supply Unit Status Indication 33 6. _ Inspection of Overload Relay 95 7, Releasing Travel-end Limit ... 36 8 Check by Machine Diagnosis Messages 37 SECTION 4 SELF-DIAGNOSTIC FUNCTION 38 1. Alarm and Error Display 39 2, Check Data Display 40 21. NG Axis Data . 42 2:2, Machine Axis Data 43 2:3. 0 Check 44 3, CNC Diagnostic Screen 7 4, Machine Diagnostic Screen 7 SECTION 5 MACHINE OPERATION CONDITIONS, DIAGNOSIS MESSAGES, AND LOGIC TABLES ....... ee 968 1, Machine Operation Conditions 98 2, Machine Diagnosis Messages 100 3. ATCIAPC Operation 120 4, ATCJACP Logic Table .. 123 4-1, Howto Read Logic Tables ....... : Bie 123 4-2. ATC Logic Table 126 48. APC Logic Table .. 1394194-E Pi) ‘TABLE OF CONTENTS SECTION 6 PLC MONITOR FUNCTION .. 1 2 3 SECTION 7 PLC PROGRAM INSTRUCTIONS, 1 oH. 32, 33, 14 12, 18. Outline of PLC Monitor Function .. Calling the PLC Monitor Function Function Details ...........cee0 PLC Data Display Function .. Ladder Diagram Monitor Function Data Trace Function Outline of PLC Program Instructions Basic Instructions Application Instructions. System Function Module SECTION 8 INSTALLING SOFTWARE .... 1 2 a4 22. 233. 24. 26. 26. 27. 3 a4 32, 38, 4 Outline of Install Glossary of Technical Terms . Flash Memory (FR) Memory Disk {MD} Install Package Floppy Disk Custom Floppy Disk System Backup Floppy Disk Work Disk Media Necessary for Installing Software Control Floppy Disks 31-1. Kinds of Control Floppy Disks ..... 31-2. Configuration of Control Floppy Disks System Backup Floppy Disk Work Disk Steps for Installing Software PAGE 158 168 159 160 160 71 180 192 192 192 192 208 213 213, 214 214 214 214 215 216 215 215 216 216 216 219 224 221 2224194-E P-(iv) TABLE OF CONTENTS PAGE 5. Procedure for Installing Software 223 Checking the Hardware Configuration .. 223 Checking the UCMB 223 MD Initialization Processing 224 Cases Requiring MD Initialization Processing 224 622, Procedure ... cereus 224 53. Data Backup 226 5-3-1, Cases Requiring Data Backup Operation 226 5 Backup of the System Data ere 226 5-3-3. Backup of the User Files, 226 53-4. Backup Procedure ..... 226 5-4. Installing the Control Software aaa er sea 229 5-4-1. Use Order of Floppy Disks 229 Operation Procedure ... 230 55. Loading the Backup Data .........ccecceeeees catiateuari 232 55-1. Backup Data Loading Procedure 232 SECTION 9 CHANGING THE BATTERY 234 1, Battery Life Warning ... 234 2. Changing the Battery... 235 SECTION 10 APPENDIX 239 1. Accessories 239 1-1, Check Sheet (Control System) 238 1-2. OSP Control Card . 239 1-3. Floppy Disks . 239 2, NC Operation Panel... 240 8. Machine Operation Panel 243 4, Other Operation Panels 245 5, Machine Electrical Parts Layout (MA-S50V/650V, MD-S50/650V) 251 6. Machine Electrical Parts Layout (MA-S50/650V, MD-S5O/650V) «..........ccscseeee 2544194-E P-1-R3 SECTION 1 OUTLINE OF OSP SECTION1 OUTLINE OF OSP Ae System Configuration eo ec a } vem e-| [SE be ema ) separa y a SE ql aa : 1] Sensor inna “45 -2) Bl ae pL earner ol ea. : {| 3 Le LE L 3 DearS i fal ele IE since ae jie & | & ‘ee pester ercser| Eta patanencaie i eb an ten renter Bra en rose 1) Aquantity and unit selection change by the spectiation, *2) Existence le chosen by the speotfstion. Fig, 1-1 System Configuration4194-E P.2 SECTION 1 OUTLINE OF OSP 2. 1/O Link and Servo Link In the 1/0 ink, network is formed between an /O unit (stave station) and an FCP board (master station) to transfer the data. At an /O unit, communications of the data is executed via the input from pushbutton switches, output to lamps, input from limit switches, output to solenoids, etc In the servo link, network is formed between a servo/spindle control unit and an FCP board to execute high-speed data communications. The servo/spindle control unit controls feed axes and the spindle. Manual pulse handle Operation panel il ‘coop i i WO unit Mode A FIpC2 FOPT 0 unit Model 8 FUB.DRS VO Link FUB-PaMa | FUBPAR2 | eo Mv unit—) MV unit Spindle Feed xs MV unit Feed axis lL | S 3 Fig. 1-2 /O Link and Servo LinkN94E P-3 SECTION 1 OUTLINE