CNC SYSTEM OSP5020M MCR-B MAINTENANCE MANUAL (2nd Edition) ME34-011-R2ar342I-E P-Ci) TABLE OF CONTENTS SECTION 1 OUTLINE OF OSP5929M SERIES I-1. SPECIAL FEATURES OF OSP5920M SERIES .. 1-2. SUMMARY OF OPERATION . 3. STRUCTURE OF OsP5#20u 1-3-1. CPU Unit vite 1-3-2. Electrical Control Unit (BC) 1-3-3. Servo Drive Unit 1-3-4. Relay and Magnetic Gircuics . 1-3-5 1-3-6 1-3-7 1-3-8 1 + Spindle Drive Motor Control . + Floppy Disk Drive Unit « + Tape Reader + Control Enclosure ++. “3-9. Operation Panel «+... 1-3-19. Absolute Position Feedback Encoders 1-3-11. Cooling Unit ...s.... SECTION 2 MAINTENANCE AND INSPECTION 2-1. INSPECTION DURING INSTALLATION 2-1-1, Installation Site : 2-1-2. Environmental Requirements 2-1-3. Power Supply Voltage Inspection ..+ 2. PERIODICAL INSPECTION . 2-3. OPERATION AND STRUCTURE OF THE NC 2 rs + Example of Operation . " + Description on Bach Major NC Unit . 3-1 -2 SECTION 3 TROUBLE AND TROUBLESHOOTING .. 3-1, ANALYSIS OF TROUBLE . 3-2. LOADING 3-3. MACHINE-MOUNTED ELECTRICALS a 3-3-1. Inspection of Limit Switches by Tester Inspection of Limit Switch By NC Check Display ..+- Inspection of Solenoid by NC Check Display . PAGE u ul B 16 Vv 18 23 23 25 ra]3U21-E P-(ii) PAGE RUSHLESS SERVOMOTOR DRIVE UNIT . 29 + BDU-A Series « 29 Configuration of BDU-A ... 30 Protection and Alarm Monitoring Function 34 Trouble ané Troubleshooting «.+++++++00+ 35 2. BDU-D Series Servo Drive Unit 44 rs Protection Functions ..sseseeeeeee 44 4 Trouble and Troubleshooting ...«+ 49 Precautions to Observe for Maintenance ..... 58 CHECK PANEL .. tes 39 INSPECTION OF POSITION ENCODER ., 60 CPU veseee 3 6 3-7-1. Operation and Structure of the GPU 61 3-7-2. Checking GPU Operation . 63 3-7-3. CPU Power Supply Unit 65 3-8. INPUT/OUTPUT PRINTED CIRCUIT BOARDS sdidagaressndeaoande 67 3 PHOTOCOUPLER INPUT Interface Princed Circuit Board (I-PT) ....., 68 3 REED RELAY OUTPUT Interface Printed Circuit Board (O-RR) « 69 3+ TRANSISTOR OUTPUT Interface Printed Gireuit Board (OTR) . ” 3 AG SSR OUTPUT Interface Printed Circuit Board (O-AC) weeseceeeee TI 3 POWER TRANSISTOR OUTPUT Interface Printed Gireuit Board (o-TRP) des a anna vadeie™ ewN n 3-9. RELAY MAGNET CIRCUIT . 3 3-9-1. Operation and Structure of a Relay Magnet Circuit 3 3-9-2. Inspection of a Relay Magnet % 3-10. REPLAGING ECP-II BATTERY PACK .+.-+e0e0ee n SECTION 4 SPINDLE DRIVE UNIT (VAC) .... 78 4-1. OUTLINE . 78 4-2. PERTODICA 7a 4-3, TROUBLE AND TROUBLESKOOTING . . VAC Drive Unit Construction . Operation Status Indication . Troubleshooting .« Recovery fron Failure Status 4-4, FUSE REPLACEMENT ... 4-5. SPARE PARTS ...eee.0e.eee 4-6, INPUT/OUTPUT SIGNAL TABLE . 11a 122 1233421-E P-(iti) SECTION 5 SELF-DIAGNOSTICS . 5-1. ALARM DISPLAY AND ERROR DISPLAY .... 5-2, CHECK DATA DISPLAY ...+-....+0 SECTION 6 MACHINE EXECUTABLE CONDITIONS, DIAGNOSIS AND LOGIC TABLES ...... 6-1. MACHINE EXECUTABLE CONDITIONS 6-2, DIAGNOSIS MESSAGE DISPLAY . 6-3. LOGIC TABLE . 6-3-1. How to Read Logic Tables . APPENDIX .. NC Operation Panel 453 Machine Operation Panel . Pulse Handle Component Arrangement Inside Control Box .... Component Arrangement Inside Operation Panel Magazine Manual Operation Panel ..... Control Power ON/OFF Panel . System Check Panel . Option Panel . Machine Mounted Electricals ~ Bed .. Machine Mounted Electricals ~ Crossrail . Machine Mounted Electricals - Spindlehead Machine Mounted Electricals ~ Sub Arm, Ready Station . Machine Mounted Electricals ~ Tool Change Unit ..-.. PAGE 125 126 127 153 153 154 187 187 206 207 298 219 ail 212 213 214 215 216 217 218 219 22 + 221SECTION 1 Ie. 3421-B P=] OUTLINE OF OSP5920M SERIES SPECIAL FEATURES OF OSP5020M SERIES Based on the OSP series that has an outstanding production record as a CNC all over the orld, che OSP5#20M series is a high performance computerized numerical control system that functions as an Intelligent Manufacturing Gell (IMG) forming an operator untended production system. a @) (3) o3) (5) A Multiprocessor ONC System The OSP5920M is a multiprocessor CNC system using plural high performance microprocessors, and features architectures capable of coping of high level NC functions. Versatility Through distributed processing by the multiprocessor, the OSPS20M provides versatile functions not available on existing NCs, such as alarm monitor data processing, link with high level computers, advanced online automatic programming function, and large capacity Part program storage. This CNC is complete also with functions such as diagnostics and operation guides, display of alarm data and display of production control information, by means of the CRT. ‘Tremendously Expandable, Never Obsolete The computer software is stored in the bubble memory. Therefore, it is easy to change the software, enabling any addition and alteration of functions in the future, and this OSP5020M can be used always as a most up-to-date system ready to meet the customer's application needs. High Reliability High reliability is ensured by various kinds of functions such as automatic memory error correction, perfect noise isolation by a photo- coupler, high integration of hybrid ICs and LSIs, etc., reduced con- sumption power and thorough monitoring of GPU power supply, and by a simple structure mounted in the totally enclosed cabinet. Uniquely Designed for Easy Operation Since a large-sized CRT is provided as standard on a pendant-type operation panel, it is exceedingly easy to operate.1-2. 3421-E P-2 ‘SUMMARY OF OPERATION ‘The OSP5026M employs a closed loop system with absolute position feedback. The following is a brief summary of its operation: ‘The value (command value, RCOM) which is read into the CNC in the form of taped commands generates path functions (operation value, RCON) within the CNC to produce @ commanded tool path at the conmanded feedrate. Also, feedrate functions (operation value, OCON), and multiplication of RCON by the acceleration/deceleration coefficient are generated. Meanwhile, the OSP position encoder detects actual position signals (RAPA) of each axis. This OGON and RAPA are continuously compared, the difference (ODIF) between OCON and RAPA is added to the feedrate command and the result is input to the drive unit as motor drive current conmand. The drive unit controls the brushless servomotor so that value ODIF will be zeroed. con econ Motor current conmand Tape Bubble Function] Opera- Drive | resder || memory |—]zenerat tion unit para Brushless & servonotor | table gu co » }@ 83 a Fig. 1-11-3, 1-1. 1-3-2. 3421-E P39 STRUCTURE OF OSPS920M This section outlines the overall structure of the OSPS@20M. For further information, consult the following sections of this manual. Section 2-3: Operation and Structure of the NC Section 3 : Trouble and Troubleshooting CPU Unit Thie is the heart of the CNC system and consists of the following printed circuit board modules and units: ‘*Printed Circuit Board MAIN BOARD-I1B Main processor MAIN CARD 13 MAIN CARD 11 MAIN CARD 15 Either MAIN CARD 15 or MAIN CARD 16 is selected MAIN CARD 16 in accordance with the NC unit specification. BUBBLE CARD .....-. Bubble memory RP BOARD . s+esees ORT operation panel control processor Bye epee ae Axis control processor SVP CARD 1 ECP BOARD-1T Control processor for the machine other than ECP CARD 3B axis control (Optional) FDC BOARD II ........ Printed circuit board to control for reading and duplication of data stored on floppy disks The parts listed above are for standard system specifications. For optional specifications, printed circuit boards for selected fune~ tions will be added. *Power Supply Unie ‘This supplies al1 the power required for CPU operation. Electrical Control Unie (EC) This interfaces input and output signale from and to the ECP board to control output to solenoids, magnets and other devices on the machine and input from machine mounted limit switches. *Power Supply Unit This supplies all the power required for the EC control unit.1-3-3 1-3-4. 1-3-5. 1-3-7. 3421-2 P-4 Servo Drive Unit The servo drive unit receives motor current command (digital value) out~ put from the servo processor to control brushless servomotors which drive independent axes. This accurately controls movements of the table, the spindlehead and others in accordance with the programmed commands. The servo drive unit consists of the following units: a) DC pover supply Supplies DC power to the servo amplifier unit. b) Servo amplifier unit Controls brushless servomotors in response to the command input from the servo processor. Relay and Magnetic Girevits These circuits are used to control machine-mounted solenoids, electric motors, etc., and also conveys signals from machine-nounted operating pushbuttons and limit switches to the CPU. The following panels are provided: MS Panel +. *Relay Panel . + Panel with magnetic switches + Panel with control relays Spindle Drive Motor Control The main spindle of the machine is driven by a VAC motor. The control unit receives speed command signals given from the CPU, in the form of analog voltage, and controls the motor speed to the commanded speed. Floppy Disk Drive Unit (optional) A floppy disk is used to load NC control software. As an optional feature, floppy disks are used for loading and duplicating machining programs. Tape Reader The tape reader is used to store taped commands into the CNC memory.1-3-9, 1-3-19. 1-3-11. 3421-E PS Control Enclosure Arranged in a single enclosure are the CPU, drive units, relay and magne- tic circuits, spindle motor drive unit and others. The totally enclosed construction provides reliable protection against the entry of oil mist, chips, dust and dirt, ensuring stable performance of semiconductors, relays and magnets. Mounted on the common machine base, this space-saving CNC package forms a compact machine-contrel combination. Operation Panel Al the controls necessary for operating the machine such as operating switches, manual switches and the pulse handle are incorporated into and mounted to this accessible pendant-type operation panel. A large-sized ORT is provided as standard, assuring ease of operation. Absolute Position Feedback Encoders To each servomotor for the X-, Y~ and Z-axis, the absolute position feed- back encoder that produces accurate information concerning the instan- taneous position of each axis is provided. The output signals from these encoders are fed into the CNC system for accurate positioning of each axis. Attached to the main spindle is 2 main spindle pulse generator to detect the spindle speed. Also, @ position feedback encoder to detect the posi- tion of the magazine to store cutting tools is used. A position feedback encoder for an additional axis such as a rotary table is provided when the machine is equipped with such an axis. Cooling Unit The cooling unit provided on the control box keeps the temperature within the control enclosure less than 8°C (46.4°F) over room temperature. This provides the CNC system with higher reliability.B421-E Pb SECTION 2 MAINTENANCE AND INSPECTION Daily checks greatly help to keep your CNC operating properly at all times. When any trouble occurs, integrated testing circuits within the CNC system will help you diagnose most malfunctions and pinpoint their location quickly, thos enabling you to reset to normal operation with little incon- venience. Consult also the following section: Section 3 Trouble and Troubleshoot ing 2-1. INSPECTION DURING INSTALLATION 2-1-1. Installation Site During initial installation, careful consideration should be given to easy access for inspection and maintenance purposes as well as for opera~ tion. Arrange the machine and the machine control unit as shown in the left figure. Since the machine control unit doors must be opened and some space must be given for 4 maintenance and inspection, install the machine and the machine control unit so that they are not close to a wall. L Tachias l Jeonerat box] 2 we 98 TS TRO i.) Fig. 2-1 Layout2-1-2. 3421-E P-7 Environmental Requirements Pay attention to the following items (1) Do not install the CNC system in a place exposed to direct sunlight. (2) The CNG system should be kept avay from chips, coolant, oil, etc. (3) The site should be free of excessive vibration. (4) Ambient temperature should be between °C (32°F) and 4¢°C (14°F). (5) The site should be free of large electrical noise sources such as welding machines. (Power should be preferably dravn from the plant power source.) (6) Avoid dirty and dusty areas. Power Supply Voltage Inspection The allowable variance in the input voltage for the CNC system is 410% of the available input voltage. An excessive voltage drop because of insuf- ficient power capacity in the plant will cause NC malfunctions. It will also be subject to unavoidable influence from other equipment. In such cases, proper measures should sometimes be taken against those sources.3421-E PB 2-2, PERIODICAL INSPECTION The CNC system incorporates highly advanced electronic circuits which are susceptible to moisture, oil, dirt, dust, and chips present in machine shops. Elevated temperatures within the enclosure may result from clogging of filters in the cooling unit. Therefore, it is necessary to check and inspect the CNC unit regularly to assure trouble free operation. (1) Weekly Inspection Tape Reader Light Receiving Surface Keep the light receiving glass surface clean at all times. Clean carefully with gauze or soft cloth so as not to scrateh it. Perforated Tape Inspection: Dirty, torn or worn out paper tape from excessive use may lead to NC malfunctions and troubles. Floppy Disk Handling: 3.5" floppy disk Lamp Keep the acrylic cover closed at all times. Fig. 2-2 4) Open the acrylic cover. b) Insert a floppy disk into A in the above figure. Before inserting a floppy disk, confirm that it is facing the right direction, otherwise it can not be inserted completely. c) When the floppy disk is correctly inserted, reading of the floppy disk becomes possible.BA21-E Po 4) Press down the portion B to remove the floppy disk. e) Close the acrylic cover. Note 1: Before switching power off, make sure that a floppy disk is not in. Note 2: Keep the acrylic cover closed at all times. Note 3: The indicating lamp lights up while reading of the floppy disk is being executed. 8" Floppy disk te ses Keep the acrylic cover closed at all times. Fig. 2-3 a) Open the acrylic cover. b) Press the portion B in the above figure, and insert « floppy disk into the slot C to set. The lamp at the upper left of the slot will then light up. Before inserting a floppy disk, confirm that it is correctly facing the right direction. ©) Press down the portion A co cover. Now, the floppy disk is ready to be read. 4) Close the acrylic cover. Note 1: Before switching power off, make sure that a floppy disk is not in. Note 2: Keep the acrylic cover closed at all times.3421-E P-10 (2) Every Three Months Inspection Cooling Unit Cleaning: Make sure that the cooling unit on the control box operates to blow air hard. If the filter mesh screens are clogged, clean it. Cooling Unit: The cooling unit is provided on the top of the machine control unit box to prevent the temperature rise in the control hox, thus improving the reliability of the CNC system. Maintenance and inspection: Check the following items at least once every three months ro keep the cooling unit functioning normally. a) Check for clogging in the air suction opening. Clogging will raise the temperature in the control box to degrade the reliability of the CNC system. Always make sure there is good ventilation. b) Check that the cooling fan is rotating normally. Cooling unit Cooling fan Control box The filter is detached by removing 8 screws. Clean away any clogging. ‘The filter is detached by removing 8 serews. Clean away any clogging. Clean by blowing air through to force ont any clogging. Fig. 2-42-3. 2-3-1. 3421-8 PAIL OPERATION AND STRUCTURE OF THE NC To gain an overall understanding of CNC operations, study the following carefully. Example of Operation When G1 X190. ddd Y1d the unit operates j00_F10 $1400 Td MO3 is given as command data, follows (1) Press the CYCLE START button, and the CPU starts running according to the command data registered in the memory. (2) S, T and M operation starts. - The 8, T, M commands read are transferred to the ECP board, controlled by ECP processor, and transferred to the EC relay cir~ cuit and solenoid, etc. via the EC control unit. Of the M com- mands, those not resulting in machine operation are not transferred to the ECP board. ~ The EGP processor selects the gear range according to the given $ command, and drives the gear shifting solenoid via the EC control unit. It calculates the motor speed corresponding to the given 8 command and determines the rotation direction. The ECP board chen converts the motor speed command into analog voltage and gives it as an output to the spindle drive VAC motor control unit, which drives the spindle drive VAG motor. ~The ECP processor gives a signal for selecting the toolpot according to the programmed T code. The control of magazine rota~ tion is made by the machine control unit. ~Thus, the spindle starts co rotate in the forward direction at 1,008 rpm with the middle gear range selected. The magazine is rotated to select the #1 tool commanded by the code TIO. ~ After these S, T and M commands have been executed and the com manded states are obtained, the execution completion signals are given to the MAIN board from the ECP board.3421-8 P-12 (3) Operation of Interpolator ~ The moment the operation by 8, T and M commands is started, func- tions are generated at the feedrate of F1 mm/min from a present coordinate point to the commanded coordinate point (X10). 