OSP-U100 OSP-U10 MacMan INSTRUCTION MANUAL (1st Edition) Pub. No. EEC1-101-R1 Oct. 1998 OKUMA This book is printed on 70% recycled paper.BE01-001-R1 P-() SAFETY GUIDELINES SAFETY GUIDELINES 3-1. Incorrect operation may lead to serious machine troubles as well as injuries. To avoid accidents, read this and related manuals carefully and operate the system correctly. The items to which special attention must be paid are stated below. Read them without fail and follow the instructions. Although these items and cautionary items given in the texts of this manual are selected carefully, they are limited to the cases which Okuma is able to anticipate and do not cover all possible cases. Before operating the machine, the operators are requested to read the manuals published by the machine tool builder in addition to this manual. Cautions on Reading the Manual (1) NC machine tools consist of the machine proper, operation panels, high-voltage circuits, servo system, NC unit, etc., and various functions are realized by the combination of them. Therefore, it is not possible to discuss all possible occurrence by assuming all available combinations in the manual. Please remind that this manual is prepared on the standpoint of NC unit and, therefore, the manuals prepared by the machine tool builder must also be read to operate the machine. The information stated in the manuals published by the machine tool builder precedes the information stated in this manual if there is any discrepancy between them. (2) For the NC unit, the following manuals are prepared in addition to this manual: operation manual, programming manual, manual explaining parameters, manual explaining alarmsjerrors, maintenance manual. Read the manual meeting the function and purpose of operation. Warning Labels and Indication on Operation Panels (1) Before operating the machine, be sure to understand the contents given in the warning labels and the indication on the operation panels. Cautions on Operating the NC Cautions on Turning ON Power (1) Make sure to ground the NC correctly. For grounding, follow the applicable local regulations. (2) Keep the electrical control cabinet doors and operation pane! doors. (3) Make sure that the energized parts of the electrical control cabinet are not exposed, causing direct touching of an operator. Ignorance to the items stated above may cause electric shock to an operator. (4) Before turning on the power, make sure that the power source voltage complies with the specifications. For the input power specifications, refer to the specifications given by the machine too! builder. Note that available power source voltage varies among the countries and areas where the machine tool is installed. Ifinput voltage does not comply with the specifications, the NC unit may be burt causing fire.BEO1-001-R1 P-(i) SAFETY GUIDELINES 3-2. 4. Cautions on Operation a (2) 3) (4) 6) © ” Follow the instructions stated in the instruction manual. Do not attempt operation other than the operation which is stated “possible”. Otherwise, the machine fail to operate correctly, causing injuries or machine damages. Although the NC unit is subject to stringent tests, if it is operated in the manner which is not anticipatable, the machine may fail to operate correctly. ‘The safety devices of the NC unit do not function in all occasions, but they function only when they are operated correctly. Follow the instructions given in the manual to ensure the correct ‘operation of such devices. If they are used in a wrong manner, it will cause injuries or machine damages. ‘Special attention must be paid on the setting values for the following safety devices (functions). + Travel end limit function... Setting for the travel end limit parameters ~ Variable travel limit function . Setting for the variable travel end limit Parameters Setting for the maximum spindle speed parameter (only for NC lathes) Setting for the chuck barrier parameter (only for NC lathes) ~ Tailstock barrier function .......... sssseees Setting for the tailstock barrier parameter (only for NC lathes) - Maximum spindle speed clamp