OF OSP 3. Construction and Outline of Units 3-1. CPU Unit ‘Tne CPU unit which function as the core of the CNC unit consists of the NC rack, the power supply unit, and the NC PCB's as shown below. Fig. 1-8 CPU Unit 3-2. NC Rack ‘The NC rack (compact rack) has several slots in it to install the power supply unit, NC PCBs, etc. Depending on the specifications of the CNG unit, docking racks are additionally used.4194-E P-4 SECTION 1 OUTLINE OF OSP NC PCB's (1) UCMB (Universal Compact Main Board) ‘The UCMB functions as the first main CPU to control the entire system. ‘As an interface, the UCMB has one channel of RS232C interface and the 3.5-inch flopoy disk drive interface, DRAM is used as the main memory and a DRAM card is installed. For the system memory, flash memory and SRAM are used, and a flash memory card and an SRAM card are installed. A battery Unit is installed to back up the SRAM memory card. ACAUTION : When removing the UCMB from the NC rack with the battery unit connected to it, pay attention so that IC pins and connector pins will not be short circuited. Short cirzut of these pine could cause malfunctioning, battery weer, and loss of information stored in memory. (2) FOP Board ‘The FCP board has the following on it; CPU and memory of the builtin PLC, VO link interface, servo link interface, sensor interface, and timing generator. (3) ACP Board The AGP board controls the operation panel including key operation at the keyboard and also the soreen display at the NC operation panel. AXCAUTION] |: 1©'s anc other etoctronic devices used in an NC PCB are susceptible to static eloctricity. Therefore, an NC PCB must be handled very carefully when itis removed from the NC rack. Since removal of an NC PCB from the NC rack while power is on could cause matfunctioning| of a power supply unit and the NC PCB, do not remove an NC PCB from the NC rack while] power Is on.494-E PS SECTION 1 OUTLINE OF OSP 34. Power Supply Unit Output Input oe Power supply unit HV 24VOG og Fig. 1-4 Receiving 24 VDC, the power supply unit supplies the CPU DC power (+5, +12V, -12V) as shown in Fig. 14. ‘The power supply unit is located at the upper right part in the compact rack (OSP CPU unit) and connection ‘10 24 VDC input and other devices are made through the connectors using special cables. ‘The power supply unit has the monitor function to check input and output voltages constantly. It stops the CPU ifan error is detected in the 24 VDG input or the +5 VOC output. For details, refer to SECTION 3, 5. “Power Supply Unit Status Indication’ i" Power supply unit Fig. 1-5 Power Supply UnitN94-E P-6 SECTION 1 OUTLINE OF OSP 35. _FieldNet Unit (VO Unit) The FieldNet unit controls inputs and outputs between the machine and the CNC unit. ‘Two types of FieldNet units, Model A and Model B, are provided according to the purpose of the control. Model B - FUB-DR3. The unit having the FieldNet interlace and the power sequence function. It has a built-in optical conversion module, FUB-PaMa ‘The unit controlling inputs and outputs for external devices. {thas built-in inputs and outputs indicated below: Photocoupler inputs (P): 4 bytes Power MOS IC outputs (M): 4 bytes FUB-PAR2 The unit controlling inputs and outputs for external devices. {thas built-in inputs and outputs indicated below: Photocoupler inputs (P): 4 bytes Relay outputs (R): 2 bytes Q] <— trout connector BEL | osm nnee \ TEL cop: ‘The interface which incorporates an optical conversion module. One card is necessary for each slave station, ~ FAPC2 ‘The card inputting signals from an extemal device. Photocoupler inputs: 2 bytes. FOPT The card outputting signals to an external device. Power transistor output: 1 byte Cards are mounted in the texrinal box ype tase: tab type terminal are provided.4194-E P-7 SECTION 1 OUTLINE OF OSP (1) FUB-DRS Equivalent relay circutt: The circuit diagram in Fig. 1-6 shows the power sequence circuit of FUB-DR3 in the form of equivalent relay circuit. With exceptions of several relay outputs, outputs are power MOS IC