000, Yip@.000) along a Gl straight-line path. M commands have two kinds: WITH and AFTER, and in case of AFTER, it is carried out after the axis interpolation is completed. Also, in case the main spindle is equipped with the rotation interlock function, the interpolator does not start to operate before the main spindle rotates in GOl, G02 and G03 modes. (A) Movement of Axes ~ OCON, the output from the interpolator, is compared with the actual position data RAPA given from the position encoder. The difference ODIF between OCON and RAPA is added to the commanded feedrate, and the result is outputted to the servo processor, where it is converted into the motor current value (digital value). This motor current value is then outputted to the servo drive. - The Servo Drive Unit controls the brushless servomotor so that the ODIF input will be zeroed at all times, and as a result, completes positioning to X1A0.600 Y1dd.000.3421-E PA13 2-3-2, Description on Each Major NC Unit a (2) The Power Supply Unit receives AC 209V supply and supplies all the power required for operation of the CPU. It also controls the Sequence for power supply ON/OFF, Press the POWER ON button on the operation panel, and the Power Supply Unit supplies first voltage to the CPU and drives the CPU. Press the POWER OFF button, and this unit cuts off voltage supply to the CPU after stopping CPU opera~ tion. Moreover, this unit detects abnormalities such as abnorual Srop and rise of output voltage, abnormal drop of input voltage, and elevated temperature within the unit, etc., causes the CPU to stop the operation, cuts off voltage supply and has a monitor function to display the abnormality cause on the monitor display. The monitor display is effective even if supply voltage to che CPU is cut off by pressing the POWER OFF button on the operation panel, unless power Supply to the ONC system is cut off by turning off the main switch (no-fuse circuit breaker). The CPU Unit is the central controller of the OSP50G0M-G and of the multi-processor structure consisting of plural processors. The standard unit consists of seven BOARDs and CARDs annexed to the BOARDs as follows: a) MAIN BOARD-IIB: Main Processor Board This consists of an LC memory, bubble memory and main processor to control slave processor and each interface. BUBBLE CARD: Bubble Memory This is @ memory to store taped commands, and control software when power is switched OFF. The operation of writing the control software into the bubble memory is called "loading". Such control software contained in floppy disks is provided to all the NC system. When loading is carried out according to Section 3-2, "Loading", if required, the contents of the bubble memory can be rewritten. The circuit interfacing the tape reader is also contained in the MAIN BOARD-115. b) CRP BOARD: GRT Processor Board ‘The circuit interfacing the CRT operation panel This consists of the interface circuit for the CRT display and the interface circuit for the inputs/outputs of the machine operation panel.Bi21-E P-14 c) SVP BOARD IID: Servo processor board This board consists of the timing generation circuit, pulse handle, spindle pulse generator, servo drive unit, position encoder, inductosyn, and sensor input interface necessary to configure the servo processor. A single board has the circuits for two axes. Therefore, the standard specification uses an SPC card additionally. SVP CARD 1: Servo processor card This card consists of the servo drive unit, position encoder, inductosyn, and sensor input interface for one axis. One SPCI card is mounted on the SVP-IID board as standard. 4) PDC BOARD II (optional) The circuit interfacing the floppy disk drive unit e) ECP BOARD=IT The processor for machine coatrol such as ATC, APC, various kinds of solenoids and main spindle motor drive unit and the cireuit interfacing position encoder for magazine rotation. ECP CARD 38: Pulse Generator Input The circuit interfacing the pulse generator for the main spindle (3) The EC Control Unit is a unit consisting of EL printed circuit boards and EO printed circuit boards. The EO printed circuit board transfers outputs from the ECP BOARD-II to relay circuits, sole~ noids, etc., vhile the EI printed circuit board derives signals to the EGP BOARD-II after reading input signals from machine-mounted Limit switches, proximity switches, etc. ‘The EC control unit is housed in che 1/0 rack, The power supply unit is also housed on this rack. The power supply unit supplies the necessary power to the EI and EO boards.3421-E P-16 SECTION 3 TROUBLE 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. It is extremely important to make detailed checks on the condition of the machine and CNC system when the trouble arose and Co carry out various Kinds of tests described in this section, Thua, che customer himself will be able to fix the machine in most cases. The test results reported to your local Okuma represeatative will be a great help in determining the nature and extent of the trouble and the remedies to be applied. Generally, check the following matters: (1) When trouble occurs, = Mode of operation ~ Current position and command position ~ What STATUS indicating lamp is going on? - 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, ~ Does the trouble occur at the same stage repeatedly? = Does the same trouble occur in other modes of operation? - How about frequency of the trouble? - Does the trouble arise regularly in terms of time, temperature, ete,? This section covers the basic troubleshooting procedures, along with structure, operation and method of inspection for the major CNC component Parts such as the CPU, servo drive units, relays in the EC control unit and the spindle control unit. When any trouble occurs, see Section 2, "Maintenance and Inspection" together with this Section 3 and carry out necessary checks in accordance with the instructions.3-1. ANALYSIS OF TROUBLE Te the ALARM Lamp on? NO @isplay changed over? Yes Check the contents oF | the‘block fa"ehich che richie has’ stopped. Fe the St tawp under NE STATUS on the operation panel on? ‘YES 3421-8 vES ‘Check the alate conteate onthe Cats Gheck each unte according to the contents of the alarn- No Display the check] dats on the xD (press [27] in. JOPERATION mode) , fend hack input? output signals: See Sectian 5-2. 3-1 Fig. "The conpoter does ‘not norsally Operace 1) Moke sure tn Examples of a) ate shown Below LDU Overload hat status che | |1) Check the computer te servosotor for stopped. See temperature. Section 3-1-2. | loa over 2) Check the power Gheck the pover | 11) 15 comection of the position wolage- 8 encoder Cannon Stcelon 3-7-3. fonnestor cording to tormel? >) teecructtone | |2) fe the From Okuna, taksl | position encoder normal? necessary sestures such a6 control tape Toading oc replacenenc of the printed eleeute board. Analysis of Trouble Poi?3421-E P-1B LOADING (For the Model Equipped with the Floppy Disk Drive) Bubble memory stores control software such system software, NC control software and EC control software. When the bubble memory has been replaced or the control software is to be replaced with new one, loading of software co the bubble memory becomes necessary. Control software of OSPSB2M is delivered by floppy disks. (1) Floppy Disks (3 floppy disks are delivered with the control.) Floppy disk Al: Basic control software for NC is stored in this floppy disk. When the program in this floppy disk is loaded, data having been stored in the bubble memory is cleared and replaced with new program. Basic control softuare for EC is stored in this Floppy disk. Floppy disk 5: after delivery. oJ Used for storing machine data which has been changed Oo 03421-E P19 Floppy Disk Al: OL Oo Control Software ansitnats . (File Name) pagel BINSA AE BBM Bubble memory initialization Osi, SYS System software MAAg—orK—%, POL NC main software MAGO*—one—%,POL Graphic, PPC NASd0~*%-*, POL NC specification code MANS —%—¥, POL No message mbUgt—w PEO Bubble memory backup Ginitial values) (Backup by the use of backup funetion key) Auge, BU Bubble memory backup initial values) (Backed up always) NSUGH—¥+-, PBU Servo data || wizeeae-taee.poL | Software specific to individual May or may not be | users supplied depending} on specifications.| | MAQK—*4—*,HSB Maker subprograns (used for i automating functions, ete.) * in file name varies depending on software version and machine model.3H2L-E P20) Control Software (File Name) Classification MEAQ*—**—". POL MESOG-¥%~*, POL, MEI, POL, MEU MPB May or may not be || MEZ#x=at—, POL, supplied depending BC main software EC specification code EC message Backup of EC processor backup area (initial values) Software specific to individual users on specifications. and machine model. Floppy Disk * in file name varies depending on software version OL Gontrol Software Classification O (File Name) @ MDUG#—**—*, PRU MAUD He, PBO MEUP HH MPB Bubble memory backup (Backup by the use of backup function key) Bubble memory backup (Backed up always) Backup of EC processor backup area * in file name varies depending on software version and machine model. Files in the floppy disk 5 stores che backup of the machine data (usually the data at machine delivery).(2) 3421-B P21 Control Software Loading Procedure Load the control software from the floppy disks Al, A2 and B in this order. =F = a rok oO ies OQ a) Turn on the LOAD MODE switch. b) Push the SYSTEM RESET button. ‘The ORT will display the following message. Control Eloppy loading wait ©) Set floppy disk Al in the disk drive. For the procedure to set disk Al in FDD., refer ta "Floppy Disk Handling" in Section 2-2. 4) Press the LOAD START button. The CRT indicates the message below: Control Floppy loading start The loading starts and the file name being loaded will be displayed on the CRT and all files in the Eloppy disk will be loaded in the bubble memory. After the completion of the loading, the CRT will display the messages indicated below Control floppy loading end Control floppy loading wait e) Remove floppy disk Al from the disk drive and place floppy disk A2 instead.£) 2) h) 0 iD kK) B421-B P-22 Press the LOAD START button. All files in floppy disk A2 will be loaded in the bubble memory in the same manner as in step d). If the bubble memory has the file of the same file name to be loaded, the old file is replaced with the new file. Remove floppy disk A2 from the disk drive and place floppy disk B instead. Press the LOAD START button. Note: Loading from floppy disk 8 will initialize the machine data (the data at machine delivery). Remove floppy disk B from the disk drive after the completion of loading. Turn off the LOAD MODE switch. Turn off power supply and thea turn it back on. The CPU will start running in several tens seconds.33, 3421-E P-23 MACHINE-MOUNTED ELECTRICALS Mounted on the machine are limit switches, solenoids, motors and other electro-mechanical components. See APPENDIX, "Machine Mounted Electricals" for their location. As these machine-mounted electricals are placed in a very bad environment affected by chips, coolant, oil, dirt and dust, careful consideration has been given in design to protect these com ponents from excessive moisture, dirt and dust. Nevertheless, electrical trouble causes a high rate of the NC troubles. However, most of the electricals are relatively simple in their operation and can be easily checked and repaired if required by the customer's main~ tenance technicians. The checking procedures given under Section 3-9 "Relay Magnet Girevit" should be also consulted for solving electrical problens. This section describes the practical method to inspect limit witches and solenoids. For other machine-mounted electricals, check in a similar way. Inspection of Limit Switches by Tester Limit switches are used for detecting travel end of individual axes, and on the ATC, APC and spindle drive gear box, ete. The procedure to check travel end limit awitehes for their operation is given below as an example. See the lamps under L.S. EMERGENCY on the check panel. Supposing that lamp X is lighted and the X-axis is not at the travel end position, the limit switch will be probably defective. Next, turn the main switch on the #C control box OFF and remove the tra- vel end limit switch for the X-axis.aw (2) @) Ics) 3421-E P-24 Tester Fig. 3-2 LS Check with Tester Disconnect the two electric wires connected to the limit suiteh. Set the tester to the resistance range. Apply tester probes to the limit switch terminals (G) and (NC). When the tester pointer deflects fully to the right on its scale, there is no problem with the limit switch. After that, press the Limit switch actuating lever to check to be sure that the tester pointer does not move at all. Then, the limit switch ean be judged to be good. When the tester probes are applied to the limit switch terminals (C) and (NO), the tester pointer moves in the reverse direction. Namely, when the limit switch actuating lever is not pressed, the tester pointer does not move, but when pressed, the tester pointer will deflect to the right.BO2I-E P-25 Inspection of Limit Sitch By NC Check Display 4 limit switch is mounted to check the spindle speed range setting at LoW. When this limit switch fails to function, an alarm is given because LOW range setting is not confirmed. Though this limit switch can be checked with a tester, this section describes a method to check it by the check display function. The procedure is as follow (1) Display the *MACHINE INPUT* display screen on the CRT, as follows: AUTO OPERATION oa pas HoRCHINE WELT Pee NO. | date bat? wits bres itd bitg BEE LiEt BHO QUINeIO*7H INDY OLS VaR VECU VACE YREE HTS? NTP AOIOLLIL=AF CU quiet CLL COLH CLP? Guay Cher ales SSYOK MORI ENENN EM OL CLE” FRED CAR POPP ER MKEZ IT ETSI PEFR Hat DILU LUBL ier CLE+ Lae CUZ’ OLY? CL LUBL COOH HEE HYDE HDT HRD COLL CUB SLLO SLOK Sa SAL SM LBYE OMe OTR ROTE ROT SPIN SEIN TP TOP SALS SHLS SRS SFLs StS EELS CLEP CRA. EPL URTL UPL PALS ROLS ROLS RLS (esp IMLS ILS MS ERLE GALS EDLS ELS SS/ NDC NCH See the bit 4 data on No. 7. (2) See the bit 4 data on check No. a) When (NO) and (C) are wired: When the limi switch is tripped, it displays "1" if the limit switch is normal. When it is not pressed, the bit data is "O". b) When (NC) and (C) are wired: "9" when the Limit switch is tripped. "I" when the Limit switch is not tripped.In addition, there controller printed E12 £2.32 7070 6060 5050 4040 3030 2020 1010 9000 7070 6060 5050 4 O040F- 3030 2020 1010 BORO 3421-E P26 is another method to check limit switches by the EC cireuit board: (1) See @ lamp on the right of 4 of the 2 byte on the printed circuit board E12. (2) In case of wiring between (¢) and (no. Actuating the limit switch causes the lamp to go on, and releasing ro g0 off. In case of wiring between (C) and (we): Actuating the limit switch causes the lamp to go off, and releasing to g0 on. _—See the bit 4 of 2. * See the electrical circuit diagrams for the relationship among the printed circuit boards, bit numbers and signal names. Signals from machine-mounted electricals such as a limit switch are first sent to the printed circuit board EI* in the EC control unit and then transferred to the ECP board. Therefore, if the lamp indi- cation on the EI* printed circuit board and bit data display on the CRT in 2 CHECK DATA display screen do not match, either the EI board or ECP board is faulty.3-3-3, 3421-E P-27 Inspection of Solenoid by NC Check Display Solenoid valves are used for the spindle air blower control. When a solenoid is defective, the air blower does act operate. Whether the solenoid is operating or not cannot be known unless voltage is applied and checked with a tester. However, since checking a signal for solenoid operation which is given from the CNC will be easily performed, the procedure for checking the status of this signal is explained below. (1) Display the *MACHINE OUTPUT display screen on the CRT as follows: AUTO OPERATION oe nara MIGOHNE OUTFUTE —paE aL 1D. dota a7 bite BIES itd bitd bie bred bite 33) 1gieotes-naCerm SPas SPOT Shur TUES TLS @S. GS. 14 GLAT CLoN CHS COLA METS COS 15 ie wa RGD SES SFS0 S050 CRUS TSAE SURS SURE 8 FSO ROSO USFS USRS UGS URS SRSO SMES 8 23 EWS EULS NSD FASO ERSO ESSO DSO Uso Fen CRS DOES BERS BoAS See the bit 6 data on No. 13. (2) When bit 6 of check No. 13 is " blower signal is active. With does not operate. it indicates that spindle air " display, the spindle air blower3421-E P-28 (3) Next, observe the lamps on the printed circuit boards inside the Electrical (EC) control unit. B04 2 aud See the printed circuit board E04. When the lamp of bit 6 is lighted, the spindle mee ‘O air blower signal is output. Spindle ai ‘blower: © In case the bit data "1" is displayed on Git 6) —O ° the CRT although the corresponding lamp on Oo this printed circuit board is off, the oO fuse on this board might have been blown ° or the solenoid disconnected. oO Oo oO oO ro bit#——O | t No. 13 No. 16 a, Check these. See the electrical circuit diagrams for the relationship among the printed circuit boards, bit numbers and signal names.3-4. 