function . = Chuck barrier function . . Pay attention so that the following items are set and operated correctly. + Zero point - Tool data = Machining program = Machining program selection Do not approach or touch any moving part of the machine while it is operating. Before using any switch or button on the operation panel, check that itis the one intended. When running a new program, check the program for its correctness before using it for production. Cautions when the Machine Is not Operated 0) When the machine is not operated, be sure to tum off the power.BE01-001-R1 P-(ii) SAFETY GUIDELINES 5. Cautions on Turning off Power (1) Protection of machining programs Before turning off the power, make sure that program editing has been completed. If the power is turned off while editing, correctness of the contents of the program being edited cannot be guaranteed. (2) Protection of parameter data, tool data, and zero point data If parameter setting, tool data, and/or zero point data is changed, always execute the backup ‘command. When power is tured off within five minutes after changing the data indicated above without ‘executing the backup command, the updated data is not saved. lf correct operation is not performed for data saving, the machine does not operate as expected ‘causing injuries and machine damages. Cautions during Maintenance Inspection and when Trouble Occurs (1) Ifa trouble occurs, either press the emergency stop button on the operation panel (or additional ‘operation panel) or tum off the power to stop the operation immediately. (2) The person responsible for maintenance, who has thorough understanding of the contents of the manual, must understand the details of the trouble. It more than one person work together, they must communicate closely using clear sign. (3) When alarm or error messages are displayed on the screen, record all of them. It is possible to view the alarm log. (4) For the corrective action to be taken, refer to the alarm or error table as well as the contents in the maintenance manual. (©) When carrying out inspection or changing parts, tum off the power. (©) Inthe power circuits in such as servo amplifier unit and spindle drive unit, high voltage is applied. Therefore, handling of such units and circuits requires special attention - always follow the instructions given in the manual and those in the warning labels. (7)_ Ifthe cause of the trouble is unknown, stop using the NC unit and the machine and contact the machine tool builder or your local machine tool builders service center.BE01-001-R1 P-(iv) SAFETY GUIDELINES 7. Other Cautionary Items (1) For the caution information on the following items, follow the instructions to be given by the machine tool builder. Transport, storage, packing, installation, test, and adjustment (2) For the disposable of the NC unit, follow the applicable local regulations. Symbols Used in This Manual The following warning indications are used in this manual to draw attention to information of particular importance. Read the instructions marked with these symbols carefully and follow them. FI) Indicates an imminent hazard which, if not avoided, will result in death or serious injury. A WARAING| : Indicates hazards which, if not avoided, could result in death or serious injury. AACAUTION) [+ tndicates hazards which, if not avoided, could result in minor injuries or damage to devices or equipment. NOTICE | |: Indicates precautions relating to operation or use.BE01-009-R1 P-() INTRODUCTION INTRODUCTION Before reading this manual, please understand the [Note for reading this manual] stated below. Use this. manual as the instruction manual for the NC functions. [Note for reading this manual] (1) This manual contains the illustrations of various switches on the machine operation pane! ‘These switches, however, are illustrated for the convenience of explanation and may be at variance with the actual ones. For the actual switches, refer to the instruction manual issued by the machine tool builder. (2) The M code described in the manual are the numbers used for NC functions and may be different from the M codes to be actually specified for execution of the functions depending on the machine tool builder. This means the M codes to be actually used should be checked with the instruction manual issued by the machine tool builder. (3) This manual describes the NC functions. For the actually provided functions, consult the instruction manual issued by the machine tool builder.BEC1-060-R1 P-(i) ‘TABLE OF CONTENTS TABLE OF CONTENTS PAGE SECTION 1 MACMAN ........ 