outputs. SESE cap a co ae eS Sea6Ffe nd ee mn y LSet seeeoson eo ae | t0snsac vt + Fe cus sc Wem Sernldiernod Se a a “ eo sp concurs aa as Geineewecnenin ei 1aS.19 COA brho rota 1 ae 7 oe DGGOM IPeKA i ie: sec oF eye FS. § 10 serenade OFF cau Lui ibs} nny Man breaker OFF Fig. 1-6N94E PB SECTION 1 OUTLINE OF OSP Input section: Rating of input: 24 VDC, 14 mA typ. XB3-12 DCCOM (P24A) Control power ON (Power ON button) 5 | | i i contotpoweron | PR 4 (Calender timer XB3-2 | Control power OFF (Power OFF button) Emergency stop (Emergency stop button) NC contol ON (PLO) XB3-8 Auto power OFFcommand = | PF OO 4d (PLC) Power shut-off command (PLO) NC-unit power ON (NC power supply) Foed Axis stroke end (Feed Axis stroke end switch) NC-Axis brake release (PLO) XB3-16 EC-Axis brake release PLO) Fig. 1-7494-E Pg SECTION 1 OUTLINE OF OSP Power MOS IC output section: Rating of output: 2 A (24 VDC} ‘XB3-12 83-13, XB4-A) ‘Axis control ON XB4-B]_Emergency stop monitor =C]_ Emergency stop monitor reserve) XB4-B2 _ Axis power ON XB4-43 Axis power ON (reserve) XB4-(2_COM2 XB4-C3 Control power ON indication Fig. 1-84194-E P10 SECTION 1 OUTLINE OF OSP Relay output section: Allowable max. relay contact current: Contacts marked with **1" 5A (80 VDC, 250 VAC, resistance load} Contacts marked with 2" 2A (80 VDC, 250 VAC, resistance load} | + 1 i ' f asco -RCOM. i | xis.) _NC-Aus brake release 1 I | I L 15.81 bonne ==o = | nd \ HEH | scr nc rate wtease 2 : I LIT Tis-91 NC Ais brake release reser be --- : 4. 1 att as.ig_EC-Axis brake release 1 i! - Bs b 1 1 aT. 1 = EC-Axis brake release 2 7 . ‘ COMS. F-- += _| 1 > cas 1 ot NC power ON 1 1 boaae Seca I a NC power OFF 1 1 “2 F - 4 I x ' =o Main breaker OFF i 156-32 Fig. 1-9A194-E P11 SECTION 1 OUTLINE OF OSP LED display cireuit On the FUB-DRS, when an output signal is turned ON, the corresponding green LED (OUT! - OUT12)isIit. The table below shows the correspondence between the LED indicators and output signals. Indicator (Green LED) ‘Output Signal ourt ‘Axis control ON our Emergency stap monitor ours ‘Axis power ON ouTa NG-Axis brake release 7 outs NG-Axis brake release 2 ouTé EG-Axis brake release 1 our7 EC Axis brake release 2 ours Control power ON/Power ON indication LED ours NG power ON OUuTIO NG power OFF ouTi Main breaker OFF ourie Emergency stopA194-E PAZ SECTION 1 OUTLINE OF OSP ‘The FUB-DRS has an oscillator of 100 Hz and the yellow LED (OSCSTP) lights if the oscillator stops, Indicator (Yellow LED) Conditions for Lighting OSCSTP ‘Stopping of oscillator4194-E PA SECTION 1 OUTLINE OF OSP (2) Input Section of FUB-P4lM4 and FUB-P4R2 The photocoupler input crcult is common to these two types of cards. xB2 4 KA KA — TSA TSA KM. TSB SQ xT (=) (4 24 VDC Fig. 1-11 FUB-P4M4, -PaR2 Card Input Circuits4194-E P14 SECTION 1 OUTLINE OF OSP (3) Output Section of FUB-PaMa The illustration below shows the output circuit of 1 byte data in the power MOS IC output section. Output rating: 2 Avbit 4 _w — Ww Ka. “This hows the sirout for 1 byte data. Four sets ofthe same olrout are eranged in FUB-P&MS, XB3-XB5 lo e avoe Fig. 1-12 FUB-P4M4 Card Output Circuits4194-E P15 SECTION 1 OUTLINE OF OSP (4) Output Section of FUB-PaR2 ‘The maximum allowable current of relay contact is 2 A (80 VDC, 125 VAG, resistance load). 3-A2 wv 3-B2 sp Az 4-B2 yp 8:08 4-03 8 sels of relays show above ace used as gop >> J 1 (lo be output fo XB, XB4). Another 8 sels are used as group 2 (1s be output lo XB5, X86), v ‘Although group 2 is not shown, has the same ‘eeu ae the one shown for group 2a VDC > 21» sor t= 2 _s5 s.01 L's 5.03 By at t= 4 _»» aor eee eee ——— 85 _» 3.81 Eee ees pe nea at EE eae SSE ersten ct PEPER EEE pg ——— 88 ___» aa {__5» 4.a3 Fig. 1-13 FUB-P4R2 Card Output Circuits4194-E P16 SECTION 1 OUTLINE OF OSP (8) Photocoupler Input Card (FIPC2) ‘One card can handle a total of 16 points and up to two cards can be used at one slave station. ‘The card is used for reading signals input from switches such as limit switches and relay contacts. + KA KA ak SA T_-_SA KM Te SB SQ xT xT 1 ( 