3-4-1. 3421-8 P~29 BRUSHLESS SERVOMOTOR DRIVE UNIT BDI-A Series Brushless Servomotors are employed to control movement of each axis of X, Y and Z at the feedrate and in the direction as commanded by the GNC. It is the brushless servo drive unit that accurately controls the rotating speed. As described in "Operation and Structure of the NO" in Section 2-3, OCON, the output from the CPU interpolator is compared with RAPA, the output from the position encoder which detects the actual position of each axis. The difference O-DIF between OCON and RAPA is added to the commanded feedrate and the result, DA is obtained. The brushless servo unit func- tions to control the brushless motor, i-e., the present position of each axis so that the ODIF is always zero. The brushless servonotor drive unit BDU-A has been developed by Okuma as the drive unit for the brushless servomotor especially for axis drive of machine tools. The brushless servomotor is also the product of Okuma, the supplier of mechatronics technology. ‘The features of the BDU-A are as follows: (1) ‘The use of a brushless servomotor does not require inspection and replacement of commutator brushes, which is the must with DC motors. (2) The transistor PWM system assures smooth and quick response. (3) It promises good acceleration/deceleration characteristics. (4) The high-resolution OSP position encoder directly coupled to the motor detects both the motor speed and position. Therefore, control and construction are quite simple. (5) Various measures to protect the motor are provided. They include: = motor overload detection = no-fuse breaker = overcurrent alarm ~ input voltage detection - circuit failure3421-E P-30 3-4-1-1, Configuration of BDU-A (1) General System Configuration The BDU-A consists of the DC power supply and the servo amplifier unit. ADC power supply can supply power to multiple servo ampli- fiers (max. six axes) and one brushless servomotor requires one servo amplifier. Fig. 3-3 shows the configuration of the BDU-A in the six-axis control cnc. DG pover i supply De-S#A i |_Sexve Servo proceso oe eeise boas board (st axis) BL-D**A (ise and 2nd axis) Servo ‘ amplifier jE BL woter 1 : (and axis) i BL-Dsta : Servo processor, ! board [Servo anplitier slau fete (sth and 6th (6th axis) ae axis) Fig. 3-3. BDU-A Configuration(2) (3) Configuration of DC Power Supply Unit 3421-5 The DG power supply unit consists of the DG-PS Board and the DG-S*A Unit. Table 3-1 Name Model (Description) De-PS Board | PCB for two-axis control f Conventional D¢-S2 unit is replaced with the DC-SIA unit by DO-S*A Unit PCH for three-axis control PCB for four-axis control PCB for five-axis control PCB for six-axis control De-S1At Do-S3A slight modification. Configuration of Servo Amplifier P31 The servo amplifier consists of the SVC-A Board and the BL-D**A Unit. Table 3-2 Name Model (Description) SVC-A Board Change DIP switch setting according to motor model. BL-D**A Unit BL-D15A Unit BL~D39A Unit BL-DS@A Unit BL-D75A Unit BL-D15A Unit3421-E P-32 (4) DC Power Supply, DC-PS Board and DC-S*A Unit Fig. 3-4 Construction of the DC Power Supply cnn Teane former Oe Saad Fw, OT oar i 1 GreenOQres Cul? Te for Tarn indication Fig. 3-5 Arrangement of Major Component Parts of DC-PS Board Resistance lo ¥SL ¥S2 ° Condenser oOo ooo 1 C oI) 5 Rectifier \ Transistor Fig. 3-6 Arrangement of Major Component Parts of DC-S#A Unit3421-8 P-33 (3) Construction Component Part Arrangement of Servo Amplifier Servo Amplifier, SVC-A Board and BL-D**A Unit ont = Sy Terminal box Fig. 3-7 Construction of the Servo Amplifier Transformer ox cx. ce 1 ea su, v Fuse Fuse o te former] S88 sua, v &) Gop he, am zeit? sa OO ece ww } i TED for alarm indication Big. 3-8 Arrangement of Major Component Parts of SVC-A Board No~fuse breaker frei, 2 oo a | : 1 Teansise Terminal box ° fal Fig. 3-9 Arrangement of Major Component Parts of BL-D#*A Unit3421-E P34 Protection and Alarm Monitoring Function Funetions Purposes and Contents Ground Protection For grounding problem of the servo amplifier or motor, 2 high speed no-fuse breaker is tripped to shut off the power immediately. At this time, the motor stops safely with dynamic brake applied. Base Circuit Protection After a breakdown of a power transistor, the fuse connected in the base line protects the base circuit from over voltage. Motor Overload Protection (MOL) A thermostat in the motor armature winding detects overload state of the motor, When an overload is detected, the motor stops safely using dynamic brake. Abnormal Temperature Rise of Heat Sink (FOL) TE the heat sink temperature rises abnormally due to heat generation loss caused by deteriorated cooling condition and main circuit elements, this overheat state is detected. When an overheat is detected, che motor stops safely using dynamic brake. High/Low Voltage (av/Lv) DC power supply output voltage is monitored to pro- tect the main circuit elements from breakdown or irregular motor operation caused by abnormally high or low DC voltage. When an alarm is detected, the motor stops safely using dynamic brake. DC Power Supply Short (Toc-s) An overcurrent caused by the short in the inverter DG power supply due to failure of the main circuit ele~ ments or control circuit is detected to protect the main circuit elements from secondary breakdown. When an alarm is detected, the motor stops safely using dynamic brake. Instantaneous Motor Overcurrent (10C-M) Instantaneous overcurrent in the motor circuit exceeding the preset level is detected to protect motor magnet from demagnetization. When an alarm is detected, the motor stops safely using dynamic brake. Control Circuit Power Supply Alarm (VR-LOSS) Voltage in the control circuit is detected if the voltage exceeds the value to guarantee safe motor operation to prevent irregular motor operation. When an alarm is detected, the motor stops safely using dynamic brake. Regenerative Resistor overheat Overheating of the regenerative resistor is detected if corrent directly flows it due to a problem of the regeneration control circuit to protect it from burning down. When an alarm is detected, the motor stops safely using dynamic brake.3421-E P-35 3-4-1-3, Trouble and Troubleshooting The troubleshooting procedure is explained below. (1) DC Power Supply Unit No. Trouble Causes Check Corrective Neasures 1 | No-fuse breaker | Incorrect wiring | Check wiring. Correct wiring. is tripped. at terminals (VIL, VL) Grounding of output terminal (VII, VL) cables Check the wiring for grounding. Replace the cable. Grounding of the servo amplifier Check the servo amplifier for grounding. Replace the servo anplifier. Defective DC power supply Check the above indicated items are all correct. Replace the DC power supply. LED "OR lights. Defective Sischarge power transistor Check the power transistor. Replace the power transistor. Loose conneetion of connector onl2 Check the con- nection of the connector CNI2. Connect the connector GNI2 correctly. Defective DC power supply Check that the above indicated items are all correct. Replace the DG power supply. The "DC PRR ON" LED is not turned off even after the pover is turned off. Defective DC power supply Replace the DO power supply. Gefore attempting replacement, confirm that the red DC PWR ON LED is off.) nid m indication NPB Fig. 3-1) Printed Circuit Board in DC Power Supply(2) Servo Amplifier 3421-8 P-36 No. Trouble Causes Check Corrective Measures No-fuse breaker is tripped. Incorrect wiring at terminals (u,v, Wy ED Check wiring. Correct wiring. Grounding of output terminal Gv, W, BD cables Check the wiring for grounding. Replace the cable. Defective power transistor Check the power transistor. Replace the power transistor. Defective servo amplifier Cheek that the above indicated items are all correct. Replace the servo amplifier. LD "PS-oN" does not light. Fuse (HM3.2) is blown. Check if the fuse is blown. Replace the fuse. Lease connection of connector ono Gheck the con- nection of the connector CNIO. Connect the connector CUI correctly. Loose connection of connector CN2 Check the con~ nection of the connector CN2. Connect the connector (N2 correctly. Defective servo amplifier Check that the above indicated items are all correct. Replace the servo amplifier. mange Lights. The no-fuse breaker for the servo amplifier or the DC power supply is OFF. Check the no-fuse breaker position. Tura ON the no-fuse breaker. 3ephase input voltage is abnormally low. Check the input 3-phase power with a multi-meter- Check the power capacity. One phase is lost in the 3-phase input power. Check the input 3-phase power with a multi-meter. Check the power supply cable.342I-E P-37 No. Trouble Causes Check Corrective Measures 6 | tap "Ly" Loose connection | Check the con- Connect the connector Lights. of connector N3| nection of the GN3 correctly. connector CN3. Defective servo | Check that the Replace the servo amplifier above indicated | amplifier. items are all correct. Defective DC Cheek that the Replace the DC power power supply above indicated | supply. items are all correct. 7 | LeD "va" Defective SvC-A -— Replace the SVC-A Lights. BOARD BOARD. 8 | Leo “rocs" Incorrect Confirm that SW7 | Re-set SW7 according setting of SW7 | setting is as to the Servo Charac~ specified in the | teristic Chart. Servo Character istic Chart. Incorrect wiring | Check wiring. Correct wiring. at terminals @, Vv, WE) Grounding of Check the wiring | Replace the cable. output terminal | for grounding. (, vy Ww, BD cables Defective power | Check the power | Replace the power transistor transistor- transistor. Defective servo | Check that the Replace the servo amplifier above indicated | amplifier. items are all correct. 9 | LED "room" Incorrect Confirm that SW1 | Re-set SW1 and SWZ Lights. setting of SW1 | and SW2 settings | according to the and SW2 are as specified | Servo Characteristic in the Servo Characteristic Chart. Chart. Incorrect wiring at terminals (u,v, W, ED Check wiring. Correct wiring.A2I-E P38 No. Trouble Causes Cheek Corrective Measures LED "TOcH" lights. Grounding of output terminal (vv, W, ED cables Check the wiring For grounding. Replace the cable. Loose connection of connector CN1 Check the con~ neetion of the connector CN1. Connect the connector ONL correctly. Defective SvP board Check that the above indicated items are all correct. Replace the SVP board. Defective servo amplifier Check that the above indicated items are all correct. Replace the servo amplifier. Defective motor Check chat che above indicated items are all correct. Replace the motor. 1p LED "F.OL" Lights. Overload operation Check load with the load meter. Review the cutting conditions and cutting tool. Loose connection ‘of connector CNS Check the con- nection of the connector CN4. Connect the connector ON4 correctly. Defective servo amplifier Check that the above indicated items are all correct. Replace the servo amplifier. u LED "av" Lights. S-phase input voltage is abnormally high. Check the input 3ephase power with a multi-meter. Check the power capacity. Defective power transistor of DC power supply Check the power transistor. Replace the power transistor. Defective DC power supply Check that the above indicated items are all correct. Replace the DC power supply.3421-2 P-39 No. Trouble Causes Check Corrective Measures ai | Lep "av" Defective servo | Check that the Replace the servo lights amplifier above indicated | amplifier. items are all correct. 12 | LED "MOL" Overload Check load with | Review the cutting lights. operation the load meter. | conditions and cutting tool. Loose connection of connector onl Check the con~ nection of the connector CNI1. Connect the connector GNl1 correctly. Loose connection of connector CN4 Check the con- nection of the connector CNS, Connect the connector (N4 correctly. Defective servo amplifier Check that the above indicated items are all correct. Replace the servo amplifier.3421-E PA (3) Others No. ‘Trouble Causes Check Corrective Measures 13 | DIFF OVER error | Incorrect Confirm that SW1 | Re~set SWI and sw2 occurs. setting of Swi | and SW2 settings | according to the and SWZ are as specified | Servo Characteristic in the Servo Chart. Characteristic Chart. Incorrect wiring | Check wiring. Correct wiring. at terminals (u,v, WB) Loose connection | Check the con- Gonnect the connector of connector CN1 | nection of the GNI correctly. connector CN1. Defective power | Check the power | Replace the power transistor transistor. transistor. Defective servo | Check that the Replace the servo amplifier above indicated | amplifier. items are all correct. Defective motor | Check that the Replace the motor. above indicated items are all correct. 14 | Motor hunts. | Loose connection | Check the con Connect the connector of connector CNL nection of the connector CNI. CNL correetly. Incorrect wiring at terminals @, v, WB) Check wiring. Correct wiring. Defective power transistor Check the power transistor. Replace the power transistor. Defective servo amplifier Check that the above indicated items are all correct. Replace the servo amplifier. Defective SVP board or TB board Check that the above indicated items are all correct. Replace the SVP board or TB board.No. Trouble Causes Check Corrective Measures 14 | Motor hunts. | Defective Check that the Replace the encoder. encoder above indicated items are all correct. Defective motor Check that the above indicated items are all correct. Replace the motor.3421-E P=62 (4) Checking Power Transistor a) Remove the SVC-A board. b) Disconnect the leads and bus bar for the power transistor to be checked. ¢) Measure the resistance between terminals using a multi-meter. Correct resistance is as indicated in Table 3-3. C2, Hl E2 cl Bl El Fig. 3-11 Transistor Module Terminal Arrangement = é B2 Fig. 3-12 Equivalent Circuit for Transistor Module3421-E P43 Table 3-3 Judgement Standard (Multi-meter setting: x19) Transistor Terminals Multi-meter | Multi-meter | Correct Aaeteat (+) probe | (-) probe er (c2) E1 (£2) | Tens to hun- | $2, oo dreds of ohms EI (£2) ch (c2) 3 @ to hundreds of ohms e1 (02) BL (82) | Tens to hun- | 922, 2@ dreds of ohms BL (B2) ci (c2) & @ to hundreds of ohms BI (B2) BI (E2) | fundreds of | 6.2, 00 ohns EL (£2) BI (B2) | Hundreds of | 92,00 ohms3-4-2. BDU-D Series Servo Drive Unit B421-E P-Ab The brushless motor servo drive unit (Type D) is used for the control of the tool magazine and crossrail automatic positioning. (optional) 3-4-2-1. Protection Functions The BDU-D series servo drive unit has the following protection func- tions. (1) DC-PS (DC Power Supply) Unit Protection Function using Protection Components: Type Indication Contents No~fuse breaker The uo-fuse breaker lever is tripped to OFF. Light emitting diodes (ED), "PH", "Lv" and “OVER DIS", light at the same time. Protects the circuits from abnor— mal current flow caused by grounding of DC output line or short of output load. Fuse Fuse element is blown. When @ fuse is blown, LED "PH" Lights. The fuse is blown when secondary side voltage of the control transformer is abnormal.Protection Function using Cireuits in PCB: Type Indication Contents Phase-loss alarm Lp "PH" Lights. When any one of three input phe~ ses of AC power supply is lost, the protection function is acti- vated and motor rotation is stopped with dynamic brake applied. Low-voltage alarm LED "LY" Lighta. The protection function is acti- vated when DC output voltage is lowered below 29 V and motor rotation is stopped with dynamic brake applied. High-voltage alarm LED "HV" Lights. The protection function is acti- vated when DC output voltage is increased exceeding 430 V and motor rotation is stopped with dynamic brake applied. Over-discharge alarm Lsp "OVER DIS" lights. The protection function is acti- vated when discharge transistor (TR5) is turned on for longer than the specified period and motor rotation is stopped with dynamic brake applied.(2) Servo Amplifier Unit 3421-E P-46 Protection Function using Protection Components Type Indication Contents No-fuse breaker 1) No-fuse breaker lever is tripped to OFF. 2) LED "LV" Lights. (SVG No. 2 board) Protects the circuits from abnor- mal current caused by grounding of unit output line or short of loads. Protects the circuits from short of transistor bridge. Fuse (control trans- former primary input side) 1) Fuse element is blown. 