Okuma OSP-E100 User manual

CNC SYSTEM
OSP-E100
OSP-E10
MacMan
INSTRUCTION MANUAL
(6th Edition)
Pub No. 4345-E-R5 (SE34-008-R6) May 2002

4345-E P-(i)
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
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The NC unit that features the IGF function is equipped with a variety of safety devices to protect per-
sonnel and the machine from hazards arising as a result of unforeseen accidents while operating
the machine.
However, incorrect use of the function can lead to serious accidents and injuries. In order to prevent
such accidents, read this manual and related manuals carefully so that you can use the IGF function
correctly.
The points presented below are those that require particular attention when using the IGF function.
Be sure to read this information and follow the instructions in it. The cautions below and the warning
signs attached to the machine cover only those hazards which we can predict. Be aware that they
do not cover all possible hazards.
1. Precautions on Reading This Manual
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This manual only provides information relating to the IGF function: in addition to this manual, manu-
als relating to the operation of the machine and NC unit, the parameters, alarms/errors, mainte-
nance, etc., are also provided.
Read these manuals before actually using the IGF function or running an NC program created using
the IGF function.
2. Precautions on Use
2-1. Starting up the IGF Function
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For details about turning on the power and selecting the operation mode before starting up the IGF
function, refer to the manuals relating to operation of the machine and NC unit. Strictly observe the
cautions given in these manuals.
2-2. Operations while Using the IGF Function
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If any alarm or error occurs while using the IGF function, determine its exact nature and take correc-
tive action by referring to this manual and the manuals relating to alarms and errors.

4345-E P-(ii)
SAFETY PRECAUTIONS
2-3. Running NC Programs Created Using the IGF Function
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(1) Use the simulation function of the IGF function to check the operation before running an NC
program created using the IGF function to perform actual machining.
(2) Never run a program created using the IGF function to perform actual machining without check-
ing its operation. Run the program with no workpiece and make sure that there is no interfer-
ence, then cut a workpiece in the single block mode. If no problems are discovered, automatic
operation may be started.
(3) Confirm safety before performing operations involving spindle rotation or axis motion.
(4) Never touch the moving parts of the machine, chips, or the workpiece during machine opera-
tion.
(5) Check the tool offset values.
(6) Check the zero offset values.
(7) Make sure that all override settings on the machine operation panel are set to 100%. Or, if nec-
essary, use a lower override.
(8) If using a machine with a cover, always close the cover before starting operation. Do not oper-
ate the machine with any safety cover removed.
(9) Check carefully that the spindle speed, feedrates, infeeds, etc. specified in created programs
are within the permissible ranges for the tools, chuck, fixture, etc., used during operation.
3. On Finishing Work
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(1) On finishing work, clean the vicinity of the machine.
(2) Return all devices to their predetermined retraction positions.
(3) Always turn off the power to the machine before leaving it.
(4) Always quit the IGF function before turning off the power.
(5) To turn off the power, turn off the CONTROL ON switch on the operation panel first, then the
main power disconnect switch.
4. When Performing Maintenance Inspections/When Trouble
Occurs
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(1) To execute an emergency stop, press the emergency stop button on the operation panel.
(2) Consult the person responsible for maintenance to determine what corrective measures need
to be taken.
(3) Before contacting the service center after an alarm or error has occurred, write down all the rel-
evant alarm and error messages displayed.
(4) Carefully read this manual and the manuals relating to alarms and errors, machine and NC unit
operation, and parameters, etc., before taking corrective action during a maintenance inspec-
tion or in response to trouble. Strictly observe the cautions given in these manuals.

4345-E P-(iii)
SAFETY PRECAUTIONS
5. Symbols Used in Manual
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The following warning indications are used in this manual to draw attention to information of particu-
lar importance. Read the instructions marked with these symbols carefully and follow them.
DANGER
WARNING
CAUTION
NOTICE
Indicates an imminent hazard which, if not avoided, will result in death or serious injury.
Indicates hazards which, if not avoided, could result in death or serious injury.
Indicates hazards which, if not avoided, could result in minor injuries or damage to devices or
equipment.
Indicates precautions relating to operation or use.