2avoe Fig. 1-14 Field Net Input Photocoupler Card (FIPC2)4194-E PAZ SECTION 1 OUTLINE OF OSP © Power Transistor Output Card (FOPT) ‘One card can handle a total of 8 points and up to four cards can be used for each communication card, ‘The card is used for driving DC load such as solenoids, relays, and lamps. wv >: al S Yr yo Ya Ya Yo $v Fig. 1-15 Field Net Output Power Transistor Gard (FOPT)4194-E PAB SECTION 1 OUTLINE OF OSP 3-6. Servo Unit ‘Servo unit consist of a DC power supply unit (MPS, MPR) and inverter units (MIV) which control the spindle ‘and numerically controlled axes, For the maintenance of the servo unit, refer to the Maintenance Manual for MCS (Motion Control System). 3-7. Motors and Position Encoders BL motors which drive numerically controlled axes have Type position encoder as a standard position sensing device. Optionally, an absolute scale which reads the position of a numerically controlled axis directly is available. ‘Amagnatic pulse generator which detects the speed and position of the spindles attached tothe spindle. 3-8. Floppy Disk Drive Unit (1) 85° Floppy Disk Drive Unit Access indicating lernp Fig. 1-16 (©) Open the cover (©) Insert a floppy disk into opening (A) shown above. Before inserting a floppy disk, make sure that the floppy disk is facing the correct direction, otherwise it cannot be inserted completely. (d) The floppy disk drive unit is ready for reading the floppy disk when its inserted into the floppy disk drive unit correctly (©) Push projection (B) to remove a floppy disk () Close the cover. AACAUTION) |: (9 Betore switching power off, make sure that a floppy disk s not let inthe floopy disk rive unit (2) Keep the cover closed. (3) The access indicating lamp does not ight even when a floppy disk is set in the floppy disk| ‘drive unit. The lamp lights when reading/writing processing is executed using the floppy| isk.4194-E P19 SECTION 1 OUTLINE OF OSP 3-9. Operation Panel All controls necessary for operation, such as operation switches, manual switches, and pulsz handle are arranged on the operation panel, including the display unit, 3-10. Cooling Unit A cooling unit is mounted to the door of the control enclosure so that temperature in the control enclosure wil not rise excessively, thereby the reliability of the CNC unit can be improved. For some machine models, a cooling unit may net be used. Control Enclosure CNC unit, servo units, 1/0 units, and electric control circuits are installed in the control enclosure. Totally enclosed construction provides reliable protection for electronic components in the enclosure against the entry of oil mist, chips, dust and other foreign matter, ensuring stable operation of them.4194-E P-20 SECTION 2 MAINTENANCE AND INSPECTION SECTION2 MAINTENANCE AND INSPECTION Dally checks greatly help to keep your CNC operating properly at all times. The self-dlagnostic function, integrated in the CNC, help you locate the trouble ifthe machine malfunctions, allowing the user to take appropriate corrective action to minimize down time. Consult also the following section: Section 3 "TROUBLES AND TROUBLESHOOTING” 1 Inspection during Installation 1-1. _ Installation Site When determining the installation place of the machine and the CNC unit, aecessibilty to the machine for ‘easy operation is an important factor to be carefully attended to, In addition, easy access to the CNC unit and the control enclosure for the purpose of maintenance and inspection must also be taken into consideration. sm jean) | Cont a Fig. 2-17 Layout ‘Arrange the machine and the CNC unit in the manner shown above. For the inspection and maintenance, space as shown in the illustration must be secured to alow doors of the control enclosure tobe opened with sufficient area for working. Donot install the enclosure close to the shop wall 1-2. Environmental Requirements Observe the following points when instelling the CNC unit and the control enclosure. ~ Make sure that the CNC unit will not be subject to direct sunlight Make sure that the control enclosure will not be splashed with chips, water, or oil. - Make sure that the control enclosure and the operation panel will not be subject to excessive vibration or shock. + Permissible ambient temperature range of the control enclosure is 0 to 40°C (82 to 104°F) Permissible humidity range of the control enclosure is 75% or lower (no condensation). - The maximum altitude at which the control enclosure can be installed is 1000 m (8281 ft},4194-6 P.2t SECTION 2 MAINTENANCE AND INSPECTION 1-3. 