2) When a fuse is blown, LED "PR" lights. The fuse is blown when secondary side voltage of the control transformer is abnormal. Fuse (secondary side of base circuit) The base circuit protec~ tion fuse is blown. Protects the base circuit from high voltage if power transistor is faulty.BA21-E P47 Protection Function using Circuits in PCB: Type Indication Contents Phase-loss alarm LeD "PH" Lights. (SVC No. 2 board) When any one of three input pha~ ses of AC power supply is lost, the protection function is act: vated and motor rotation is stopped with dynamic brake applied. Low-voltage alara LED "LV" Lights. (SVC No. 2 board) The protection function is acti~ vated when DC input voltage is lowered below 204 V and motor rotation is stopped with dynamic brake applied. Motor overcurrent alarm LED "Ioc-M" lights. (SVG No. 2 board) The protection function is acti- vated when overcurrent (more than 129% of current limit value) Flows to generate an alarm and motor rotation is stopped with dynamic brake applied. Inverter short alarm LED "IOC-S" lights. (Sv No. 2 board) The protection function is acti- vated when overcurrent (more than 125% of transistor rating) flows the transistor bridge to generate an alarm and motor rotation is stopped with dynamic brake applied. High-voltage alarm LED "HV" Lights. (SVC No. 2 board) The protection funtion is acti- vated when DC input voltage is increased exceeding 436 V and motor rotation is stopped with dynamic brake applied. PCB control power supply alarm LeD "VR" lights. The protection function is acti- vated when +12 V power supply of the control cireuit lowers below 410.8 V to generate an alarm and motor rotation is stopped with dynamic brake applied.3421-E P48 Type Indication Contents Encoder pattern data alarm LED "E8" Lights. (SVC No. 1 board) This alarm is detected when data Format of upper digit data sent from the motor incorporated encoder is abnormal. An alarm is generated and motor rotation is stopped with dynamic brake applied. (Equivalent to SVP pat- tern data alarm) Encoder velocity alarm LED "MPR" lights. (SVC No. 1 board) This alarm is detected when lover digit numerical values sent from the motor incorporated encoder abnormally change. An alarm is generated and motor rotation is stopped with dynamic brake applied. Encoder check data alarm LED "APA" lights. (SVG No. 1 board) This alarm is detected when upper digit numerical value read Erom the motor incorporated encoder does not conform to the nunerical value obtained through the calcu lation of lower digit numerical value. An alarm is generated and motor rotation is stopped with dynamic brake applied. (Bquivalent to SVP APA check data alara) Encoder alarm LED "ALA" lights. (SVC No. 1 board) This LED is turned on when any of the encoder alarm indicated above s detected. Note: An encoder alarm will be displayed until an alarm reset pulse is input from the ECP II board after power supply is turned on. This alarm display does not indicate actual occurrence of an alarm and may be ignored.3421-E Pad 3-4-2-2. Trouble and Troubleshooting If any problem occurs, locate the cause of the problem referring te the inspection items indicated below. (1) De-PS (DC Power Supply) Unit No. Problem What to Cheek Measures to Take 1 | No-fuse breaker | Connection at output ter- | Correct wiring. is tripped. minals (VH, VL) for short, grounding and wrong connec~ tion Rectifier (REC) Replace defective rectifier. 1) If any one of three phases is lost, LED "PH lights up. 2) Tf two phases are Lost, neither of LED lighte up because power is nor supplied to control POR. 2 | Fuse is blown. | Pin Nos. 1, 2 and 3 of out-| Correct wiring. put connectors (CNS, 6, 7, 8, 9, and 19) Wrong fuse Replace fuse. 3. | LED "PHY Lights | No-fuse breaker Refer to No. 1. up. (Phase~loss Phase-loss of 3-phase input | Check 3-phase input pover alarm) power supply. supply using a multi~ meter. Gircuit breaker on control box If circuit breaker tripped to OFF is reset to ON too quickly, LED "PH" might light up. Turn OFP the control box circuit breaker again then turn it back ON more than five seconds later. Connection of connector onl Check the connector. Malfunetion of circuits on POB Replace the PCB.3421-E P50 No. Problem What to Check Measures to Take 4 | LED "LV" lights | Abnormally low voltage of | Check input voltage with a up. 3-phase input power supply | multi-meter. (Low-voltage alarm) Phase-loss of 3-phase input | Check input voltage with a power supply multi-meter. Connection of connector Gheck the connector. cni2 Malfunction of cireuits on | Replace the PCB. PCB 5 | LED "uv" Lights | Wire broken in resistor RS2| Replace defective resis~ up. tor. (High-voltage alarm) Transistor (TR) Replace defective tran- sistor. Connection of connector Check the connector. oni Malfunction of circuits on | Replace the PCB. PCB 6 | LED “oveR Dis" | Wire broken in resistor RSI | Replace defective lights up. resistor. (Over-discharge alarm) Transistor (TR) Replace defective tran- sistor. Connection of connector Check the connector. onl2 Malfunction of circuits on | Replace the PCB. PCB3421-E P-SI (2) Servo Amplifier Unit No. Problem What to Check Measures to Take 7 | No-fuse breaker | Connection at output ter- | Correct wiring. is tripped. ninals (U, V, W, and E) for short, grounding and wrong connection Transformer on BDC board | Replace defective trans~ former. Power transistors Replace defective power (RI ~ TR6) transistor. Note: If a power transistor is faulty, the fuse (base circuit protection fuse, 9.5 A) on the BDC board might be blown, or base current amplifying eran- sistor (ET296) might be faulty. If this occurs, the BDC board itself must be replaced. 8 | Fuse at the Wiring to three BDC board | Correct wiring. prinary side of | transformers the control transformer is | Transformers on BDC board | Replace defective trans~ blown. former. (on BDC boards 24 x3 pes.) | Wrong fuse Replace fuse. 9 | Fuse at the Power transistor Replace defective power secondary side of the base circuit is blown. (G.5 A fuse soldered on BDC board) (TRI - TR6) transistor. For replacing, refer to No. 7. Output transistor ET206 Replace defective output transistor ET206.3421-E P52 No] Problem What to Check Measures to Take 10 | Le "PHY Tights | Refer to No. 3 Refer to No. 3. up. (Phase-loss | Fuse (24) on BDC board Refer to No. 8. alarm) Transformers on BDC board Replace defective trans- former. Connection of the unit con-| check connectors. nector (CN1@) and BDC board connector (CN7) Malfunction of SVC No. 2 Replace SVC No. 2 BDC BDC board board. 11 | cep Ly rights | tripping of no-fuse breaker | Refer to No. up. of servo amplifier (Low-voltage alarn) LED "LV" of Do-PS unit; is | Refer to No. 4. | st Lighted up? Connection of the BDC con- | Check connectors. nectors (CN9, CN6) and SVC No. 2 board connector (CNS) Malfunction of SVC No. 2. | Replace defective board, board and BDC board SVC No. 2 board, or BDC board. 12 | Leo "toc-w" | Setting of SWI and SW2 on | Re~set SW1, SW2 according lights up. SVC No. 2 board to Servo Characteristic (Motor over- Chart. current alarm) Connection at output ter- | Correct wiring. minals (U, V, W, and £) for short, grounding and wrong connection Power transistor (TRI ~ TR6) Replace defective power transistor. For replacing, refer to No. 7. Connection of SVG No. 2 board connectors (CN7) Check connectora. Malfunction of SVC No. 1 and No. 2 board Replace defective board, SVC No. 1 board, or No. 2 board.B021-E P53 No. Problem What to Check Measures to Take 13 | LeD "r0c-s" Setting of SW7 on BDC board | Re-set SW7, according to Lights up. Servo Characteristic Cinverter short | Chart. alarm) Connection at output ter- | Correct wiring. minals (U, V, W, and 5) for short, grounding and wrong connection Power transistor Replace defective power (TRI - TR6) transistor. For replacing, refer to No. 7. Connection of the BDC con~ | Check connectors. nectors (CN9, CN5) and SVC No. 2 board connector (CN5) Malfunction of SVC No. 2 Replace SVC No. 2 board or board or BDC board BDC board. 14 | LED "AV" lights | Refer to No. Refer to No. 5. tia Connection of the BDC board Sigieveh tage connectors (CNS, CN6) and | Check connectors. ae SVC No. 2 board connector (ns) Malfunction of SVC No. 2 Replace SVG No. 2 board or board and BDC board BDC board. 15 | LED "VR" lights | Voltage across COM and +12 | Replace SVC No. 2 board or up. (PCB control power supply alarm) V, and COM and -12 V at check terminals of SVC No. 2 board; they must be +12V and -12 V, respectively. BDO board. Connection of the BDC board connectors (CN6) and SVC Wo. 2 board connector (CNS) Check connectors. Connection of connectors (GNI, GN2) in 5 V power supply (LT-18) mounted on SVC No. 2 board Check connectors.Note 1: 3421-E P-54 How to check power transistors ° ° c o2, EL BL B2 EL, C2 82 a rE ° a —H) © fh- EL E2 (Serew Terminal Type) (Faston Terminal Type) Sree Check voltage across ron, cz —| these terninats ao BL EL, C2 B2 Fig. K A 2 3-13 Equivalent Circuit of Power Transistor3421-E P-55 No. Problem What to Check Measures to Take 16 | LED "EB" lights | Wiring between connector | Check connector and cable. up. | GNI et SVC No. 1 board and | (Mainly, upper digit (Encoder pat- | ECP II, and between CN2 and| signal line) tern data motor incorporated encoder alarm) Malfunction of motor incor~ | Replace motor incorporated porated encoder encoder. (upper digit) Malfunction of SVC No. 1 | Replace SVG No. 1 board. board 17 | usp "MPR Wiring between connector | Check connector and cable. lights up. ONL at SVC No. 1 board and | (Mainly, MPR signal line) (Encoder velo- | ECP II, and between CN2 and city alarm) | motor incorporated encoder Malfunction of MPR of motor | Replace motor incorporated incorporated encoder encoder. Malfunction of SVC No. 1 | Replace SVC No. 1 board. board Motor speed; higher than | Replace ECP II board. 3,750 rpm? (speed command voltage Check connector and cable. normal?) 18 | LED "APA" Wiring between connector | Check connector and cable. Lights up. ON at SVG No. 1 board and (Encoder check data alarm) ECP II, and between CN2 and motor incorporated encoder Malfunction of motor incor- porated encoder Replace motor incorporated encoder. Malfunction of SVC No. 1 board Replace SVC No- 1 board, Excitation signal from ECP IL for motor incorporated encoder Replace ECP II card, card 4, or distribution card. Is reset pulse (ALOFF) input to CNS of SVC No. 2 board from ECP II after power supply is turned on? Check connector and wiring.(3) Brushless Servomotor Operations S421-E P-56 No. Problem What to Check Measures to Take 19 | Servonotor does | Are magnet switches in 1) Check connector (cN4) not rotate even | DC-PS unit and servo in DO-PS unit. when a command | amplifier unit ON? is given. 2) Check connectors (ONS, 6, 7, 8, 9 and 1) on PCB in DC-PS unit. 3) Check connector (GNI) in servo an~ plifier unit. Is LED "SAOP" on SVC No. 2 | 1) Check SW6 of SVC No. 2 board lighted down? board. 2) Check connector (CN1) on SVC No. 1 board. 3) Replace the SVO board. Is input signal correct? | 1) Check waveform at check terminals on SVC No. 2 board; COM-Tuo, CON-Ivo. 2) Gheek connector (CN) on SVC No. 1 board. DO-PS unit function Refer to (1). Servo amplifier unit fune~ | Refer to (2). tion Wiring to brushless servo- | Correct wiring. motor3421-E P-57 No. Problem What to Cheek Measures to Take 29 | Irregular Gonnectar (CN5) of SVC No, | Check connector. rotation of 2 board servomotor Connection to brushless servomotor (loose connec~ tion) Check wiring. Malfunction of SVC board and BDC board Replace SVC board, or BDC board. Matching error between servo amplifier and machine 1) Lower position loop gain Kv value (VR - vou) 2) Change velocity loop gain (VR ~ VLG) 3) Change velocity feed~ back amount (WR ~ VNB) Mal functioning position encoder | Replace defective encoder.3621-8 P-58 Precautions to Observe for Maintenance a (2) (3) @ Before operating the no-fuse breaker of the DC power supply unit and servo amplifier unit, alvays turn off the no-fuse breaker (main circuit breaker) at the control box. Before replacing fuses, or printed circuit boards, or checking terminal screws, always turn off the main circuit breaker at the control box and press the discharge pushbutton of the condenser for about 2 seconds. When replacing the SVC board or BDC board, set the switches according to the Servo Characteristic Chart. Since current feedback, overcurrent detection, and other setting are all made by the switches, power transistors will be faulty if setting is not made correctly. If a power transistor is faulty, base circuit protection fuse might be blown depending on danaged mode, and output transistor BT206 might further be faulty. Therefore, check the power tran- sistor and BDC board when carrying out repair.35. CHECK PANEL B421-B P-59 Open the tape reader door, and the check panel will be found at the side the tape reader. hen the emergency limit switch at each end of the X-axis, Y-axis, and Z~ axis is tripped, the corresponding L.S. EMERGENCY lamp lights up. If any one of these lamps lights up, turn OFF for all axes; but as servo drive unit power supply activates the emergency limit the servo drive unit power supply units will long as che RETURN button is held down, the unit renains ON. Therefore, if any cause switch, press the RESET button again, while pressing the RETURN button, and move the axis manually away from the emergency limit position. The machine then returns to a normal state, so even if the RETURN button is released, the machine will return to the pre~ vious normal condition. lO O| xy 2 O00 ov ag Sensor OO Oo oO Fig. 3- 16 Check Panel3-6. 3421-E 2-60 INSPECTION OF POSITION ENCODER The position encoder detects the present position of each axis accurately. Any fault in this encoder prevents the present position from being found easily, which will result in any of the following troubles. = Rough cut surface ~ Hunting - APA check data alarm, APA pattern data alarm, APA speed alarm and DIF over alarm Checking the Position Encoder: While moving each axis slowly with the pulse handle, check that the output value from the position encoder changes smoothly by the following proce— dures. 1) Obtain the CHECK DATA 4NC AXTS DATA* display screen on the CRT. 2) Then, the position detected value of each axis, R-APA, operational value R-CON, and the difference R-DIF can be monitored. Here, note the RAPA, the position detection value of the axis to be checked. 3) Switch the mode to MANUAL, and move the axis slowly with che pulse handle. = Check that the value changes from the smaller digit slowly. = Check that no value is omitted and that no value repeats. ~ Check that the digit carry is done properly. Normal case: 18 —+ 19 —» 29 —~ 21 —= 92 Abnormal case: 18—~ 29—~21—— 22... 18 —= 19 —=21 —= 26 22. If the value and change are not normal, it can be assumed that there is a fault in the encoder. In addition, there is a possibility that there is a fault in the connector contact or the CPU printed circuit boards.3-7. 3421-E P-61 cpu This section describes matters related to the CPU. The complete operation of the NC machine is described in Section 2-3, "Operation and Structure of the NC", and should be referred to. Operation and Structure of the CPU Refer to Fig. 2-4, "OSP5920M System Configuration". As described in Section 2-3, the main component of the OSP5#29M is the CPU, which consists of BOARDs and CARDs added to the BOARD. The CPU uses a multiprocessing method where, under the main processor on the MAIN BOARD-II B, the axis control processor on the SVP BOARD-IT, and the machine control processor and interface provided on the BOP BOARD-II operate. For each processor, a high performance microprocessor is used and for the I memory, a highspeed very large scale TC memory is used in order to accomplish high-grade NG functions. In addition to the IC uemory, a bubble menory for storing machining programs and control program (control software) storage is provided. ‘The bubble memory is a read/write memory, allowing stored data to be altered as needed. Its memory capacity is up to 6 Mbytes. Signals are communicated between each processor and external equipment (tape reader, position encoder, operation panel, servo drive, etc.) through the interface circuit contained in the BOARD or CARD. The OSP5920M is a computer NC with control programs (control software) designed specially to each user's specifications, and delivered as control floppy disks with each NC system. The operation to store control software into the bubble memory is called software loading. When the specifications are changed or a bubble memory is replaced, loading is required. The power source unit supplies all power required for the CPU. An AC 20V input direct switching method is employed because it gives high efficiency and causes less heat generation. Refer to Fig. 3-15 for the actual configuration of the CPU and power source unit.3421-E P-62 Fan motor connector (9900000990000008, Auxiliary function connector Voltage check terminal CPU power supply unit on O4l sc input connector Power supply alarm \Leeu operation check indicating 1amp indicating lamps ac me ow ov qa 2ay aay sv’ le 6666966605909909 fod fed Hed Rei Red Red Se_HedyGroenGieended 860 Ret Rod Rod Rod Fig. 3-153-7-2. 3U21-B P-63 Checking CPU Operation Simple checking for proper computer functioning can be carried out by checking if the indication on the CRT screen operates properly. For example, try to change the display screen indicated on the CRT screen. If the display screen is actually changed, it can be assumed that the computer works well. In order to check what condition the computer remains in, make check by the CPU operation check indication on the CPU unit. Refer to Fig. 3-15. GPU Operation Check Indication Lamp Symbol Indication Contents POWER ........+. Power supplied to CPU RUN ...ss.se.4++ CPU running. B: BUS ERROR . More than two errors occur at same time. CPU stops E: ECC ERROR ...... Error in more than one bit is caused in the main memory. D: DIA ERROR ...... Errors occur in self diagnostics. 