4345-E P-(i)
INTRODUCTION
INTRODUCTION
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Thank you very much for purchasing our numerical control unit.
Before using this NC unit (hereafter simply called NC), thoroughly read this manual in order to
ensure correct use.
This manual explains how to use and maintain the NC so that it will deliver its full performance and
maintain accuracy over a long term.
You must pay particular attention to the cautions given in this manual, read them carefully, and
make sure you fully understand them before operating the NC.
Display Screens
The NC display screens vary with the selected NC specifications.
The screens shown in this manual, therefore, may not exactly the
same with those displayed on your NC.

4345-E P-(i)
TABLE CONTENTS
TABLE CONTENTS
SECTION 1 MacMan......................................................................................................1
1. MacMan Provides the Live Productions Status Information ......................................................... 1
2. MacMan Slashes Down Time ....................................................................................................... 3
3. Screen Transition Diagram ........................................................................................................... 3
SECTION 2 MacMan MAIN SCREEN............................................................................4
1. Machining Status .......................................................................................................................... 5
2. Recent Machining Report ............................................................................................................. 6
3. Adjusting the Number of Work Count ........................................................................................... 7
4. Changing the Reason of Not-operating Status ............................................................................. 7
SECTION 3 REPORT INFORMATION DISPLAY ........................................................11
SECTION 4 MACHINING REPORT DISPLAY.............................................................14
1. Daily Machining Report (Today) ................................................................................................. 14
2. Daily Machining Report (Pre Day) ..............................................................................................16
3. Period Machining Report ............................................................................................................ 17
4. Output to Floppy Disk ................................................................................................................. 18
SECTION 5 OPERATING REPORT ............................................................................19
1. Daily Operating Report (Today).................................................................................................. 19
2. Daily Operating Report (Pre Day)............................................................................................... 20
3. Period Operating Report ............................................................................................................ 21
SECTION 6 OPERATING HISTORY ...........................................................................23
1. Daily Operating History (Today) ................................................................................................. 23
2. Daily Operating History (Pre Day) .............................................................................................. 25
SECTION 7 TROUBLESHOOTING INFORMATION ...................................................26
SECTION 8 ALARM HISTORY ....................................................................................27
1. Displaying the Alarm History....................................................................................................... 27
2. Changing Logged Alarm Levels..................................................................................................28
SECTION 9 OPERATION HISTORY ...........................................................................30
1. Operate Panel............................................................................................................................. 30
SECTION 10 PARAMETER SETTING .........................................................................33
1. REPORT DATA .......................................................................................................................... 34

4345-E P-(ii)
TABLE CONTENTS
2. OUTPUT DATA .......................................................................................................................... 36
3. Initialization ................................................................................................................................. 39