1-4, Primary Power Supply Prepare the primary power supply that complies with the following requirements, ~ Voltage: 200 V ~ Voltage fluctuation: + 10% max. = Power supply frequenoy: 50/60 Hz + Donat draw the primary power supply from the distribution panel that also supplies the power to a major noise source (for example, an electric welder and electric discharge machine) since this could cause ‘malfunctioning of the CNC unit. - If possible, connect the control enclosure to a ground independently. If there is no choice but to use a ground with other equipment, avoid connection to the ground where noise generating equipment such as an electric welder or an electric discharge machine is connected, Main motor kW ‘Apparent power KVA_| Please prepare the power source 5 conforming to the items specified ower fecuiremsnits. KW _Jin the final specifications. Cable size mame ‘Momentary vollage variation rate Refer to 1-4 and 1-5, Power source inductance HH Input Voltage Range Including Voltage Variation Make sure that the voltage of the power source, including the momentary voltage variation, is within the range indicated below. Ifthe Input voltage is outside the range indicated below, acceleralionideceleration time of the spindle will be elongated, Input voltage range: 200 VAC ~10% to 230 VAC +10%A194-E P22 SECTION 2 MAINTENANCE AND INSPECTION 1-5. Momentary Voltage Variation Rate and Power Source Inductance Table 2-1 indicates the permissible inductance of the power source for MPS and MIP units, If the inductance of the power source is larger than the permissible value, acceleration/ceceleraticn time of the spindle will be elongated even if the power source vottage is within the range indicated above. Since it will be difficult to measure the inductance of the power source, measure the rate o' momentary voltage variation caused by acceleration and deceleration of the spindle instead of the inductance and ensure that the measured value is within the momentary voltage variation rate indicated in Table 2-1. Ifthe inductance of the power source is large, momentary voltage variation rate gets larger accordingly. Table 2-1 Power Source Inductance Momentary Voltage Variation Rate Unit [230 V Power | 220 V Power | 200 V Power | 230 V Power | 220 V Power | 200 V Power Source |” Source | ~ Source” | Source | Source | Souroa ow] Gow | cron ee or less) or less) or less) a0 He] (40 oH] a0 wesso] (AONE | THOnN | CADW | ase ortess | 15% orless | 15% oless 400 wH 400 WH 400 wH eS or less or less or less marae | OW] tO orless)_| _orless Fetal UI At Ut orless) | o%ortess | 15% or loss men | @20KH | 200uR : ) criessy | orloss Note: A value in ( ) shows an estimated value. ACAUTION (1), Ifmore than one machine is connected to the same power source, the value of “inductance of power source’ for each machine is obtained by dividing the value in the table by the number of the machines to be connected. (2) Wiringinductance in 50-meter cable (164.05 ft) is approximately 12 .H when general KIV| cable is used.A194-E P23 SECTION 2 MAINTENANCE AND INSPECTION [Calculating momentary voltage variation rate | eet 8 aT ‘Siphase power source \VACUILcrive unit AC voltmeter Momentary voltage variation rate = Vo: Voltage while the motor is stopped. Vj: Maximum voltage during motor deceleration, Vo VAC motor Mi =Vo (1) Connect an AC voltmeter to the power supply terminals at the spindle drive motor controller as: shown above. (2) Measure the voltage while the spindle motor is stopped and take this value as “V0”. (3) Measure the maximum voltage while the spindle motor is decelerating and take this value as vr (4) Calculate the momentary voltage variation rate using the following formula. Momentary voltage Variation rate = (V ~ Vo)IMo [Supplement] 1. Since a digital AC voltmeter has slow response, momentary voltage variation rate obtained using the values measured with the digital AC voltmeter is smaller than the actual value, To obtain the precise value, itis recommended to use an analog AC voltmeter. 