1; LOOP ERROR ..... Errors occur when the control software execution is Looped. C: CYCLE ERROR .... Errors occur if the control command of the control software is not completed within a specified time. W: WPRT ERROR ...,. Errors occur if the control software enters a memory address area not yet defined. ~ Two lamps, for POWER and RUN, light in normal condition. = When errors occur For any error except BUS ERROR: The CPU continues running and processes errors, and the CRT screen on the operation panel indicates the contents of the errors. For BUS ERROR: The RUN lamp goes off and CPU operation stops. - Error indication means abnormality in the computer and will not go off when the OSP5090M-G is reset.3421-E P64 To start NC operation again, switch OFF the power and chen switch ON again. The computer starts RUN automatically and goes into NC opera~ tion several tens of seconds later. If the abnormality is continuous, the error occurs again and the com- puter stops. When the computer carries out normal NC operation, con- tinue using it and observe the operation.3421-£ P-65 CPU Power Supply Unit ‘The power supply for the CPU has the arrangement shown here. AC 208V is input into the power supply unit and this supplies the voltage required for the CPU. This unit is mounted on the CPU unit as shown in Fig. 3-15. For the connection with the CPU unit, input of AC 20(V, and for connection with other devices, dedicated cables and connectors are used. Each output voltage is supplied for the following destinations. +v Ac 2g0V eae supply av unit +2ay “— +424 (180) +5 Power for the ICs in the CPU unit +12 Bubble memory, position encoder, main spindle pulse genera~ tor, manual pulse generator +24 Bubble memory, tape reader 180+24V: Power supply for EC input/output isolator Voltage check terminals for each output are provided to check these out~ put voltages. A variable resistor to adjust the voltage is provided for +5V. Refer to Fig, 3-15. This power supply unit has the function that continuously monitors input/ output voltage and temperature. When an abnormality occurs, the cause is indicated by the power supply alarm indicating lamps shown in figure below, and CPU operation stops.3421-E P66 Power Supply Alarm Indication Lanp Symbol Indication Contents AC see Input voltage dropped too low TEMP (TP) . Power supply unit temperature rose too high W seeeee A voltage dropped tao low (including short-circuit) OV verses A voltage rose too high rs024y +24V The voltage on which UV or OV alarm has occurred is +12 indicated. +5v When any of these alarm lamps lights, power supply to the CPU is turned OFF and the CPU stops running. This alarm indicates an abnormality in the power supply unit or in the input and output parts. In this case, all power supply in the NC system, including the operation panel, are cut off. To start the NC operation again, turn OFF the AC input to the NC system once (switch OFF the main breaker), and turn back ON the main breaker after confirming that the alarm indication disappears several tens of seconds later. Then press the POWER ON button. The GPU starts RUN automatically and the NC system starts operation. If the abnormality is continuous, the power supply alarm comes on again, but if the CPU runs normally, continue using it and observe the operation.3-8. 3421-E P-67 INPUT/OUTPUT PRINTED CIRCUIT BOARDS Ec control unit contains following five printed circuit boards. Input interface printed circuit board: PHOTOGOUPLER INPUT Output interface printed circuit boards: REED RELAY OUTPUT ‘TRANSISTOR OUTPUT AC SSR OUTPUT POWSR TRANSISTOR OUTPUT Printed circuit boards are equipped with LEDs for easy visual checking of input and output signal statuses. In addition, the following boards are provided with fuses. AC SSR board POWER TRANSISTOR OUTPUT board3-8-1, 3421-E P-68 PHOTOCOUPLER INPUT Interface Printed Circuit Board (1-PT) As illustrated below, one board can handle a total of 32 input signals. 3 byte 2 byte 1 byte 6 byte When the input signal device (LS, pushbuttons, etc.) is closed, current Flows through the corresponding cir~ cuit, thus turning on input display LED. Power supply to the printed cireuir board is +5 volts, with input line provided with power supply indication LED. Fig. 3-163621-E P69 REED RELAY OUTPUT Interface Printed Circuit Board (0-RR) As illustrated below, one board can handle a total of 8 signals. The board is used for driving small power relays. LEDs are provided for visual checking of ON/OFF status of connected reed relays. Power supply to the board is +5 volts and +12 volts, with input line pro- vided with power supply indication LED. ow ce TYE B 3 a es aw 2 i e So 2 : = 3« |“ |x, a yyvyyyyeyy Fig. 3-173-8-3. S421-B P-76 TRANSISTOR OUTPUT Interface Printed Circuit Board (0-TR) As illustrated below, one board can handle a total of 32 output signals. The board is used for driving or control relays. LEDs are provided for visual checking of ON/OFF status of connected transistors. Power supply to the board is +5 volts, with input line provided with power supply indication LED. 2 byte 3 byte Lyte 0 byte Fig. 3-1834 3421-E P-71 AC SSR OUTPUT Interface Printed Circuit Board (0-AC) 4s illustrated below, one board can handle a total of 8 output signals. The maximum load is 1 ampere (at 60°C) and small solenoids and magnet switches are driven under this rating- In case a load current higher than @.1 amperes is detected, the indicating LED is turned on, thus facilitating the diagnosis of the circuit. Power supply to the board is +5 volts and +12 volts, with input Line pro- vided with power supply indication LED. Fuses used for each device are of glass-tube filled type, which can be replaced easily. ns Elecite yg aa Pover for current detection encoder Fig. 3-19 — ae 197 ——3-8-5. Port 1 Pore 2 3421-E P72 POWER TRANSISTOR OUTPUT Interface Printed Circuit Board (0-TRP) As illustrated below, one board can handle a total of 16 output signals. The maximum load is 2. amperes (5 or less bits ON simultaneously) and small solenoids are driven under this rating. ON/OFF status of the power transistors connected can be visually checked by LEDs on the board. Power supply to the board is +5 volts, with input line provided with power supply indication LED. pe 24v, Fig. 3-203-9-1. 3421-B P-73 RELAY MAGNET CIRCUIT The relay magnet circuit controls devices requiring high voltage which can- not be controlled by semiconductors, such as motors, clutches, and sole- noids. Because the relay magnet can be checked visually, the operation check is relatively easy, Check according to the relay circuit diagrams provided for each machine. Operation and Structure of a Relay Magnet Circuit The same operation principle applies to all magnet relays. When an energizing voltage is charged at both ends of the coil (a) and (b), an attractive force is generated in the coil and turns ON contact point A which is normally open, and turne OFF contact point B which is normally closed. (a) fa) 4A (noreal open) contact point output (b) 2 (b) Fig. 3-21 Relay Operation When the coil is energized, contact point A is closed and contact point B is opened. On the other hand, when the coil de-energized, contact point A is opened and contact point B is closed. The coil will be energized by either DC voltage or AC voltage. Generally, most small relays energize by direct current, while most large relays by alternating current. With the OSP5020M, most of the relay control circuits are replaced by computer software, and only the absolutely necessary nunber of relays are used. For arrangement of the relays, refer to "Component Arrangement inside Control Box" in Appendix.3-9-2. BA21-B P-74 Inspection of a Relay Magnet Large relays are called magnet switches. They are mainly used to control motors. a (2) Operation Check of 2 Magnet Switeh (MS) When a magnet switch is actuated (coil is energized), this part is pulled in. @}/@][9||@}|@ When a magnet switch is actuated, all al connections such as 1-2, 3-4, 5-6, 135 5b 1 ete., are closed (ON) or opened (OFF). 2 4 6 16 14 B]/@||@]/@]/@ Fig. 3-22 Magnet Switch When the magnet switch is actuated: @ If the connection between 1-2 is closed, it is called contact point "a", and indi- cated in a circuit diagram by the symbol a. LE the connection between 1-2 is opened, @ it is called contact point "b", and in @ cirouit diagram by the symbol (2). Sometimes troubles of @ relay magnet are caused. When the coil is energized, 2 contact point may fail to open and close (due to poor contact or foreign matter clogging), or the Part A may occasionally remain pulled in (fused, etc.) even when the coil is not energized. The OSP5920M employs a miniature relay called MY2 relay, where ten relays are mounted on each printed board. Operation Check of Relay (CR) The operation and work of the relay is the same as for the magnet switch. For contact point (a) and (b), it is also the same.3421-E P-75, When the relay is actuated, the LED lights. hen the relay ts sot sctuated, the LED renaine off Fig. 3-23 Relay Panel Gis contact potnt ts opened and closed. Fig. 3-243421-E P-76 (3) Overload Relay Check For protecting motors and solenoids, etc., from overcurrent and overload, an overload relay is used. To reset the tripped relay, push in the reset rod. Note that pushing in the reset rod right after the relay has been tripped, cannot reset the relay. Allow the switch to cool before resetting ite Magnet contactor B]|O]/@]/@}|e 23 5 15 13 1 or 2 minutes after ooo oo the overload relay is tripped, press the CR TST white pare to reset. — This dial is factory B}/@]/@/|@|/@ adjusted. Do not touch ite @]}@}|@ Overload relay 2} [ele] Fig. 3-25 Overload Relay3421-8 P+77 3-1. REPLACING ECP-IL BATTERY PACK The CPU unit has the ECP-II printed circuit board; the semiconductors on this PCB retain the machine related data. Generally, the data saved in semiconductor devices are lost when the power supply is turned off. However, the semiconductors on the ECP-II PCB are backed up by the battery to retain the saved data even after the power is turned off. Whea the battery voltage lowers, the following message appears on the screen to give a warning to the operator. 3 Alarm D Battery voltage low Battery Replacement Procedure: 1) Turn on the power supply to the NC to make sure that it operates correctly. 2) Remove the screws of the connector and the battery case. Replace the battery. 3) Connect the connector and tighten the battery case screws. EGP-II PCB Battery Specification: E5593-499-02 (Okuma part number) Lithium battery (3.6 V) Toshiba ECP board 11 Battery Screws3421-E P-78 SECTION 4 SPINDLE DRIVE UNIT (VAC) 4-1. OUTLINE Okuma VAC motors, providing sufficient performance as a spindle driver for machine tools, feature high reliability, wide constant output range, com- pact construction, ete. Okuma VAC drive unit is a vector control type driver, using 16-bit micro- processors. It provides quick response and stable control. 4-2. PERIODICAL INSPECTION AND MAINTENANCE VAG motor and VAC drive unit do not require daily inspection. However, to maintain their high performance for a long period, it is recommended to inspect and clean the following points at least every six months. For each of the inspection items, change inspection intervals depending on contamination degree. Table 4-1 Inspection Items Where to Check What to Check Measures to Take VAC motor Check whether dust is accumu-| Clean or blow away with lating. compressed air or vacuum VAC drive unit: cleaner. Cooling fan Fan guard (net) Ventilation hole4-3. 4-3-1. TROUBLE AND TROUBLESHOOTING VAC Drive Unit Construction 3421-E P-79 Arrangement of component parts which should be checked at an occurrence of a problem is shown in Figs. 4-1 through 4-4. Before beginning tracing the cause of a problem, make sure that AC supply voltage is within the range indicated below: Table 4-2 Allowable Voltage Range Sein! ov [funy [teas Yew | hak ates 200 50, 60 189 ~ 229 | tnput terminal 220 50, 60 187 ~ 242 We 249 6 192 = 2523421-E P-89 Heat sink cooling fan (at_the back) Diode module Fuses No-fuse breaker (Power input) Terminal block for fan motor cables L. Power supply Terminal block for grounding terminal motor power cables moter power caples | 7 I nufacturing No. Type \ Version No. Fig. 4-1 Major Component Parts Arrangement for D6A and DBA3421-B P-81 Heat sink cooling fan (at_the back) 2rpied.| ‘Iaais'|) | eanie Transistor module Door TRML gla Dios ule aisle de modul Baa ‘TRM2 ‘TRNS Fuses No-fuse breaker ——sT @ower input) Terminal block for a) | She fan motor cables a Power supply Terminal block for 4 grounding terminal motor pover cables fu can fect deta | Now “| type \ version to. Fig. 4-2 Major Component Parts Arrangement for DIIA3421-E P-82 Heat sink cooling fan (at_the back) Door Transistor module RMA ‘TRL RMS | rRM2 "TRME | 7RN3 Pe at bs Diode nodule Terminal hole for motor power cables Terminal block for motor power cables \, No-fuse breaker (over input) Terminal block for fan motor cables Power supply grounding terminal Fuses Fig. 4-3 Major Component Parts Arrangement for D22A3421-E P-83 Warning fuse pe — eeearence “com ov f =. Tl [| breton: Herning fone 28 name +1sv oxo a rs fl asv say I>] ln 9 sa] [sv | Leo Im @ o0000000 0000000000 io fl ee # yoaevou-ovA ous ens ma | Lt = \ ross ub wo] 4 Tas Wa © tév OND Ive Eve GND slselvelusive sos ae now Tue Bue Daz vane vw Soo ‘SL vanvpavas 7 Pushbutton a gp sat suiceh oes ALIRST. ons on oe | oh ou otor signal RSVID sevial pore ‘Control signal cable cable connector connector connector Remark: ©: Check terminal @): Variable resistor Fig. 4-4 Major Component Parts Arrangement on Type A Control PCB (For £4869-045-084-D or the versions succeeding it)4-3-2. The VAC drive unit has indicate the operation Lighting conditions of Operation Status Indication status. the cover. Fig. 4-5 shows the LED Control PCB operation status indicating lamps aw names. POWER “y CPUALM = >O OF 2 fo} O° 9 0. 0 3421-E P-B4 LED's on the control printed circuit board to Che LED's can be checked through the opening in sO Oe FO Of 5O Ow GO Om» Operation status indicating Lamps Fig. 4-5 LED Names Control PCB Operation Status Indicating Lamps The following three LED's indicate the operation status of the VAC drive unit. ‘The relationship between the lamp illumination and PCB operation status is indicated in Table 4-3. Table 4-3 Relationship between LED Illumination and PCB Operation Status Name | Color Operation Remark POWER | Green Power supply for VAC drive unit control circuit is being supplied. If this is not illuminating while power supply to the VAC drive unit is on, it indicates an occurrence of a trouble. oss | Red Voltage in the calculation circuit of the VAC drive unit is outside the specification. If this LED calculation functioning is turned on, the circuit is not normally. CPUALM] Red The lamp indicates an occur— rence of a problem in the calculation circuit in the VAC drive unit. Contents of the problem are indicated by the operation sta~ tus indicating lamps.(2) 3421-B P+85 Operation Status Indicating Lamps The operation status indicating LED's show the operation status of the VAC drive unit and the VAG motor. They have two indication modes as the failure operation status indication and the normal operation status indication. When LED's Ml - M3 are all off, it indicates the normal operation status indication mode. When LED's Ml ~ M3 are flashing or on, it indicates the failure operation status indication mode. Table 4-4 shows a list of the failure operation condition indication and Figs. 4-6 through 4-8 indicate the failure contents in each The normal operation status indication mode shows the input/output status of the input/output signals. Fig. 4-9 shows the contents of indication. Section 4~6 gives a simple explanation of major input and output signals.3421-B P86 Table 4-4 Failure Operation Status Indication Mode LED status ach wy JBigheing Failure Contents LED No. 1 | Res | Resolver alarm 2 |ar | a/o access alarm eer 3 [par | RAM parity error (on/OFF) 4 [acc | microcomputer access error 5 [Loop | 1nr6 loop error 6 | woos | Watchdog error Washes erase 7 | toca | Power transistor overcurrent ing jing 8 | 10cs | Power transistor short 9 | 10CR | Regeneration unit power transistor short on 1s lov |aigh voltage 11 [ov | tow voitage 12 |PH_ | Phase open (1oss) 13 |Loss | Power supply lost at calculation circuit 1 Jos over speed 2 [ReaD | speed command read error 3 |uve | Power circuit low voltage 4 — [RAER | RAM error on | ore | oFF 5 |psz | DIP switch setting error 7 |Loor4|1NT4 Loop error 8 |LooP1|INT1 1o0p error 9 |WCHER| Winding changeover error 1 OR |Heatsink overheat orF | on orF 2 |oL |Motor overload3421-E P87 (2ura owes 24a 78 USETS ZA PUP IK) 8,qgT voraeoTpUT snavag woriwaadg oanyyeg Aq S2uequop einjyeg Jo uoTIws;pur g-y “Sta wreye ayno279 2eM0g Wiv-d quaainsapa0 soastsuesa z2M0a oor 240ys 20; 8TsuEI3 TMOG so01 j20Ys 2028TsuB1z aaMEd yun NOTIPr>NEB>y wor a8eaqoa usty a0 a8eaqoa #07 an (#801) uede aseug Ra 3¥noay woTIwIND[eD 3B ysoT ATddns tem0g SSOT 0132 Hopyoaey 30239 door 9znr 40238 §59099 aaandwosoa97H gorse Ay3ed yy uaeTe esaace a/y WIETE r9n]os0y 90am 001 ov ava yy sme Burysers “a zeacaueyo Sutpury| — YaHOM } od '0'd"0%o8oto™ 0,0,0,0,0,0 @ © SY, TL, Wy \3421-E P88 (No Tw) 8, q31 worze9zpur snavag uoresadg aanqreg Aq squequoy van{yeg Jo uoyaeo;pul f-¥ ‘Sta 30212 dool INI ya00 0132 dooy TINT Ta001 20219 sancaSueys Suypury YGHOM oaze Suraqas yoatas ara 20239 Rye e8e2T0A MoT aynoaTa aaHog 30233 pea puvumos paads paads zan9 Z 2. trots 6. aS 2S EH oo0000 Sve tl tay asa Ws wave aan avaa 80 dsoBA21-E PHO uorawoTpuy snqwag noyzexedg Tewsoy Y3TM uoTaeoTpUT GAT Aq S3uezUCD TeUSTS G-y “Fry Teusys andang Teusys *yno payases s} uojveiedo uayA uD pods siazgnsegg| 3008 Teudrs yoarw poods| myo¥ Tufts peeds osaz| owaz reuars uotqa1ap pads a Teufys 37uy1 enbaoy| TTL qevits doqs Soua8zeu3 oe *gnduy 67 TeuBys weqa uo Teudys y1wy] enbsoz| AIT Teusys woyzeauatig| KOH qeudys woraez02 ssavagy| ABS 1eulys | yas worae303 premz0g treks fea soryoenl xo qeullys qnduy ago Net\ztS TNT 6 SS eS fH eoo000000 0.0:9 '9:'0.00)/0 9, Sy by Eyty ly iy IN4-3-3. Troubleshooting 3421-8 P-91 Measures to be taken when a problem has occurred are explained in (1) and (2). Locations of the component parts are shown in Figs. 4-1 through anh. High Voltage Warning: Before attempting any rep; r inside the VAC drive unit, be sure to torn off power supply after noting down the numbers of lighting LED's. (1) Confirmation of Power Supply, Connectors and Signals Before carrying out the steps explained in (2), check power supply, connectors and signals according to Table 4~ Table 4-5 Confirmation of Power Supply, Connectors and Signals Ttems to Check How to Check Measures to Take Power supply Measure voltage across input terminals R, 8, T of no-fuse breaker and power supply grounding terminal to check if it is within the allowable range. Allowable range: AC 3-phase 170 ~ 240 v 50/68 He, 1% Correct input power supply so that it is withia the allowable range. Connector | - Make sure that the MR connectors (CNL, | Connect correctly. 