6.2.00 e cece e eee ence eee eee eens teens, 1 1. OVERVIEW....... a 1 1-1. MacMan Provides the Live Production Status Information 1 1-2, MacMan Slashes Down Time ............2005 4 1-3. MacMan Streamlines In-process Setup Time . .. 5 1-4. List of MacMan Operations eee eee 6 SECTION 2 MACMAN MAIN SCREEN 241, Machining Status 2:2, Today's Machining Report . 2-3. Today's Operating Report . cee 2-4. Changing the Reason of Not-operating Status ... SECTION 3 DOCUMENT DISPLAY ........- 22.0 0- cece cece cece e tees eeeeeee SECTION 4 MEMO DISPLAY . 4-1. Displaying a Memo File 4-2, Readinga Memo File ......... 4-3, Selecting a File from Directory .. SECTION 5 JOB PROCEDURE DISPLAY .............2. 22220555 c cece eee eee 5-1, Display a Job Procedure File .. 5-2. Reading a Job Procedure File ... SECTION 6 MACHINING PREPARATION .. 61. Display of Operation Files and Preparation Files ..... 62. Reading a Machining Program File 10 " 12 14 16 BRB RK 8 88 88BEC1-060-R1 P-(i) TABLE OF CONTENTS PAGE SECTION 7 REPORT INFORMATION DISPLAY ......... 00. 00e reece een eee eee ee 40 SECTION 8 MACHINING REPORT DISPLAY ...........--- 2200 seee eee cence ee 46 81. Daily Machining Report (Today) ...........- cote tees eteeeteeetneeees 46 82, Daily Machining Report (Pre Day) 49 8-3. Period Machining Report : 5t 8-4. Outputting the Machining Report to Floppy Disk . . 583 8-5. Outputting the Machining Report to Printer ... 55 SECTION 9 OPERATING REPORT ...........-- 2: eee e eee e eset eee e renee eens 56 91. Daily Operating Report (Daily) 56 9-2. Daily Operating Report (Pre Day) .. 58 9-3. Period Operating Report (To-Today) ...... 60 9-4, Outputting the Operating Report to Floppy Disk eae 5 63 9-5. Outputting the Operating Report to Printer .........0sscceseeseeeee cae o SECTION 10OPERATING HISTORY .........- +20 0ceee eee eeeeeneee ee eeeer ones 65, 10-1. Daily Operating History (Today) . eee 65 10-2, Daily Operating History (Pre Day) - we 67 10-3. Outputting the Operating History to Floppy Disk - 10-4. Outputting the Operating History to Printer ......... 70 SECTION 11 TROUBLESHOOTING INFORMATION ...........-- 260022 22eeee eee 71 SECTION 12NC STATUS AT ALARM 75 12-1, Selecting the Alarm for Output ......6.266s020+ 76 12-2. Outputting the NC Status at Alarm to Floppy 0 Disk 7 12-3. Outputting the NC Status at Alarm to Printer 79 SECTION 13CURRENT NC STATUS .......-. 20.0 e cece eee etree eee e eens 80 13-1. Selecting the Output Data . 81 13-2. List of Output Data 6... eccseeeeeeeseeeeteeeeee 84BEC1-060-R1 P-(ii) TABLE OF CONTENTS: PAGE 13-3, Outputting the Current NC Status to Floppy Disk .... eee eee nT, 13-4, Outputting the Current NC Status to Printer ......06..22005 89 SECTION 14ALARM HISTORY 14-1, Displaying the Alarm History . .. eee eee eee 91 14-2. Outputting the Alarm History to Floppy Disk. ceveeteeeeeeeeseeeeees 92 14-3, Outputting the Alarm History to Printer 94 SECTION 15OPERATION HISTORY 95 15-1. Operation History - Console Line .... 95 15-2. Operation History - Operation Panel 7 15-3. Operation History - 1/0 Signals 101 15-4. Outputng the Operation History to Floppy Disk 103 15-5. Outputting the Operation History to Printer ...... 105 SECTION 16VARIABLE HISTORY . eee eee 106 164 1g the Variable History . eee een 107 16-2. the Variables History to Floppy Disk . een) 16-3. _Outputting the Variables History to Printer cette cecceeeeee M2 SECTION 17PREFERENCE SETTINGS ....... see eeeereeeeescecececeenns 1 17-1, REPORT/PRINTER Screen 118 17-2, _ INPUT DATA Screen 124 17-3. OUTPUT DATA Screen . 123 17-4. JO Signals - ee eee 127 17-5. VARIABLES-A Soroon to VARIABLES-D Screen =... oe sere 130 SECTION 18LIST OF OUTPUT MESSAGES .. 