2. Voltage “V1” cannot be measured accurately if motor deceleration time is short Therefore, it is recommended to start deceleration from as high spindle speed as. possible.4194-E P24 SECTION 2 MAINTENANCE AND INSPECTION 2. Daily Inspection The CNC unit incorporates electronic devices which are susceptible to moisture, cil, dirt, dust, and chips, and also elevated temperatures in the enclosure caused by clogging of fiters in the sooling unit. Therefore, daily inspection and maintenance of the CNC unit is important. 24. Daily Inspection (1) Inspection of Appearance of Control Enclosure and Operation Box Visually check the control enclosure and the operation box for adhesion of water, oll, dust, and chips and alsa the cooling unit fer for clogging. If the control enclosure and the operation box are dirty, clean them. At the same time check the inside of the control enclosure and the operation box 2-2. Every Three-month Inspection (1) Cleaning the Cooling Unit Make sure that the cooling unit mounted at the control enclosure door operates to blow air hard. If the filter is clogged, clean it 2-3. Cleaning the Floppy Disk Drive (1) Cleaning the 3.5" Floppy Disk Drive Head Adirty read/write head may sometimes cause the floppy disk read/write error. Clean the head using a head cleaning disk, ‘The head cleaning disk may be either a market product or the one ordered from Okuma. Okuma part No: £0241-602.008 Okuma part name: Floppy head cleaning disk FCD-8.6W (Maker: Nippon Microccating) (2) Head Cleaning Procedure To clean the head with the above cleaning disk, proceed as follows. When using the other maker's cleaning disk, follow the attached instructions. (@) Insert the head cleaning disk into the floppy disk drive unit (6) Drive the cleaning disk using the disk initializing function 1} Press EDIT AUX key. 2) Press the function key [F8] (EXTEND). 3) Press the function key [F2] (INIT) 4) Key in as follows: IN FDO: Initialization OK (Y/N) !¥ Formatting (VIN)! Format (2DD ~ 720K = 0, 2HD — 1.44M = 1) 10 5) The drive unit's LED blinks when cleaning is started,A194-E P25 SECTION 2 MAINTENANCE AND INSPECTION 6) Aiter 90 seconds, the floppy disk read/write error occurs and the cleaning is finished. This error occurs because no data can be written onto the cleaning disk as a matter of course. (¢) This is the end of cleaning. If no good effect is found, repeat cleaning a maximum of five times. (@) If satistactory result is not obtained after five times of cleaning, the drive unit or the floppy disk may be faulty, (3) Precautions for Cleaning Excessive head cleaning will give damage to the floppy disk unit head. When using the above recommended disk, remember that the adequate frequency is once in three months and do not exoeed the limit of four times a month, (4) Cleaning Disk Lite ‘The above cleaning disk will ose effect when used for attotal of one hour {40 times) because the disk is clogged with dirt4194-E P26 SECTION 3 TROUBLES AND TROUBLESHOOTING. SECTION3 TROUBLES AND TROUBLESHOOTING The purpose of this section Is to minimize downtime of the machine through speedy detection and remedies of the cause of any trouble that might occur. itis extremely important to make detailed checks on the condition ofthe machine and CNG system when the trouble arose and to carry out various kinds of tests described in this section, Thus, t1e customer himself will be able to fix the machine in most cases. The test results reported to your local Okuma representative will be a great help in determining the nature and extent of the trouble and the remedies to be applied. 