2, 3) are all secured by screws. (red ons mark) 7 - For the PCB connectors (CN4 - CN7), make sure that the red mark on the connector guide can be seen at the surface of the connector on the 4 control PCB. PCB No. Signal Make sure that the LED's light up See Table 4-6. corresponding to the input signals while they are in normal operation status indi- cation mode.3421-B P-92 Table 4-6 Measures to Take when LED's do not Light Up Corresponding to Input Signals Failure Factor Check Measures Gontrol signal cables | Disconnect the signal | Replace the control are open. cables and conduct the | signal cables. continuity test. Cause of failure is in | Refer to the instruction | Refer to the instruction the machine. manual for the machine. | manual for the machine. Others Make sure that all the | Contact your local Okuma items above are correct. service representative. (2). Trouble and Troubleshooting If a problem is found, take necessary procedures as indicated in Table 4-7. Table 4-7 Classification of Failures Failure will lie in Failure Reference Control | Power PCB unit POWER LED does not light up. a) ° ° LOSS LED Lights up. a) ° ° LED's show failure occurrence condition. ») ° ° Although LED's indicate the normal operation i 7 status, an alarm is detected with the machine. Motor hunts. 4) ° ° Commanded motor speed cannot be obtained. e) ° ° Motor does not rotate, Low cutting performance 8) ° Long acceleration and deceleration time 8) ° ° Spindle orientation cannot be correctly i a performed. Excessive vibration and noise while the motor is i j : rotating.3421-E P-93 POWER LED does not light up. LOSS LED lights up. Table 4-8 Failure Factor Check Measures Input power supply is See Table 4-5. See Table 4-5. abnormal. Fuse F2, F3, F4 or F5 is | Check whether the fuses | Replace blown fuse. blown. have been blown or not. Warning fuse SMP32 or MP5 is blown. PCB connector CN7 is not | Check to be sure that Insert the connector inserted properly. the red mark on the properly. connector guide can be seen at the surface of the connector on the control PCB. Power is not supplied to|1) Detach the cover. | Replace the power supply the control PO3 from the unit. power supply unit, or | 2) Check voltage across supply voltage is other Land 3, and 2 and 3 than AC 19V. of connector CN7 with a voltmeter voltage must be AC i9v. = cis 1 2 [Regeneration 3 [eoserar High voltage is applied to the base circuit and the regeneration cir~ cuit. Caution: Control PCB is faulty. |Make sure that all the | Replace the control PCB. items above are correct.b) LED's show failure occurrence condition. 3421-8 P-9% If the LED's are indicating the failure occurrence status, first check the contents of failure referring to Table 4~4, and follow the measures as indicated in Table 4-9. Table 4-9 Failure will Failure will Contents | Reference |_b¢ im Contents | Reference |_1#¢ *" of Failure | Item Goneroi| Power | of Failure | tcem Taaizar los POR Unie PCB Unie RES D ° Loss 8) ° ° a os 9) ° PAR READ 10) ° ace 2) ° uve m ° ° oor RAER 12) ° woe psa 13) ° Toot 3) ° ° psc 14) ° ° Toes 4) ° ° 100P4 15) ° Toor 5) ° ° 1.00P1 ov 6) ° ° ow 16) ° ° w oL 7) ° D ° ° Pa WCHER 18) ° Remark: Tf the LED which does not correspond to the failure content indicated above lights up, follow the steps indicated in 19).1) RES Lamp is on. Table 4-19 3421-E P-95 Failure Factor Check Measures Loose connection of the comnectors of motor signal cables Check whether connector CN3 and the connector in the VAC motor terminal box are inserted properly. Insert them properly. Broken motor signal cables (Resolver signal) Remove the motor signal cables and conduct the continuity test. Replace the motor signal cables. Control POR is faulty. Make sure that all the items above are correct. Replace the control PCB. The resolver is faulty. Make sure that the RES is indicated even after the replacement of the control PCB. Replace the resolver in the VAC motor. Remark: Normally, resolver resistance measured at the connec- tors in the VAC motor terminal box is as indicated below. Approx. 259 across: SI - $3, 82 - S4, Rl ~ R2 Checking Resolver Signals Resolver signals can be observed with an oscilloscope after turning on power. To check them while rotating the motor by hand, do so only while the operation conmand signals (SPR or SRV) are off or while the machine ready signal (MRDY) is off.3A2I-B P96 Table 4-11 Check Stee Contents Failure Factor Across Resolver excitation The control PCB is 81 - GND | signal faulty. Approx. se Tepe Weel vo 24s Across Resolver excitation 82 - GND | signal Approx. Cosine wave 9 17.6 0 weas Across | Resolver feedback signal Ta case the excita~ RI — GND tion signal is normal: Approx. When motor stops 3.8 v|0v Te12aus | ~ The motor signal cable is faulty. Sa - The resolver is - Phase difference to the excitation signal changes as the motor rotates. ~ Frequency f (Hz) varies as indicated below according to the motor speed N (rpm). 1 at 128 x 19-6 oo (+ in the forward rotation and - in the reverse rotation) faulty. - The control PCB is faulty. 2) AD, PAR, ACC, LOOP or WDOG lamp is ON. Replace the control PCB. If another alarm is occurring at the same time, take measures for that alarm. These alarms the occurrence of another alarm. might be caused by3421-E P-97 3) TOCM lamp is ON. Table 4-12 Failure Factor Check Measures Loose connection of Check motor power cable | Gonnect the cables motor power cables at | connection at the correctly. terminal block terminal block of the motor and the VAC drive unit. Motor power cables are | Check continuity. Replace the cables. broken. Loose connection of the | Check the connectors at | Insert the connector motor signal cables the VAC drive unit (0N3) | properly. and in the VAC motor terminal box ~ are they inserted properly? The VAC motor is faulty. | Measure resistance Replace the VAC motor. between the VAC motor power cable terminal and the frame using a Megger | ineularion tester. The control PCB is Make sure that all the | Replace the control PCB. faulty. items above are correct. (Check the settings at DIP switches SW3 and sig.) The power supply unit is | Make sure that the LOCM | Replace the power supply faulty. is indicated even after | unit. the replacement of the control PCB. Remark: For the VAC motor of the winding change specifica— tion, malfunction of the magnet switch for changing winding or magnet switch drive relay must algo be checked. For the procedure to check them, refer to the main- tenance manual for the machine.3421-E P98 4) Tocs lamp is ON. Table 4-13 Failure Factor Check Measures The control PCB or VAC | Refer to Table 4-14. Refer to Table 4-14. motor is faulty, Motor power cables are | Check continuity. Replace the cables. broken. The VAC motor is faulty. | Measure resistance Replace the VAC motor. between the VAC motor power cable terminal and the frame using a Megger insulation tester. Remark: For the VAC motor of the winding change specifica- tion, malfunction of the magnet switch for changing winding or magnet switch drive relay must also be checked. For the procedure to check them, refer to the main- tenance manual for the machine. Table 4-14 (1/2) Process Contents 1 Turn off power supply. 2 Check the fuses in the TRI - TR6 base circuits. 3 Check the transistors in the TR1 - TR6 base circuits. 4 Remove the control PCB and check to be sure that the con Bhs. | Rector pins at the supply unit 1 4 side of the connector ONS or _ guise pin (NG are fixed to the connector. “Connecter | Tf not pull, the connectors pin up to fix them. Fover supply3421-E P-99 Table 4-14 (2/2) Process Contents 5 Check the transistor modules TRL ~ TRI3. 6 Install the control PCB. 7 Run the VAC drive unit. Check whether the I0CS lamp lights up. 8 If the IOCS lamp lights up again, replace the control PCB and then tun the VAC drive unit. 9 If the TOS lamp still Lights up, replace the power supply unit. 5) TOCR Lamp is ON. When the TOCR lamp lights up, check the control PCB and the power supply unit following the procedure indicated below. Table 4-15 Process Contents 1 Turn off power supply. 2 Check the fuses in the TR7 ~ TRI2 base circuits. (Note 1) 3 Check the transistors in the TR7 - TR12 base circuits. (Note 1) 4 Remove the control PCB and check to be sure that the connector pins at the power supply unit side of the connector CN6 and CN7 are fixed to the connector. 3 Check the transistor module TRM4 - TRM6. (Note 2) 6 Check the thyristor module. (only for former type power unit) 7 Install the control PCB. 8 Run the VAC drive unit. Check whether the TOCR Lemp lights up. 9 If the IOCR lamp lights up again, replace the control PCB and then run the VAG drive unit. 16 If the TOOR lamp still lights up, replace the power supply unit. Note 1: The former type power unit is not equipped with TRI ~ TRI. Note 2: The former type power unit is not equipped with TRUS and TRM6,6) OV Lamp Lights up. Table 4-16 3421-E P-10d Failure Factor Cheek Measures Source voltage is abnormally high. See Table 4-5. See Table 4-5. Power supply cable terminal screws are loose. 1) Turn power supply off. 2) Check the serews if they are loose. Secure the screws tightly. ‘The regeneration circuit is faulty. Follow the steps in Table 4-15 to check if the OV Lamp lights up. See Table 4-15. Power supply impedance is high. The OV lamp lights up only while decelerating. Use a power supply unit with a low impedance. 7) Wor PH lamp Lights up. Table 4-17 (1/2) Failure Factor Check Measures Power supply voltage is low, or one of three phases is open. See Table 4-5. See Table 4-5. The no-fuse breaker is in the OFF position. Check the no-fuse breaker setting ‘The no-fuse breaker is tripped. visually. ow ou om 1) 1! N-) OFF oF OFF low setting Tripped OFF aetting| No-fuse Breaker Handle Positions Set the no-fuse breaker in the ON position. Check the power supply unit following the proce-| dure explained in Table 4-18. (Note) Fuses F5, F6 or F7 is blown. (only for A type unit) Check the fuses whether they have been blown or nots Replace blown fuse.Table 4-17 (2/2) 3421-E P-101 Failure Factor Check Measures The serews in the diode module is loose. Check the screws in the diode nodule. Secure the screws tightly. The diode module is faulty. Check the diode module. Replace the diode module. PGB connector CN6 is aot plugged in properly. See Table 4-5, See Table 4-5. Control PCB is faulty. Make sure that all the items above are correct. Replace the control PCB. The power supply unit is faulty. Check to be sure thar the UV and/or PH lamp Lights up even after the replacement of the control PCB. Replace the power supply unit. Power supply impedance is high. The UV and/or PH lamp lights up only during acceleration and decel- eration of the motor. Use a power supply unic with a low impedance. Note: When the control PCB type A is mounted on the former type power unit, the no~fuse breaker is tripped and the PH lamp Tights up. In this case, both the control PCB and the power unit are damaged. Replace both of them.3421-B P-1p2 Table 4-18 Measures to Take when No~fuse Breaker is Tripped Process Contents 1 | Turn off power supply. 2 | Check the diode module, transistor module TRM4 — TRM6, TR7 = TRI2 base circuit fuses, transistor thyristor module. If any other failure state auch as IOCM, TOCS and 10GR is indi- cated at the sane time, then take measures for them. 3 | Reset the no-fuse breaker handle in the ON position. 4 | Ron the VAC drive unic. 5 | IE the no-fuse breaker is tripped again, replace the power supply unie. 8) LOSS lamp lights up. Refer to Table 4-8. 9) 08 lamp lights up. Table 4-19 OS Lamp Indication in Ranges near Max. Speed Failure Factor Check Measures Wrong setting The control PCB is faulty. Check the setting. Is the setting as specified on the VAC Series Characteristic Chart? Change the setting. Replace the control PCB. If the OS lamp Lights up at a speed outside near-the- maximum-speed range, check the motor signal cables and the control PCB referring to Table 4-ll. 1) READ lamp lights up. Replace the control PCR.11) OVP Lamp lights up. Table 4-29 3421-E P-1p3, Failure Factor Cheek Measures Source voltage is low. See Table 4-5. See Table 4-5. The screws in the diode module is loose. Check the screws in the diode module. Secure the screw tightly. The diode module is faulty. Check the diode module. Replace the diode module. PCB connector is not plugged in properly. See Table 4-5, See Table 4-5. The power supply unit is faulty. Make sure that all the items above are correct. Replace the power supply unit. The control POR is faulty. The UVP lamp lights up after the replacement of the power supply unit. Replace the control PCB. When the former type control PCB is mounted on type A power unit, UVP lamp lights up. In this case, both the control PCB and the power unit might be damaged. 12) RABR lamp Lights up. Replace the control PCB. 13) DSE lamp lights up. Table 4~21 Failure Factor Cheek Measures Wrong DIP switches setting ROM version does not match the motor specification. The control PCB is faulty. Settings must be as indicated on the VAC Series Characteristic Chart and make sure that the ROM currently used is the version as indicated on the VAC Series Characteristic Chart. Set as indicated. Replace the control PCB with the one on which correct ROM is set.14) DSC lamp lights up. Table 4-22 3421-E PIB Failure Factor Cheek Measures Operation in overloaded condition Check the Loaded conditions with the load meter. Check the cutting conditions and cutting tools. Open or loose contact of motor power cables Check the motor power cables. Connect the motor power cables correctly. Broken or loose contact of motor signal cables Check the motor signal cables. To confirm the resolver signal, refer to Remark 2 on Table 4-19. Connect the motor signal cables correctly. The regeneration cireuit is faulty. Check whether DSC lamp lights up during the procedure as explained in Table 4-15. Check the operation conditions. Are accel- eration and deceleration repeated frequently? The inverter cirevit is faulty. Check whether DSC lamp Lights up during the procedure as explained in Table 4-14. Refer to Table 4-14. The control PCB is faulty. Make sure that all the items above are correct. Replace the control PCB. Remark: For the VAC motor of the winding change specifica- tion, malfunction of the magnet switch for changing winding or magnet switch drive relay must also be checked. For the procedure to check them, refer to the main- tenance manual for the machine. 