133, SECTION 190UTPUT FILES - 137BEC1-061-R1 P-1 SECTION 1 MacMan SECTION 1 MacMan 9. 9-1. OVERVIEW ‘The MacMan has been developed by focusing on the following problems among a variety of problems to be solved: = What should we do to improve operation efficiency of the machine tools and other production equipment? = What should we do to shorten lead time to output products? Higher operation efficiency and shorter lead time are both the key themes to be achieved to successfully shiftthe production style to small lot production with a large number of workpiece kinds and then to variable lot size production. ‘The MacMan will provide you the information necessary for finding solutions to these themes. MacMan Provides the Live Production Status Information If you want to run the production equipment more efficiently, the first step you must take is to “find” the actual operating efficiency. Here, the term “find” does not mean “seeing”, but t includes the processing to “digitize” the information. Similarly, to shorten the lead time, you must “find” the status how the production progresses. To “find” the actual status is the first step to improvements. ‘The MacMan collects and outputs the continuously changing actual status of production. - It outputs the actual status to the NC screen. Improvements at the production field by an operator is possible by viewing the actual status. - lt outputs the actual status to the printer. The accurate production report can be output in one-touch operation - ltoutputs the actual status to the MS-DOS format floppy disk. Production field management by using a personal computer is possible.BEC1-061-R1 P-2 SECTION 1 MacMan (1) Machining Report Job progress status is displayed for each of the selected main programs. 3/07/17 93/07/17 93/07/17 93/0717 23 PARTORS-LABS3. IN FOE DAILY | DAILY | PERIOD PRINTER | DATA (rooav) | (eRe) ourpur | output | quit (2) Operating Report Operating status is displayed in bar graph. [RUNING lOPERATING. lcurrine INoT oPERATWS 1:37:16 41 In-ag SETUP 1:40:10 32 No OPERATOR 5 PART WAITING ° MAINTENANCE 0 joner | SPINDLE RUN 8 EXTRA INPUT ALARM OW DAILY] OAILY | PERIOD PRINTER | OAT crooay) | (ere) asteut | ostput | quitBEC1-061-R1 P-3 SECTION 1 MacMan (3) Operating History Operating status is displayed in time chart. DAILY | DAILY PRINTER | DATA crooayy! (PRE) output | outeur | ourBEC1-061-R1 P-4 SECTION 1 MacMan 9-2. | MacMan Slashes Down Time Precise understanding of the situation of a trouble is the key to pin-pointed troubleshooting and quick recovery of the machine operation. Using the MacMan, you can get the information necessary for troubleshooting either from a printer or on MS-DOS format floppy disk. - Telefax the print out to Okuma service center. Your are not bothered with time consuming telephone call to explain the service technician ‘what happened” any more. - If you output the information to the floppy disk, the information can be analyzed by using a personal computer by either yourself or Okuma service technician. eemenenety Customer Service Center Personal Computer]. oct oubleshoo rant maintenance & [output example } production superviser ‘Service technician DATE : 1993/07/30 MAUUAAATVEAATUTTAUATTTTAATAT teen 80 Corin THE SEAT : PHO: Ms-Dos oe disk eon 737.283 ¥89.421 0.000 W0.000 croorst Lnsetten 722. 768 182.635 00.000 W0.000 a LMT. =o 100,000 130.000 a 4 ‘ = == CON: Acutual pesotion data | fled ailmaem) (Se ees ) e 7 LIMITE: Pls stroke init data (1) _ Ifyou are in trouble due to alarm, switch the display to NC STATUS AT ALARM. The status of the NC (actual position, zero offset data, travel limit data, etc.) when an alarm has ‘occurred is output to the printer or floppy disk. (2) Ifyou are in trouble although an alarm has not occurred, switch the display to CURRENT NC STATUS. ‘The current status of the NC (actual position, zero offset data, travel limit data, etc.) is output to the printer or floppy disk. (8) _ if you want to know about the operation, switch the screen to OPERATION HISTORY. The operations you have done, ‘what operation has been made, when and what