1 General Check Procedure When Trouble Occurs Generally, check the folowing matters: (1) When Trouble Occurs, (a) Mode of operation {o) Current position and command position (c) What STATUS display lamp is going on? (d) Is the ALARM lamp on? When the ALARM lamp is on, the cause of the alarm can be known from the contents of the alarm message given on the CRT. (2) After Resetting the CNC System, (a) Does the trouble occur at the same situation repeatedly? (b) Does the same trouble occur in ather modes of operation? (©) How about frequency of the trouble? (d) Does the trouble arise regularly in terms of time, temperature, etc.?A194-E P27 SECTION 3 TROUBLES AND TROUBLESHOOTING Trouble Analysis ‘The machine stopped and does not restart a woes soroon ON? ae Is an alarm’ ha No message ~~ displeyen? Is the screen display changeable? Yes No ‘Check the contents of the block in which the machine has stopped. is the NC STATUS = ‘STM lamp on the operation panel it? Yes No Refer to the “ALARM & ERROR LIST’ supplied separately to locate the cause of the trouble. Display the CHECK DATA screen and check the inputfoutput signals. Soe 8. "Checking the Input/Output Signals” in this, ‘section See Section 4, 2 “Check Data Display’ Please contact your local Okuma representative. The computer is not operating normally. (1) Cheok in what status the ‘computer has stopped ‘See 4. “CPU Status indication” in this section (2) Cheok the power supply unit for is input voltage. See 5. “Power ‘Supply Unit Status Indication” inthis section (@) Contact your local Okuma representative.A194-E P28 SECTION 3 TROUBLES AND TROUBLESHOOTING. 3. 3-4. Checking the Input/Output Signals A variety of electric parts such as limit switches, proximity switches, solenoid valves, and motors is mounted in the machine, and these machine-mounted electric parts are placed in very severe environment affected by chips, coolant, oll, dir, and dust. Although water- and dust-proof construction is adopted to protect these electric parts, electrical trouble causes a high rate of the CNC troubles. However. most ofthe electric parts are relatively simple in their operation and can be easily checked and repaired by the user's maintenance technicians. This section describes the practical methods for checking the input/output signals. Checking the Input/Output Signals at the CHECK DATA Screen (1) Displaying the /0 CHECK Screen ‘The ON/OFF status of the input and output signals of the CNC unit can be checked at the /O CHECK screen. «< Procedure > (1) Select an operation mode (automatic, MDI, manuel). (2) Press function key [F7] (CHECK DATA). ‘The CHECK DATA screen is displayed (8) Press the page selection key to display the YO CHECK screen. (/ aiT0 OPERATION oT @ \ en/oayor 12:00:00 CHECK DATA 1/0 CHECK HO. 0 rai 1 ine so 12 coveur) 1 toxren DIT LABEL BIT LABEL. | BUT LABEL BET LABEL 0 pte =} py |e MLL 8 1 oiprage | § ipIPUP | 1 ph 2 ipPSRL A ipPHON LE OpPBIL A gL, 5 ipmsk «= ApAKSS [8 opBSHL, Bp 4 iow SMS onal Copal 5 ipwmlZ > ABMKSZ |S omMRaL © paKTL & ine SpatsY 1 6 opMM pat 7 MeN ABAKSK |Top, FpaK DaTHeDon—” aTASdoa |” ‘DaTAsoow =" ‘DaTAeCon Paseo ja) woe |) | (TET lu! fren nee! ome / (F1(F2)(F3)(F4)(F5)(F6) E78) Fig, 3-14194-E P29 SECTION 3 TROUBLES AND TROUBLESHOOTING < Contents of display > AUTO OPERATION AMIN 0 N 1 CHECK DATA WOCHECK =—NO.0 PAGE 1 1mm | | ssot 12 Page number within Indicates the sereen ene tie - WO CH : tite -VO.CHECK. sclayed display screen pages eee vO number number indicates page 1 in2 pages. If an VO bit is ON, the label section (9 characters) is highlighted Signal ON stetus ipAXSX Signal OFF status At the bottom line in each column, the value of 6 bits of that column is displayed in hexadecimal. DATA=41H : BIT7 BIT6 BITS BIT4 BIT3 BIT2 BIT1 BITO Oe roto Hera teeeO eeeera eee Lt 4 1 (2) Checking the Input Signals ‘The procedure for checking the status of the proximity switch that checks the spindle tool clamp using the /O CHECK screens explained below as