15) LOOP4 or LOOP lamp Lights up. Replace the control PCB.16) OH Lamp lights up. Table 4-23 3421-E P-L Failure Factor Check Measures Fuse Fl, F2 or F3 is blown. Check whether the fuses have been blown or not. Replace the blown fuse. PCB connector CNS is not inserted properly. See Table 4-5. Insert the connector properly. Heat sink cooling fan is faulty. Check if the heat sink cooling fan is operating when power is turned on. Replace the power supply unit. Heat sink cooling fan and heat sink are contaminated, Check contaminated condition at the back of the power supply unit. Clean with compressed air or using vacuum cleaner. Operation in overloaded condition Check the loaded conditions with the load meter. Check the cutting conditions and cutting tools. Control PCB is faulty. Make sure that all the items above are correct. Replace the control PCB. The power supply unit is faulty. Make sure that the OH is indicated after the replacement of the control PCB. Replace the power supply unit.17) OL Lamp lights up. 3421-E P-106 Table 4-24 OL Lamp Lighting up during Motor Rotation Failure Factor Check Measures Operation in overloaded condition Check the loaded conditions with the load meter. Check the cutting conditions and cutting tools. Fuse Fl, F2 or F3 is blown. Check whether the fuses have been blown or not. Replace the fuses. Loose connection of the fan motor cables at terminal block The motor cooling fan does not operate when power is turned on. Check fan motor cable connection at the terminal block of the motor and the VAC drive unit. Connect the cables correctly. Fan motor cables are bloken. ‘The motor cooling fan does not operate when power is turned on. Check continuity. Replace the fan motor cables. Motor cooling fan is faulty. The motor cooling fan does not operate when power is turned on. Replace the motor cooling fan. Motor cooling fan, fan guard, ventilation ports, etc. are contaminated. Check contaminated degree. Clean with compressed air or using vacuum cleaner. Control PCB is faulty. Make sure that all the items above are correct. Replace the control PCB.3421-R P-197 Table 4-25 OL Lamp Lighting Always Failure Factor Cheek Measures Loose connection of the motor signal cables Check the connectors at the VAC drive unit (CN3) and in the VAC motor terminal box - are they inserted properly? Insert the connector properly. Broken motor signal cables (Overload signal) Remove the signal cables and conduct the continu= ity test. Replace the signal cables. ‘The thermostat inside the VAC motor is faulty. Measure the resistance between thermostat terminals of the con nector in the VAC motor terminal box, If it is an infinite value (co), it indicates that the thermostat is fauley. Replace the VAC motor. Control PCB is faulty. Make sure that all the items above are correct. Replace the control PCB. 18) WCHER lamp lights up. Table 4-26 WCHER Lamp Lighting with Winding Changeover Specification Failure Factor Check Measures Magnet switch and/or magnet switch drive relay for winding changeover is faulty. Refer to the maintenance manual for the machine. Replace magnet switch and/or magnet switch drive relay. The control signal cable is faulty. (broken or loose contact) (magnet ewitch operation signal, confirmation signal) Check the cables. Connect the cables pro~ perly. The control PCB is faulty. Make sure that all the items above are correct. Replace the control PCB.3421-8 P-198 Fig. 4-27 WCHER Lamp Lighting with the Specification Other Than Winding Changeover Specification Failure Factor Check Measures Wrong setting Check the setting. Is | Change the setting. the setting as specified The control PCB is on the VAC Series Replace the control PCB. faulty. Characteristic Chare? 19) An LED corresponding to non-existing alarm content is lighting. Replace the control PCB. Note: The LED's lighting up differ depending on the ROM version. Check to see if the LED lighting corresponds to alarm state in another display method.B621-E P1909 ©) Although LED's indicate the normal operation status, an alarm is detected with the machine. Table 4-28 Failure Factor Check Measures Loose contact of the control signal cables Check the connection of connector CNI with the mating connector at the machine side. Connect the connector correctly. Broken control signal cables (spindle alarm A and B cables) Disconnect the signal cables and conduct the continuity test. Replace the signal cable. Control PCB is faulty. Make sure that all the items above are correct. Replace the control PCB. Cause of failure lies at the machine side. Make sure that all the items above are correct. Refer to the maintenance manual for the machine,4) Motor hunts, Table 4-29 3421-E P-110 Failure Factor Check Measures Broken or loose contact of motor power cables and motor signal cables Check the cables. To confirm the resolver signal, refer to Remark 2 on Table 4-19. Connect the cables correctly. Fuses in TRI - TR6 base cireuits are blown. Check the fuses in the TR1 - TR6 base circuits. Replace blown fuse. Transistors in TRI ~ TR6 base circuits are faulty. Check the transistors in the TR1 - TR6 base cir- euits. Replace the control PCB. Transistor modules TRM1 = TRN3 are faulty. Check the transistor module TRMI ~ TRM3. Replace the transistor module. Noise is interposed to velocity command voltage. Check the control signal cables (DAI, DA2). Check the velocity com- mand circuit referring to the machine main- tenance manual. Remove the cause of noise generation. Control PCB is faulty. Make sure that all the items above are correct. Replace the control PCB. Remark: 1. With the VAC motor winding change specification, the motor power cables are wired through the winding change magnet switch. Therefore, the possibility of loose contact, wiring error, etc. related with the magnet switch for changing winding must also be checked. 2. Checking Velocity Command Voltage This voltage can be checked at the check terminals indi- cated in Table 4-39.3U21-B P-LLL Table 4-36 Check 4 eerste Contents Failure Factor Across | Velocity conmand voltage DA input to the control | Terminal DAL Dal - GND | PoB: - 418 V does not exist on the control Across | Output voltage of velocity command voltage input | PCB £4809-045- DA2 ~ GND | circuit: 24, =A, -B. If the velocity command voltage DA is low, within 49.27 ¥, carry out switching to measure the offset in the cizeuit. varyp Lomas gary “OO OE Ov emia 4.27 ¥ 9 Over aha? v DAZ voltage If the input circuit resolution is increased for such as orientation, voltage across DA2 and GND is approximately 16 times the DA value. Terminal DA2 is indicated "Da" on the control PCB B48 69-045 084, A, -B.BA21-E P2112, e) Commanded motor speed cannot be obtained. Motor does not rotate. Table 4-31 (1/2) Failure Factor Check Measures The VAC drive unit is fauley. When a rotation command is given, the LED's Light up indicating the faulty operation con dition. Refer to b), "LED's show failure occurrence condition. Problem lies in the control signal cable and the machine. Check whether che LED Lights up in response to the input signal when a rotation command is given. See Table 4-5. Velocity command voltage is not output from the machine. Check the velocity command voltage referring to Table 4-30. Input the velocity command voltage correctly. Broken or loose contact of the motor signal cables and power cables Check the motor signal and power cables. Connect the cables correctly. The resolver is faulty. To confirm the resolver signal, refer to Remark 2 on Table 4-19. Replace the VAC motor. Wrong setting Check the setting. Is the setting as specified on the VAC Series Characteristic Chart? Change the setting. Emergency stop signal is input. Check the signal. (See EM in Fig. 4-9.) Reset the emergency stop signal. The VAC drive unit standup sequence is wrong. Check the following with LED: ‘The machine ready signal MRDY is first input, the operation ready SRDY is then output. After that, the operation signal SFR or SRV is input. Refer to Fig. 4-13. Correct the VAC drive unit standup sequence.Table 4-31 (2/2) 3421-E P13, Failure Factor Check Measures Control PCB is faulty. Make sure that all the items above are correct. Replace the control PCB. The power supply unit is faulty, Make sure that all the items above are correct. Replace the power supply unit. Note: The motor speed is maximum when the velocity command voltage is +19 V. The motor rotates at a speed 2 percent higher than the rated speed at the voltage input to the control PCB to compensate for the command circuit output impedance and error in the input circuit. Example: When 1 V is input to the control PCB (the rated maximum spindle speed: 6,00 rpm) The motor rotates at 6,120 rpm (= 6,000 x 1.92). Motor speed error of ~ +2% from the velocity command does not mean error, therefore.£) Low cutting performance Table 4~32 3421-8 PHL Failure Factor Cheek Measures Torque Limit command is provided. Check the signal existing. See TLIM in Fig. 4-9. Clear the torque limit command. Problem lies with the machine spindle. Refer to the maintenance manual for the machine. Refer to the maintenance manual for the machine. Wrong setting Check the setting. Is the setting as specified on the VAC Series Characteristic Chart? Change the setting. Control PCB is favity. Make sure that all the items above are correct. Replace the control PCB.3421-E P-115 g) Long acceleration and deceleration time Table 4-33 Failure Factor Check Measures Operation in overloaded condition Check the loaded conditions with the load meter. Reduce Load. Torque limit command is provided. Check the signal existing. See TLIM in Fig. 4-9. Clear the torque limit command. Wrong setting Check the setting. Ts the setting as specified on the VAC Series Characteristic Chart? Change the setting. Source voltage is high. See Table 4-5. See Table 4-5. Broken or loose contact of motor power cables Check the motor power cables. Connect the motor power cables correctly. Fuses in base circuits are blown. Check the fuses in base circuits. Replace blown fuse. Transistors in the base circuits are faulty. Check the transistors in the base circuits. Replace the control PCB. Transistor module is faulty. Check the transistor module TRMI ~ 'TRM3. Replace the transistor module. Thyristor module is faulty. Check the thyristor module. Replace the thyristor module. Control PCB is faulty. Make sure that all the items above are correct. Replace the control PCB. Power supply impedance is high. Only deceleration period is elongated. Use a power supply unit with a low impedance.3421-8 P-116 h) Spindle orientation cannot be correctly performed. Table 4-34 Pailure Factor Cheek Measures Wrong setting (Especially, VR 1) The control PGB is fauley. Check the setting. Is the setting as specified on the VAC Series Characteristic Chart? Change the setting. Replace the control PCB. Cause of failure lies at the machine side. Refer to the maintenance manual for the machine. Refer to the maintenance manual for the machine. i) Excessive v ibration and noise while Table 4-35 the motor is rotating. Failure Factor Check Measures Motor installation is loose; coupling with the spindle is loose. Check motor installation or motor coupling to spindle. Install the motor correctly. VAC drive unit or connection of cables is faulty. Refer to Table 4-29. Refer to Table 4-29. VAC motor is faulty. Make sure that all the items above are correct. Replace the VAG motor. Remark: To determine the cause of the problem, run the VAC motor freely. be: 1) 2) 3) low. Start the VAC motor. For this, follow the procedure Trip the no~fuse breaker in the VAC drive unit to ovr. The PH (phase-loss) alarm occurs and the VAC motor runs freely.4-3-4. 3421-8 P-117 Recovery from Failure Status When LED's indicate the faulty operation status, it is necessary to remove the cause of failure first and then reset the alarm state to recover the operations of the VAC drive unit. To reset the alarm, 1) Turn ON the alarm reset signal ARST (connector CN1 - 42, 26), 2) Turn off power supply to the VAC drive unit, or 3) Press the ALMRST pushbutton switch at the control PCB.3421-E P-118 4-4, FUSE REPLACEMENT (1) Puse Blown Condition Blown conditions of fuses used in the VAG drive unit are shown in Table 4-36. Table 4-36 Fuse Blown Conditions Fuse Name Blown Condition Thises Neon tube Fl - F6 Lighting up (A type motor) FL ~ F4 (former type The neon Lamp lights up as illustrated notor) at the left when viewed from the front. After slight (only wien power is ON.) modification of 22 Excluding D224 Fuses Blown fuse FL -¥7 element (n22a) ——— FL - FS (after slight The fuse element is blown as illustrated modification of at the left when viewed from the front, 22) Warning fuse White ‘SMP32 gy MP5 The white fuse blown indication appears at upper portion of the fuse cartridge when viewed from the front. Base circuit fuse Blown fuse RMLO element There might be cases where the blown fuse element cannot be found visually.3421-E P-119 (2) Inspection and Replacement Procedure for Fuses a) Fuses FI ~ F6 (After slight modification of D22, exeluding D22A) 1) Preparation D3, D6, DB: Turn off power supply, then open the power supply unit door after removing the door clamping screws. DLL, D22: Follow the procedure explained below when power is off or after turning ic off if fuse blown indication is provided. 2) Grip the fuse holder knob and pull out the fuse holder assembly. aT fuse holder Knob Ze elses = = Glass-tube Filled fuse Fig. 4-10 Fuse and Fuse Holder 3) Measure resistance across the glass-tube filled fuse element using a multi-meter. Reading must be #Q. When it is "co", it indicates that che fuse has been blown. 4) If the fuse is blown, replace the fuse. 5) Set the fuse holder. 6) For D3, D6 and D8, close the door and fix it in place withb) 3421-B P-128 Fuses Fl ~ F7 (After slight modification of D22, for D224 only) 1) Turn off power supply. 2) Remove the fuse cover using a screwdriver. 3) Remove the glass-tube filled fuse element using a screwdriver. 4) Measure resistance across the glass-tube Filled fuse element using a multi-meter. Reading must be MM. When it is "oo", it indicates that the fuse has been blown. 5) If the fuse is blown, replace the fuse. 6) Set the fuse holder. 7) Place the fuse cover. Fuse cover ‘lass-tube filled fuse Fuse holder Fig. 4-11 Fuse for D223421-E P=121 c) Warning fuse SMP32, MP5Q, and base circuit fuse KMIg 1) Loosen the screws and remove the cover. 2) Check the fuse. Warning fuse: Visually check the blown indication. Base circuit fuse: After removing the fuse, measure resistance between the ter~ minals using 2 multi-meter. In either case, reading must be OM. When it is "oo", it indicates that the fuse has been blown. Terminal LO Fig. 4-12 KMip 3) Remove the blown fuse and set new fuse in the holder. 4) Place the cover and secure the screws. (3) Fuse Rating For fuses Fl - F7 in the A type unit, use 5A and ).5 A rating fuses as indicated in Table 4-37. When replacing a fuse, always use the one with the same current rating. Fuses used in the former type unit are all 5 A rating fuses. Table 4-37 A Type Unit Fuse Current Rating Fuse Rating (A) Unit Type Remark Fi| F2|F3]r4|es |r6 |r? D6A, DBA DIA Only for power units of Ver. 1-0, all fuses were 5 4 rating. 5| 5] 5] 5|o.s}o.5] - D228 5] 5] 5] 5| 5 |o.s]o.54-5. SPARE PARTS 3421-R P~122 ‘The VAC drive units have the following spare parts as indicated in Table 4-38. Table 4-38 Spare Parts Fuse Name ‘Type Parts No. Qty Fuse 200.V 5A P7161 | £2442-299-124 2 (Bl, F2, F3, F4, F5) Warning fuse | sMp32 3.24 E2445-392-228 2 (SMP32) Daito Tsushin Warning fuse (p59) MPS 5 A Daito Tsushin 2645-392-2154-6. INPUT/OUTPUT SIGNAL TABLE (1) Input Signals 3h21-E P=123 Connector | When Signal Mame | eee eee ted Contents Machine NL Closed | When this signal is input after power Ready supply to the VAC drive unit is turned on, Signal 43 the drive unit is ready for receiving a MRDY 27 speed command. Forward ont Closed | When the output contact signal SRDY is Rotation turned ON (closed), the forvard rotation Command 44 command (SFR) or the reverse rotation com SFR 28 mand (SRV) can be received by the drive unit. Reverse Rotation 45 When the SFR or SRV is turned ON (closed), Command 29 the motor begins rotation in accordance SRV with the speed command. Orientation | Nl Closed | When the orientation command ORCM is turned Signal ON (closed), the speed control loop gain in orca 47 the control unit is inereased and the 31 orientation allowed condition is established. Torque ont Closed | When the torque control signal TLIM is Control turned ON (closed), the motor rotates in Signal 46 the torque limited condition. LIM 30 Emergency onl Opened | When the emergency signal EM is turned ON Stop Signal (opened) during machine operation, the eM 4 motor is braked with regeneration brake and 25 then stopped. Current flow to the motor is interrupted and then power supply to the motor is turned off.(2) Output Signals BA2I-B Po124 Connector | When Signal Name | pon'yo.. | Aceuated Contents Torque out When motor output shaft torque is limited Control with torque control signal input, this Signal 7 signal is output. TLTM 8 Speed owt Closed | This signal is output when the motor output Detection shaft speed drops below the set value. Signal 9 Dr ad Zero Speed cnt Closed | This signal is output when the motor output Signal shaft speed drops to zero speed (below 30 ZERO 5 zpm). 6 Speed Match| GNI Closed | This signal is output when the motor output Signal shaft speed reaches the predetermined range AGRE 3 from the commanded speed. 