time”, “what key has been pressed, when and what time”, etc. are output to the printer or floppy diskBEC1-061-R1 P-5 SECTION 1 MacMan 9-3. MacMan Streamlines In-process Setup Time As ordinary production style shifts from mass production to small lot production, the data used for machining must be changed frequently in response to frequent change in workpiece kinds. Imagine your supervisor talks to you “This is the program for the workpieces to be machined next” and you receive floppy disk. The process to start machining after that is not simple; first you have to store the program into the NC memory from the floppy disk. Then, you are required to select the program after changing the NC mode to automatic. The MacMan allows you to store and select the program very simply. - The same procedure can be used to read and store the program for the floppy disk of different format (OSP or MS-DOS). Because the format is not visible, there may be cases that an alarm message is displayed insisting you to return to the first step of operation if you follow the procedure for reading the OSP format floppy disk while the floppy disk is MS-DOS format or vice versa when the required procedure differs between OSP format floppy disk and MS-DOS format floppy disk. - When selecting the program having been read and stored, you do not have to specify the file name. ‘Simply press the function key, and the read program is selected. Tocarry out set-up work quickly while machining data or other data must be changed frequently, document such as job instruction are necessary. ‘The MacMan displays the texts created using a personal computer on the NC screen. You can make and display your own job instructions such as set-up change procedure, alarm list, and G/M code table. @ Management of machining programs Personal Computer | @Make your work sheets on a — word processor. te WOR POW S0C.Y AUS: ME RO SE.2 aS: WOK TP orice hs {a mest Po 1 1 OE ‘TAs: fotiae Smo seve Ace iT Toor or Ss ulus slr oe enc TAs staat SrueLbOO oR. tT v. . Ost a © enpuvouiput machining __MacMan__} "programs with your MS-DOS = topo. @Work sheet input & display | possible. Pat) ABEC1-061-R1 P-6 SECTION 1 MacMan 9-4, fas Fz rz Fe F. i 7 Fe {use} Fins List of MacMan Operations Ferrin te ease tne operating bye ade mamba RCE DISA ‘wow ---- Dsays he mom le np procs ERBERE -- "Displays ne joo procoaure fie np previously Mactan MA Two erepaaTion | [ET - Fa [A Fs ° Fe] ter NG ProGrau FiLe| 7] our 2 a) sa Tear emia | [ET] BEBE ~ anata rete aca FF] Be Sonmerena cnc 3] SEP cna tartan * Fa re + tH ot | a TREE) TET] Beg «ore ctaem ven nene stn mami | [Fe] BAB. Detoenemtenonme. iesonr Forming ecrss, sn etre, of vaio A, For eng ess, sae, ate, vac B. For ening eres, sam an, of vale C Fer sering eae, se, rb, of eral 0,BECI-061-R1 P-7 SECTION 1 MacMan cH) uso DIF FE = iz cao muy) [ET 5 F2| S02 3 Fst Fa Fe] mat re ra”) rr conor 01s “4 ‘oe ProceDuRe oiseLay ) LF 1 _— Fz Fa Fe FS Fe | Seu cai [fe monn nn) i Ros q we) Lea) es Fz BA GATT 3 revert ore ow) | | Tee DATO ma FS REPORT (Took) Fa za Fe pio arn reat) [ET] BS) Die omwia ee Machan| 2] ey Displays dey operating reper (previous day) mat DALY eT FS] resco |. Oates nee a er tre ow) | LEE ONY ST F3| "RG —Speamgrporaare | Surmow) | |S eee Senta FET WRRATION) [FT] MSS £6 | Sin a Fe Fa | sae Fe 1-05 Fe EWU £7] ur ‘DAILY OPERATING ET) fot Displays daty operating nsory Rody) re] MAST ee oxy | [EE] age Desc ewmna ony rcp 5 | tes easy operon sates << eusrgrerarye EH ee et ae" Operating history cispayed Fe SevenBECI-061-R1 P-8 SECTION 1 MacMan =m fez} Fs Fe es] Se co Fe] SA, _secunensectam 7] our Fe > TPOLRLESOTING INFERUATION Lus-oos_} utp pro ve sane | [ET] BREE Soecnercre ncaa Fs S| SOF “Saeaes iG ame FG | Bu _(eurene NCeatush 1G STARE AT ALL tan AN fey er (cmos Fe [eza) rewssserie nesurion-<— ROLBLESHOOTING, Fi] 5G ‘New HISTORY eT eemarion | tea] Sear 2 Fa] freee >| = Fs ae es | Ser Fs £8] Ser 7] our ra Fa TROARLESCOTING 1h CAUTION Ls-0s_} Machen AN TPBUTIN ASTER) [FT] GRE... Decay operation nay cont ie. wosenns | Tea] BRA ‘oases opvaton nity (oman pan. ‘EATON ASTOR Fs api para sory (0 