4345-E P-1
SECTION 1 MacMan
SECTION 1 MacMan
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The MacMan has been developed by focusing on the following problems among a variety of prob-
lems 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 suc-
cessfully shift the 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.
1. MacMan Provides the Live Productions Status Informa-
tion
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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 it includes the pro-
cessing 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 opera-
tor is possible by viewing the actual status.
•It outputs the actual status to the MS-DOS format floppy disk. Production field management by
using a personal computer is possible.
(1) Machining Report
Job progress status is displayed for each of the selected main programs.
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4345-E P-2
SECTION 1 MacMan
(2) Operating Report
Operating status is displayed in bar graph.
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(3) Operating History
Operating status is displayed in time chart.
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4345-E P-3
SECTION 1 MacMan
2. MacMan Slashes Down Time
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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 to be output onto MS-
DOS formatted floppy disk.
•If you output the information to the floppy disk, the information can be analyzed by using a per-
sonal computer by either yourself or Okuma service technician.
3. Screen Transition Diagram
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Which Non op.
Report Info.
Trouble Info.
Network (*1)
Refresh
F1
F2
F3
F4
F5
F6
F7
F8
IN-PRO SETUP
NO OPERATOR
PART WAITING
MAINTENANCE
OTHER
Quit
F1
F2
F3
F4
F5
F6
F7
F8
Machine Report
Operate Report
Operate History
Quit -> Return to the previous screen
F1
F2
F3
F4
F5
F6
F7
F8
NC status at alaem
Current NC status
Alarm History
Operation History
Variable History
System configuration
Quit -> Return to the previous screen
F1
F2
F3
F4
F5
F6
F7
F8
Daily (Today)
Daily (Pre day)
Period
File
Quit -> Return to the previous screen
Refresh
F1
F2
F3
F4
F5
F6
F7
F8
MaMan
MAIN
Mac
Man
Daily (Today)
Daily (Pre day)
Period
File
Quit -> Return to the previous screen
Refresh
F1
F2
F3
F4
F5
F6
F7
F8
Daily (Today)
Daily (Pre day)
File
Quit -> Return to the previous screen
Refresh
F1
F2
F3
F4
F5
F6
F7
F8
[Selecting the reason for not-operating]
[Report menu]
[Trouble information menu]
[Machining report]
[Operation report]
[Operating History]
(*1) This function is displayed for network function
(IT plaza set,DNC-T etc.) specification only.

4345-E P-4
SECTION 2 MacMan MAIN SCREEN
SECTION 2 MacMan MAIN SCREEN
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4345-E P-5
SECTION 2 MacMan MAIN SCREEN
1. Machining Status
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(1) 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.
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Executing the program
Selecting a program
A main program has not been selected (NOT START status).
To be set by selecting "REPORT/PRINTER" on the PREFERENCE SETTING screen.
The default machine name is "MC.NAME".
Date and time (today, current time)
A main program is not being executed (NOT OPERATING status).
The reason for "not-operating status" is in-process setup.
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 in-process setup.
A main program has been selected (START status).
A main program is not being executed (NOT OPERATING status).
The reason for "not-operating status" is in-process setup.
Reason for "not-operating" is displayed here:
IN-PRO SETUP, NO OPERATOR, PART WAITING, MAINTENANCE, or OTHER

4345-E P-6
SECTION 2 MacMan MAIN SCREEN
2. Recent Machining Report
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(1) Recent machining report is displayed.(up to 16 main programs)
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•MAIN PROGRAM
The file name of the main program having been selected
•START DAY
Date of the main program selection [year/month/day]
•START TIME
Time of the main program selection [hour:minute:second]
•NO. OF WORK
The number of times the M02 or M30 command has been executed
Execution 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 [%]
(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]
•CUTTING
Length of time for which an axis has been moved at a cutting feedrate [hours:minutes:sec-
onds]
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/pc.]
(Cycle time = Power on time (RUNNING) / No. of workpieces (NO. OF WORK))
•MACHINING
Length of operating time used for producing one piece of workpiece [hours:minutes:sec-
onds/pc.]
(Machining time = Operating time (RUNNING) / No. of workpieces (NO. OF WORK))
(2) The items of report are scrolled right or left by pressing the "right" or "left" cursor key (1 item/
cursor key operation). Note that the MAIN PROGRAM is not shifted.
Machining report for the program currently selected

4345-E P-7
SECTION 2 MacMan MAIN SCREEN
3. Adjusting the Number of Work Count
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You can correct the report data if the number of machined parts recorded in the machining report
differs from the number of actually machined parts.
When including the test-cut parts in the total number, for instance, you can increase (+1) the number
of parts. Conversely, when defective workpieces are found, you can decrease (-1) the number.
To correct the number, use the arrow keys and move the cursor to the [+1] or [-1] button for the
report data that you want to increase or decrease. Then, press the WRITE key.
If this page does not include the data that you want to correct, select a required report from the
report information screen.
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4. Changing the Reason of Not-operating Status
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The current reason is in-process setup. Now, you are starting maintenance and the reason must be
changed to maintenance accordingly.
Decreases the number of parts by one.
Increases the number of parts by one.