an example. Other input signals can be checked in the same manner. From the Field Netinput wiring diagram, supplied separately, confirmation signal is input to check No. 29, bit 8 So, display the CHECK DATA screen for I/O CHECK No. 29 and see the label “iISCL” of bit 8 of INPUT. When the label is highlighted, it indicates that the input signal is ON. Conversely, when the label is not highlighted, It indicetes that the input signal is OFF. Ifthe spindle tool clamp confirmation inputsignal is OFF (label not highlighted) in the state the signal must be ON, the spindle tool clamp confirmation proximity switch will be faulty found that the spinde tool clamp4194-E P-30 SECTION 3 TROUBLES AND TROUBLESHOOTING (3) Checking the Output Signals The procedure for checking the status of the spindle too! internal cylinder unclamp sclenoid using the VO CHECK screen is explained below as an example. Other output signals can ba checked in the same manner. From the Field Netinput wiring diagram, supplied separately itis found that the signal for operating the spindle tool internal cylinder unclamp solenoid is output from check No. 28, bit & So, display the CHECK DATA screen for /O CHECK No. 29 and see the label “olSUC" of bit 8 of OUTPUT. When the labels highlighted, itindicates that the output signal is ON. Conversely, when the label is not highlighted, it indicates that the output signal is OFF. Ifthe spindle tool internal cylinder unclamp solenoid has not operated although the output signal for operating the spindle too! internal cylinder unclamp solenoid is ON (label highlighted), the spindle tool intemal cylinder unclamp solenoid will be faulty,4194-E P.3t SECTION 3 TROUBLES AND TROUBLESHOOTING 4. CPU Status Indication Whether the computer is running normelly or not can be checked by simply observing the display in the screen at the operation panel. If it is operating, the computer is judged to be running normally. For ‘example, changeover the screen display and when the screen display changes accordingly, you can judge that the computer is running normally To check the status of the computer, status indicating LED lamps are provided on the UCMB (UC main board) (see Fig. 3-2) (1) Contents of Indication RUN: RUN The GPU is running to execute an instruction (calculating an instruction). PRT: PROTECTERROR |The CPU has accessed an address area in the prohibited mode, or it has accessed an unused address ares. PAR: PARITY ERROR During the access to the system bus by the GPU in this board, a party error was detected in the read data. LOP: LOOP ERROR ‘An interruption processing occurring in a predetermined ‘eycle (RTC) has not finished before the oocurrenca of the next interruption. ECC: ERROR CHECK & [Inthe access to the main memory, there was an error in the CORRECT ERROR _|contents of the memory at the specified address. DIA: DIAGNOSTIGERROR | The output diagnose data differed from the normal data ($55), CYO: CYCLE OVER ERROR |The CPU bus cycle of this board has not finished within a preset time. ‘SBER: SYSTEM BUS ERROR |A slave station detected an error while the OPU of this board was accessing the system bus as the bus master, (2) CPU Operating Status Indication (@) While the CPU is running normelly, only the RUN lamp (green) is lit (0) At the occurrence of a bus error, an LED lamp (red) showing the cause of the error lights. ‘The RUN lamp (green) stays lt during bus error processing, (©) Ifthe GPU enters the hait state due to double-bus error, the RUN lamp (green) goes off ‘The LED lamp (ted) showing the cause of the double-bus error lights (@) Mall of the LED lamps are lt, either the 5 V power is not supplied or the CPU is in the reset state. (@) An error indication shows the trouble of the CPU and it s not cleared by the CNC reset ‘operation (9 To restart the CNC, turn off the power once and then turn it back on. If the trouble which has ‘occurred continues, the same error occurs again and the CNC stops. If the CNC operates normally, allow the CNC operating to observe the situation.