4 Operation onl Closed | This signal is ovtput when the condition to Ready allow the receiving of the speed command Signal 15 signal is established after the MRDY signal ‘SRDY 16 has been received.3421-E P-125 SECTION 5 SELP-DIAGNOSTICS ‘The OSPS020M is a sophisticated CNC system that is designed to make the most of its built-in computer capabilities. The self-diagnostic function is one of the advantages @ computerized numerical control system can pro- vide, This function is classified into the following four items: ~ Check function by alarm display and error display Check function by check data display Check function by CNC diagnostic display Check function by machine diagnostic display Gheck Function By Alarm Display and Error Display This function constantly monitors any defect including programming, operational errors and NC malfunctions. When any defect such as the programming error and NC malfunction requiring stop of the machine operation occurs, the ALARM lamp goes on, the machine is brought to @ stop, and the contents of the alarm will be displayed on the ORI. When the defect is an operational error in editing operation, etc. not requiring the machine to be stopped, the ALARM Lamp does uot go on, but the contents of the error only will be displayed on the CRT, From these displays, the contents of the defect can be judged. Check Function By Check Data Display With check data displayed on the CRT, it is possible co check internal conditions of the CNC, input/output signals of the NC and so on. This is a useful function to adjust and check the CNC. Check Function By CNG Diagnostic Display This is the function to constantly monitor the memory in the CNC in the display form of decimal numbers, hexadecimal numbers, floating-point number, bit-string, etc. Check Function By Machine Diagnostic Display When the machine does not operate because of any of the requirements for the operation of the machine not fulfilled, that unfulfilled con- dition will be displayed in characters to facilitate operator's inspec- tion work.3421-E P-126 ALARM DISPLAY AND ERROR DISPLAY The CNC constantly monitors the operating conditions of the machine, the program data and the operation of the machine operator. When any defect takes place, it gives the operator a warning by displaying an alarm message or error message. Alarm Display ... Error Display «++ CPU Alarm .. The machine is stopped. The ALARM lamp under NC STATUS goes on. The corresponding alarm message is displayed on the 2nd line of the CRT. Mainly warning against any of the items input by the operator, and does not cause the machine to be stopped. ‘The ALARM Lamp does not go on and the error message is displayed on the 19th to 22nd line on the CRT. This alarm indicates CPU malfunction, When this type of alarm occurs, machine operation cannot be resumed until power supply is turned on again. Naturally, the machine instantly stops. When the CPU does nor function normally, the message is displayed below the central portion on the CRT. Note: Refer to the separately attached manual, “Alarm & Error List for OSP592GM (Publication No. 3353-E)"3421-B P-127 CHECK DATA DISPLAY The CNC constantly monitors internal conditions of the CNC and input/output signals of the NC, and the operator can see these data through check data displayed on the CRT. Check data displayed on the CRT and its contents are shown in the following display screens. Operation proceudres for check data display are as follows: 1) Press any of AUTO, MANUAL and MDI keys. HR eee) RE 3) Press page keys and advance the display page by one. 2) Press function key [P7] (CHECK DATA). 1) Press any of AUTO, MANUAL and MDI keys. The function keys are assigned the same functions for {F2] through [F7]. Functions available with function key [Fl] depends on the mode selected: man] acruAL] Part [81008 |seacy neck Terex seuect | oszr. procaay| pata. | S48 pata | CEATERPL AUTO PROGRAM SELECT MOL DATA INPUT MANUAL ... None3421-E P-128 2) Press function key [F7] (CHECK DATA). This displays the check display screen. 3) Press page keys|[T]]and|[*Jluntil the desired display screen is obtained. advances the display screen by one. returns the display screen by one. Note that required display screen can be accessed using che search command instead of using page keys. Procedure to display the required display screen using the search conmand is as follows: First follow steps 1) and 2) above to select the check display screen display mode. 4) Press the function key [F5] (SEARCH). Prompt "=F" will be displayed on the console line. 5) Key in the display screen number of the required display screen through the keyboard. The data key-in is displayed following "=F _", Example: =F_ 1p 6) Press WRITE key. The required check data display screen will be displayed. The data accessed on the check data display screens is summarized on the Following display screens. On display screens that follow provided are the check data tables of PANEL INPUT, PANEL OUTPUT, NC INPUT, NC OUTPUT, MACHINE INPUT and MACHINE OUTPUT which are often used.a) S421-B P-129 Panel Input On the "CHECK DATA *PANEL INPUT*" display screens, the on/off status of individual switches on the machine operation panel are displayed. Provided on the following display sereens are the CRT display and corresponding signal names. The numerals, a combination of Js and Is, at the left side of the CRT signify the on/off status of the corresponding switches. Switch ON (normal state for contact "B"*) Switch OFF (active state for contact "BM"*) * Contact "B" represents normally close contact.3421-E P-139 Panel Input (MCR-B, MCR-B-HS) AUTO OPERATION wana semen eure bie? bit6 bias bie bes bite bits bite GRIF JeaP Jor JOG RETR Sea. RET EOP RIN FH SAS KS ZENS YDS MEDS FARO FNT GPST SEL SST BLS2 BUSS BLSL TILK MLO: DRVR STL ZL.OK FRIZ PRIY REX Weld spa CRT SHIR ESP SCH Sa foeneenn-08 OL HEE OOH OL OF (8c008620-08 ILKR CYST RTCY STHW STAN ATC FEC FAC 1GLEGIO-FE TOV? Jove TONS Jova Sova JOV2 JOWs EKO s1eiie19-s 30¥3 BOVE SOV Soa ROVE ROV2 ROVE OVO eeoi201-00 Fova Fova FOv2 FOV FOVO cOCOCiGO-64 FIP AIP PHS EFAS ATEL NGTR TEFL [BOEOEOSO-GS PICO FHED PuLG FHS FHA PHE PHY Pree St coat or = Sa * dwn Cottng Hantrte ele . Seine Sele ore ei ed om fT = RIT PT a eE cra sa [gest one3421-E P-131 Panel Input (MGR-B, MCR-B-HS) AUTO OPERATION oe0¢ ora verte IneUTe HO. data bat? 84e6 bits bred bits bit? BiEd DIVO 13) voleocoa-2e BACH DNC TG? IGF IGF TUPS TcPa TOP: 14 coveace9-e6 PS 15 GopemLG-o4 FI? FIG PIS Pia FIs FI2 Fil FiO 16 eavomoaa-ea Fz? F265 FES Fed Fed Foe FES 17 eoiecoea-2a Far Fac Fas Fad Fea Fae FL 10 Gogeagaa-0o Far Fas Fas Fad Fad Fae Fal 19 Gpeemi@o-o4 F57 FSs FSS Fa FSS Foe FSI 2 epoouoe-02 FE? Fee Fes Fea Fea FE2 Fel 21 enieaaee-2o F77 76 FYS Fra Fa Fre FPL 22 cooaoase.en Fer Fes Fes Fee FES FEZ FOL eroroa1e-s2 2a ereioee-s2 Eo ee aa at el IS a@ BU21-B P-132 Panel Output On the "CHECK DATA ¥*PANEL OUTPUTS" display screens, the on/off status of individual indicator lamps on the machine operation panel are displayed. Provided on the following display sereens are the CRT display and corresponding signal names. The numerals, a combination of Js and 1s, at the left side of the ORT signify the on/off status of the corresponding indicator lamps. Lamp ON Lamp OFFPanel Output (MOR-B, MCR-B-HS) am ‘SELECT Ene OF ERATION 3421-B P-133 senteL OUTPUT docs bt ‘naeoseno-00 ILS o0o1e00-02 Hal ‘seoacen-co Cael ‘sanweeso-ae ‘esn0e00-08 ‘beesceca-0° ‘seaec00-00 (eneeom-c0 (ee0e0c00-08 eeooecas-e0 ‘eeeeeaea-e8 bits bits bits bird bee? BIEL bio PUR TR SLM GLa. PRL HNL TRA. sea Pa ORL NTR Con SeM hee lec ure ocr FOL PL shou. seve Zee, eve RIG ISAC SRL ATC WOME oBAL SELL S=TL East Beck TOFL Gast. FUL RCAC [PART] BLDC oar Posi. [Proce] ama | sence pave [texte >| cute oretege tele hs “Tatsieatee | on ws Tso ATT cee Neilso eo eI Jue eeaseure [High PrensorePanel Output (MOR-B, MCR-B-HS) AUTO OPERATION oreo bare Pee OUTPUT pee 6 IAT live bitS bitd wird bie? bits BHO PIL TPR ToL 3421-E P-134(3) 3421-E P-135 Ne Taput On the "CHECK DATA *NC INPUTS" display sereens, the on/off status of individual input signals to the NC processor are displayed. Provided on the following display screens are the CRT display and corresponding signal names. The numerals, a combination of #s and 1s, at the left side of the CRT signify the on/off status of the corresponding input signals. + Input signal oN + Input signal OFFNC Input AUTO OPERATION MEO pata wee eure asta eacoeoce-ae ‘20202000-08 ‘ea00000- 8 eeaaae-0 ee02e0a0-20 eecaecoa-c0 oraeeaa-60 eeoaae80-c eeneaeeo-00 eaie0ee9-20 eniaeeee-23 ‘eaneee28-02 EDEDED but7 bits bie5 ered e443 bine outl stun Bun peor waco ane eee OS FORO cree Leva Loe LOM Lowe Ls Lee Coxe He? HEE es pd tea Hee He Heat #50 Wes Heze Heer Hoe Wes SR TRE IB RTAB RSE PRET EnST ESR eT cls sy cLsu cLs2 cis ist LSB Tee pata exer 3421-B PH136No Input AUTO OPERATION ° rece para 3 35 16 ? 18 8 2 a 2 a ee ie INeuT oomane0.ca ‘eaaneee0-00 ee00000~00 20002002 ‘azo02020-08 ‘pex03000-20 eoneee8-3 ‘22000000-00 ‘92009000-2 ‘aaoaee00-23 ‘ae020690-00 s1e022000"80 pace 18 bie? bite wits wat bine Foi cue * seer 0c FOB wees Wee Fei HPO PIS Weis Hela fia Wie Heal Sv SvRV SVR Weis Hei? weio 19, ‘Sve? Sv SVR SRB FRATL Fea ATL REL CK FRA RILK PILE NTLK oEX Dara 3421-8 P-137 in bio a0 extenTable 5-1 Alarm Level Symbol Mark 4ML2 | AMLL | ALO Alarm Level No alarm a 8 @ Alarm P 1 a 9 Alarm A 0 1 1 Alarm B 0 1 g Alarm ¢ 0 a 1 Table 5-2 Axis Code Symbol Mark (bic 3) | axp2 | xpi | axng Axis x a i es y 8 og] 1] @ 2 4 a] 1 1 u 4 1} go] 6 v a 1} gf} 4 w a 1] a) 6 A a af af oa B 1 6} go] @ c 1 go) go) 4 3421-E +138(@) 3421-E P-139 NG Outpuc On the "CHECK DATA *NC OUTPUT#" display screens, the on/off status of individual output signals from the NC processor are displayed. Provided on the following display screens are the CRT display and corresponding signal names. The numerals, a combination of @s and Is, at the left side of the CRT signify the on/off status of the corre- sponding output signals. D vce Prenwsine + Output signal ON + Output signal OFFNC Output AUTO OPERATION ° oo para No. ase. 1) e02caee-) Tigeuay OF storm Are input conditions in operation ves Sequence number 2 met? No Display of alarm wtest OK? >| Thakendae code YES3421-E P=190 Code Table for ATC System Condition Judgement The code number below is displayed with the alarm message "911 ATC system condition". A test (9191) Tool change arm up position confirmation LS is not ON. (9192) Tool change arm down position confirmation LS is not ON. (0104) Tool change arm swing to A position confirmation LS ie not ON. (8168) Tool change arm swing to B position confirmation LS is not ON. (9149) Tool change unit vertical position confirmation LS is not ON. (Note 1) (@188) Tool change unit horizontal position confirmation LS is not ON. (Note 1) (0201) Ready station horizontal position confirmation LS is not ON. (9202) Ready station vertical position confirmation LS is not ON. (0204) Ready station tool clamp confirmation L§ is not ON. (9208) Ready station tool unclamp confirmation LS is not ON. (0218) Magazine clamp confirmation LS is not ON. (0228) Spindle drive motor zero speed confirmation LS is not ON. (0248) No tool at magazine confirmation LS is not ON. (8289) W-axis or crossrail clamp confirmation LS is not ON. (0301) Sub arm extract position confirmation LS is not ON. (9302) Sub arm insertion position confirmation LS is not ON. (9304) Sub arm at magazine position confirmation LS is not ON. (9308) Sub arm at ready station position confirmation L8 is not ON. (9319) Sub arm grip position confirmation LS is not ON. (0320) Sub arm retract position confirmation LS is not ON. (0481) Tool change unit at magazine position confirmation LS is not ON. (0402) Tool change unit at home position confirmation LS is not ON. (9404) Tool change unit at spindle position confirmation LS is not ON.(9498) (9419) (420) (044g) (0480) (51) (592) (0504) (9508) (9520) (0540) (9580) (goo) (602) (9701) (782) (ag2) (p88) (9820) (901) (992) (919) (0920) (9940) 3421-E P-191 A test Attachment advance confirmation LS is not ON. (Note 1) Attachment clamp confirmation LS is not ON. (Note 1) Attachment tool clamp confirmation LS is not ON. (Note 1) Attachment tool unclamp confirmation LS is not ON. (Note 1) Magazine manual operation intervention switch OFF signal is not input. Tool in spindle clamp confirmation LS is not input. Tool in spindle unclamp confirmation LS is not input. Tool in spindle clamp confirmation LS is not OFF. Tool in spindle unclamp confirmation LS is not OFF. Adaptor is not confirmed. (Note 1) ATC door close confirmation LS is not ON. (Note 2) ATC door open confirmation LS is not ON. (Note 2) AAC cover close confirmation LS is not ON. (Note 3) Weaxis position is not within the ATC enabled position. Spindle orientation confirmation signal is not ON. Spindle is not at a still. Magazine index is not completed. Safety tool is set on the ATC NO./TOOL NO. TABLE. Next tool is not set. Tool change position (HPI) is not confirmed. Tool change arm retract position (HP2) is not confirmed. Z-axis retract position (HP5) is not confirned. Angular attachment tool change position (HP6) is not confirmed. (Note 1) Angular attachment tool change arm retract position (HP7) is not con- firmed. (Note 1)cgi) (aga) cag4) (198) cag) (i189) (1291) (1262) (1294) (2s) (391) (1392) (1304) (1308) (a38) (132) (aga1) (1492) cag) (1428) (144g) 3U2I-E P-192 B test Tool change arm up position confirmation LS is not OFF. Tool change arm down position confirmation LS is not OFF. Tool change arm swing to A position confirmation LS is not OFF. Tool change arm swing to B position confirmation LS is not OFF. Tool change unit vertical position confirmation L§ is not OFF. (Note 1) Tool change unit horizontal position confirmation LS is not OFF. (Note 1) Ready station horizontal position confirmation LS is not OFF. Ready station vertical position confirmation L8 is not OFF. Ready station tool clamp confirmation LS is not OFF, Ready station tool unclamp confirmation LS is not OFF. Sub arm extract position confirmation LS is act OFF, Sub arm insertion position confirmation LS is not OFF. Sub arm at magazine position confirmation LS is not OFF. Sub arm at ready station position confirmation LS is not OFF. Sub arm grip position confirmation LS is not OFF. Sub arm retract position confirmation L$ is not OFF. Tool change unit at magazine position confirmation LS is not OFF. Tool change unit at home position confirmation LS is not OFF. Tool change unit at spindle position confirmation LS is not OFF. Attachment tool clamp confirmation LS is not OFF. (Note 1) Attachment tool unclamp confirmation LS is not OFF. (Note 1) Note 1: With attachment tool change specification Note 2: With ATC door open/close specification Note 3: With AAC specificationP-193 3421-83421-E P-194 a3421-E P-195 i i3421-E P-1963421-E P-197 SSeeresk (1/2) vena3421-B P-198 vega Logie (2/2) poration tent3421-E P-199-AL STACOW UAMAN YO 78TH NAGNON aNTHOVH3421-E P-299-a13421-E P-2p1-AL3421-B P-292-A1 alaaeleh Ba BeB421-E P-203-Al3421-E P-2M4-AL3421-E P~205-aLAPPENDIX NC OPERATION PANEL MACHINE OPERATION PANEL PULSE HANDLE COMPONENT ARRANGEMENT INSIDE CONTROL BOX COMPONENT ARRANGEMENT INSIDE OPERATION PANEL, MAGAZINE MANUAL OPERATION PANEL CONTROL POWER ON/OFF PANEL SYSTEM CHECK PANEL OPTION PANEL MACHINE MOUNTED ELECTRICALS MACHINE MOUNTED ELECTRICALS MACHINE MOUNTED ELECTRICALS MACHINE MOUNTED ELECTRICALS MACHINE MOUNTED ELECTRICALS - BED = CROSSRATL ~ SPINDLEHEAD ~ SUB ARM, READY STATION = TOOL CHANGE UNIT 3621-2 P-2063421-E P-297 ‘VaNvd NOLLVBaEO ON ® WOz0SdSO_ AAOe (ee) a &) ) | aeo03021-E P-208 ‘awa NOTLVYSdO aNTHOVK ans VY3421-E P-299 a@: oS MACHINE OPERATION PANEL oS © OO © a3421-E P-219 PULSE HANDLE gee SPINDLE 101 © " PULSE HANDLE3421-B P-211 suoraeor3r9ads suzysem 3x3 uo Turpusdap paduey> aq Kew quauazuesay 4 “I {| [es | =x_— oz] = i {-¥ON - NOM TOWINOD ACISNI LNSHZONVERY INaNOAHODPANEL - MCR-B COMPONENT ARRANGEMENT INSTDE OPERATION B421-E P-212342I-E P-213 Manual intervention enabled indicating lamp Manual intervention ON/OFF selector switch Continuous magazine index ON/OFF selector switch ‘oak Magazine index start pushbutton switeh Magazine index stop pushbutton switch Emergency stop pushbutton switch MAGAZINE MANUAL OPERATION PANEL3421-E P-214 Work Lamp ON/OFF switch Control power ready indicating Emergency stop ON Lamp reany One stop|| indicating Lamp On Control power OW pushbutton switch Control power OFF pushbutton switch ey << = = Emergency stop pushbutton switch CONTROL POWER ON/OF¥ PANEL3421-E P~215 J OD Dios xy gz Lon Lo tb Stan O00 ose ! ‘TOUCH @ = . 45 SENSOR Sys Reser 500 O° La he nevunw “noma /Sys Reser a fo Q SYSTEM CHECK PANEL3421-E P-216 ‘anya Noza0 apon pug uoyaexodg 3929q 2noy uoTaeasdo aaypung, © 3} fe ° ° ' ' 440 waned ouny tH! woUNs Kosa U. Ve AOO! OV ° ° ' ' 4HOIT—-uazzNe 0 aviaas © x@F 3O0W ONS NOLLWH3dO. §3.L3N NOH YBHONNd3421-E P-217 MACHINE MOUNTED ELECTRICALS ~ BED (MCR-B) X-axis type FB position encoder EX K-axis drive motor MX Terminal block on bed (TB5MI) Coolant] pump t i motor M7 X-axis lubrication delivery ! confirmation PS2 = X-axis Bea 1abstea son { inductosyn scale* motor M3 Crossrail lubrication motor MI” ‘axis induetosya pre-amplifier* Y-axis inductosyn slider* X-axis emergency limit switch L811 % For the model equipped ne with inductosyn scale X-axis lubrication delivery confirmation ss PSLB421-E PH218 a duey jussssx0mg (@-¥OK) ‘IVSSO¥D - STVOINZORIS aaINNON BNTHOVH ‘aqes udsoronpur yata paddtnbe tapom oq 30g » ioe TOT GIST aHMyT TSAO []exESORD Tist stu] sedan [yeasso3y Esa wopaewayyuSS uoyaeyagnt Tye188019 6 z181 dupyoun [yex88039 A A0s0m Sapap STRe—p We aaposus woyaqsod ga edSa syxe-y 17187 dusjoun [yerse0I erst (@) aT Koue8z0me sqxe-4 F108 duetoun [ze29s039 Visi (=) IiWiI Aouetieus sep aeTeas UAsoJonpuy S]XB-§ #29py1s Uksovonpur STxe=_ is }3]]due—oad wksOaoNpUy S]KE-A WEL TFeassor9 uo ysoTq TRUTOAAL Wan t0}0u SUTJEASTS TyeaSsOID3421-E P-2ig (@-YOH) CVEHEIONTaS ~ STVOTUIDTTa GaLNNON BNTHOVAP29 3421-2 (28K) NOTIVES KaVRy ‘wa¥ ans ~ SIVOTWLOSTA GALNAON BNIHOVK3421-E P-221/E (-¥OH) LIND GONVHD TOOL - STVOTHLOATS GSINNOH aNTHOVALIST OF PUBLICATIONS Publication No. Date Edition 3421-E-R1 April 1993 2nd ¢ This manual may be ot variance with the eetual product due to specification In changes. © note that specifications ere subject to change without notice. If you require clarification or further explenation of ony point in this manual, ploase contact your OKUMA representative, or des 9306-01-50 ©