4345-E P-8
SECTION 2 MacMan MAIN SCREEN
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Press the function key [F1] (Which Non Op.).
Press the function key [F4] (Maintenance).

4345-E P-9
SECTION 2 MacMan MAIN SCREEN
(1) Reasons for Not-operating Status
The MacMan provides five categories for the reasons for not-operating status.
•IN-PRO SETUP
Select this reason when you perform setup change by stopping the machine.
(Setup change performed without stopping the machine is called post-process setup.)
•NO OPERATOR
One operator usually takes care of tow or more machines. Select this reason when you must
go to another machine.
•PART WAITING
If a workpiece, cutting tool(s), and/or a workpiece holding device is not ready or is not sup-
plied to the machine on time, the machine will not be able to operate until all of them are
supplied to it.
Select this reason if the machine has to be stopped in such status.
•MAINTENANCE
Select this reason if the machine has to be stopped due to maintenance.
•OTHER
Select this reason if the machine has to be stopped due to the reasons not given above.
(2) Changing the Reason Manually
If you want to change the reason for not-operating status, press function key [F1] (WHICH NON
OP) and input the code number heading the reason to be selected. For example, change the
reason to "MAINTENANCE" before you begin maintenance.
•After pressing function key [F1] (WHICH NON OP), if you do not want to change the reason,
simply press the [WRITE] key without keying in a code number.
•It is possible to change the reason for not-operating status while the machine is operating. If
you have to leave the machine while it is operating to take care of other machine, you can
change the reason to "NO OPERATOR" before you leave the machine.
(3) Changing the Reason Automatically
The MacMan can determine the reason for not-operating status automatically. If you select "IN-
PROCESS SETUP" for the reason, you are not requested to change the reason while the
machine is operating continuously.
•Ordinary not-operating status, due to such as changing workpieces and removing chips, is
classified into "IN-PROCESS SETUP".
•Assume that you leave the machine, without changing the reason:
While you are not attending the machine, that situation is recognized by the NC from the fact
that none of keys on the NC operation panel has not been pressed for a period longer than
the parameter-set time. Upon recognition of this, the NC automatically changes to reason
from "IN-PROCESS SETUP" to "NO OPERATOR".
•If you come back to the machine for which the reason for not-operating has been changed to
"NO OPERATOR":
The NC recognizes that you have returned to the machine from the fact that a key on the NC
operation panel has been pressed. Then, the NC automatically switches the reason back to
"IN-PROCESS SETUP".

4345-E P-10
SECTION 2 MacMan MAIN SCREEN
•If the reason for not-operating status is "PART WAITING", "MAINTENANCE", or "OTHER",
the automatic change function is not valid. If the machine has to be stopped, due to any of
these reasons, change the reason manually. When the machine restarts, change the rea-
son for not-operating status manually again.
The initial parameters are so set that the NC does not automatically change the reason for
not-operating status. To make the NC change the reason automatically, select MacMan
PARAMETER in the parameter setting mode and set the required data at the following
parameters:
•USE NOT OPERATING ITEM FOR AUTO DECISION (0=NO,1=YES)
0 (No)
•TIME ALLOWED BEFORE DETERMINING NO OPERATOR PRESENT (hh:mm:ss)
00:20:00 (20 minutes)

4345-E P-11
SECTION 3 REPORT INFORMATION DISPLAY
SECTION 3 REPORT INFORMATION DISPLAY
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Press function key [F1], [F2], or [F3], and the corresponding machining or operation report screen is
displayed.
Machining Report
The report shows the progress of each of the selected main programs.
Program progress report:
•MAIN PROGRAM
The file name of the main program having been selected.
•START DAY
Date of the main program selection [year/month/day]
•START TIME
Time of the main program selection [hour:minute:second]
•NO. OF WORK
The number of times the M02 or M30 command has been executed
Execution 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 [%]
(Operating % = Machine operating time (OPERATING) / Power ON time (RUNNING))
•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.