ra, ceaurionra. | | Tea] FERTIL SO FS | SO ‘an UME Fh ee 7) or fa TRELBLESIOTING INFORMATION Sa a ommtncaes Bcc comin: Hic oo gomosame B[cS commen a >. os Variable history | He EE EH TROURLESOTING INFORMATION~~ Er FONT ear oe ‘ona TA 70 slows 7 an Z| wa cae FS. oe wae wae BEC1-061-R1 P-9 SECTION 1 MacMan vnpbeoet ov eo SSrapbeonset omg ovon se ‘veces vnc Fvgteonset vgn fon teonet ove sen ‘Smpteonsee on Sn onan ord ora se eng toonet Beds oe cae Fin Soense rece srs > rege erin > rege ers > reso ers > reve srsBEC1-062-R1 P-10 SECTION 2 MacMan MAIN SCREEN SECTION2 MacMan MAIN SCREEN IPARTO4S-14392.MIN- 93/07/17 12 sum 93/07/17 8:19:23, ‘PARTO45-L4392, MIN “TODAY” S_ OPERATING REPORT. [RUNNING JOPERATING lcurTiNG NOT OPERATIG IN-PRO SETUP INO_ OPERATOR PART WAITING WAITENANCE lonerBEC1-062-R1 P-11 SECTION 2 MacMan MAIN SCREEN 2-1. Machining Status On the screen, whether or not a program has been selected is indicated by “START” and whether or not a program is being executed is indicated by “OPERATING”. ‘The area indicating the status explained above is common to all display screens. ‘Amain program has not been selected (NOT START status). ‘A main program is not being executed (NOT OPERATING status). ‘The reason for ‘not-operating status” is machine maintenance (MAINTENANCE). START OPERATING MACH NAVE: MC NAME 93/07/17 _13:32:56 ‘To be set by selecting "REPORT/PRINTER™ Date and time (today, current time) on the PREFERENCE SETTING screen. ‘The default machine name is “MC.NAME". Selecting a program ‘A main program has been selected (START status). ‘main program is not being executed (NOT OPERATING status). 1e reason for “not-operating status” is machine maintenance (MAINTENANCE). Reason for ‘not-operating’ is displayed here: IN-PRO SETUP, NO OPERATOR, PART WAITING, I MAINTENANCE, or OTHER’ Executing the program v ‘The main program has been selected (START status). ‘The main program is being executed (OPERATING status). ‘After the completion of the main program execution, the machine enters the NOT OPERATING status due to maintenance. WATRTENANCE ACH NAME: NAVE SB/OT/17_13:32:56BEC1-062-R1 P-12 SECTION 2 MacMan MAIN SCREEN 2-2. Today's Machining Report (1) Today's machining report is displayed. ‘Machining report for the program currently selected (blank if io main program has been selected) ‘TODAY'S MACHINING REPORT. WAIN PROGRAM, ‘START_DAY START TINE NO.OF WORK OPERATING PARTOSS-L4392. WIN 93/07/17 12:12:08 8 a su 93/07/17 8:19:23 34 45 PARTOSS-LAGO2. MIN PO File name and program name of the main program currently selected Machining result for today (SUM) ‘The START TIME indicates the time when the main program was selected first today. tem Contents MAIN PROGRAM __| The file name of the main program having been selected (START DAY Date of the main program selection [year/monthiday] ‘START TIME ‘Time of the main program selection [hour:minute:second] NO.OF WORK |The number of fimes the M02 or MO command has been executed Exeoution of the M02 or M30 command in the machine lock mode operation ‘and dry run mode operation (NC lathe) is not counted. ‘OPERATING % | Percentage of machine operating time in reference to power ON time [96] (Operating % = Machine operating time (OPERATING) / Power ON time (RUNNING) x 100) RUNNING Length of time for which power supply to the NC has been ON. {hours:minutes:seconds] (Length of time for which main program has been selected) OPERATING Length of time for which a main program has been executed [hours:minutes:seconds} Length of time the main program has been executed in the machine lock mode or dry run mode (NC lathe) is not counted. CUTTING Length of time for which an axis has been moved at a cutting feedrate hours:minutes:seconds} Length of time an axis has been moved at a cutting feedrate in the machine lock mode or dry run mode (NC lathe) is not counted. CYCLE TIME Length of time for which power has been ON for producing one piece of ‘workpiece [hours:minutes:seconds/pe.] (Cycle time = Power on time (RUNNING) / No. of workpieces (NO. OF WORK)) MACHINING Length of operating time used for producing one piece of workpiece ]