4345-E P-12
SECTION 3 REPORT INFORMATION DISPLAY
•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 moves 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:min-
utes:seconds/pc.]
(Cycle time = Power on time (RUNNING) / No. of workpieces (NO. OF WORK))
•MACHINING
Length of operating time used for producing one piece of workpiece [hours:minutes:seconds/
pc.]
(Machining time = Operating time (RUNNING) / No. of workpieces (NO. OF WORK))
Operating Report
The report shows the operating status of the machine.
Machine operating report:
•RUNNING
Length of time for which power supply to the NC has been ON [hours:minutes:seconds]
(Power ON (RUNNING) = OPERATING + NOT OPERATNG)
•OPERATING
Length of time for which a main program has been executed
Length of time the main program has been executed in the machine lock mode or dry run mode
(NC lathe) is not counted.
(OPERATING = CUTTING + Not cutting)
•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.
•NOT OPERATNG
Length of time for which a main program has not been executed
(NOT OPERATING = IN-PRO SETUP + NO OPERATOR + PART WAITING + MAINTENANCE
+ OTHER)
•IN-PRO SETUP
Constituent of not-operating time: machine has not been operating due to in-process setup.
•NO OPERATOR
Constituent of not-operating time: machine has not been operating due to no operator atten-
dance.
•PART WAITING
Constituent of not-operating time: machine has not been operating due to waiting for workpiece
to be machined.
•MAINTENANCE
Constituent of not-operating time: machine has not been operating due to machine mainte-
nance.
•OTHER
Constituent of not-operating time: machine has not been operating due to reasons not classified
into the items indicated above.
•SPINDLE RUN
Length of time for which the spindle has been rotating
Length of time the spindle has been rotating in the machine lock mode is not counted.

4345-E P-13
SECTION 3 REPORT INFORMATION DISPLAY
•EXTERNAL INPUT
Length of time for which an external input signal has been ON
•ALARM ON
Length of time for which the NC has been in an alarm state (alarm A, alarm B, alarm C)
Operating History
The operating history shows the operating status (ON/OFF) of the machine using the time chart in
intervals of 10 minutes.
Machine history:
•RUNNING
Length of time for which power supply to the NC has been ON
•OPERATING
Length of time for which a main program has been executed
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
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.
•NOT OPERATNG
Length of time for which a main program has not been executed
•IN-PRO SETUP
Constituent of not-operating time: machine has not been operating due to in-process setup.
•NO OPERATOR
Constituent of not-operating time: machine has not been operating due to no operator atten-
dance.
•PART WAITING
Constituent of not-operating time: machine has not been operating due to waiting for workpiece
to be machined.
•MAINTENANCE
Constituent of not-operating time: machine has not been operating due to machine mainte-
nance.
•OTHER
Constituent of not-operating time: machine has not been operating due to reasons not classified
into the items indicated above.
•SPINDLE RUN
Length of time for which the spindle has been rotating
Length of time the spindle has been rotating in the machine lock mode is not counted.
•EXTERNAL INPUT
Length of time for which an external input signal has been ON
•ALARM ON
Length of time for which the NC has been in an alarm state (alarm A, alarm B, alarm C)
(1) You can output the report information to the floppy disk.
•Simply press the function key [F6] ( File), and the operation report presently displayed on
the screen is output to the floppy disk. The default device and file names can be set at the
MacMan parameters displayed in the parameter setting mode. These parameters are fac-
tory-set so that the date is entered in the file name.