Okuma OSP 5000 Installation guide

5000/5020 CONTROL5000/5020 CONTROL
5000/5020 CONTROL5000/5020 CONTROL
5000/5020 CONTROL
LALA
LALA
LATHE / MACHINING CENTERTHE / MACHINING CENTER
THE / MACHINING CENTERTHE / MACHINING CENTER
THE / MACHINING CENTER
ELECTRICAL MAINTENANCEELECTRICAL MAINTENANCE
ELECTRICAL MAINTENANCEELECTRICAL MAINTENANCE
ELECTRICAL MAINTENANCE
TRAINING MANUTRAINING MANU
TRAINING MANUTRAINING MANU
TRAINING MANUALAL
ALAL
AL
EL 501EL 501
EL 501EL 501
EL 501
REVREV
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Intro

Factory Training
for
Basic Electrical Maintenance for Okuma
Lathes, Machining Centers and Grinders
with the OSP 5000/5020/500 series control.
Course Code : EL 501
Prerequisite : Basic Electronics
Credits : 0
Course length : 4.5 days
Class Size : 6 persons
COURSE OBJECTIVES - Upon completion, the individual will be proficient in all basic skills
necessary to troubleshoot an electrical side problem on any Okuma CNC machine tool with the
OSP 5000/5020 or 500 control.
The course is designed to provide the information needed to diagnose any machine problem.
The individual will be capable of diagnosing a problem and be able to communicate via the
phone to Okuma service representatives if the need arises for further assistance.
Course emphasis is a blend of classroom instructional theory and “hands on” time spent on the
machine tool.
COURSE REGISTRATION – To obtain program availability dates, please contact Von Pickett
at (803-981-7000) the Institute for Manufacturing Productivity to obtain program availability
dates, or check our website http://imp.okuma.com

Basic Electrical Maintenance for Okuma
Lathes, Machining Centers, and Grinders
with the OSP 5000/5020/500 series control.
Course Outline
MONDAY SECTION
1. Instructor and Class Introductions
2. Okuma History
3. Terminology
4. Safety One
5. Okuma Documentation Two
6. Machine Definition Three
A) Introduction to CNC
7. Machine Operation Four
A) CNC Operation Panel and Functions.
B) Machine operation panel and Functions.
8. Schematics Nine
A) How to Read Okuma Prints
a) Symbols (old and new)OSP 5020 Construction

TUESDAY SECTION
1. OSP 5020 Construction Five
A) Power Supplies
B) Printed Circuit Board Functions
C) Servo Systems
a) Axis Drives
b) Spindle Drives
D) Feedback Systems
2. Diagnostics Six
A) Using Actual Position Pages
B) Using Block Data Pages
C) Using Check Data Pages
WEDNESDAY
1. Diagnostics continued
D) Alarms
2. Parameters Seven
A) Setting Stroke End Limits
B) Setting Zero Offsets
THURSDAY
1. Software Eight
A) Data Management Card
B) Software Transfer Procedures
a) Backing up parameters
b) Initializing a B diskette
c) Loading software
2. Hands-On
FRIDAY
1. Hands-On
A) Troubleshooting

1
Okuma America Corporation
Okuma HistoryOkuma History
Okuma HistoryOkuma History
Okuma History
Rev. 8-21-01
In 1898 Eiichi (ah-ee-ee-chee) Okuma started a special engineering firm in Nagoya, Japan. By
1904 Okuma Machinery Works Ltd., (OMW) started manufacturing lathes and milling ma-
chines. The Okuma Symbol depicts two pieces of metal conjoined in a perfect union to symbol-
ize the union of two cultures, teamwork, and a single supplier of machine and control. A blend-
ing of two separate forces to provide a single source in support of a common purpose.
The following is a history of Okuma’s technological advancement. Other milestones are noted
on Okuma’s path to becoming one of the world’s best machine-tool builders. Okuma employs
over 1600 people worldwide.
1959 Okuma introduces the first Japanese imported engine lathe to the American market.
1963 Introduced the first OSP series NC unit, the OSP 220. Developed the Absolute Position
Encoder which is standard on all Okuma machines.
1964 Introduced its first Grinder.
1968 Developed mm/rev feed control on lathes.
1969 Opened a new plant in Oguchi, Japan.
1972 Okuma develops the first FMS (Flexible Machining System) and exhibits it at the Chi-
cago Metal show (pre IMTS).

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Okuma America Corporation
Okuma HistoryOkuma History
Okuma HistoryOkuma History
Okuma History
Rev. 8-21-01
1973 Introduced Japan’s first CNC control, the OSP 2000 series. Developed tape edit function
which allowed operation by data stored on paper tape.
1974 Introduced tool nose radius compensation feature.
1975 Formed “Single Source mechatronics”manufacturing policy.
Introduced the OSP 2000 series control to the American market.
1976 Takeo (tah-kay-o) Okuma, son-in-law of founder, became 4th president.
Introduced the first 2-saddle, 4-axis lathe.
1978 Introduced automatic gauging built into control.
1979 Introduced the next generation CNC, the OSP 3000 series.
Okuma opened a branch office in Long Island, New York for sales and service.
1980 Started using CRT’s on controls along with a tool path display feature.
1981 Introduced the industries first 16 bit CNC which provided parallel background
editing and graphics programming (IGF), the OSP 5000 series.
1982 Developed the machine monitoring function (MOP).
Started using fiber optics for data communications.
1983 Introduced high-precision fully digital servo systems with brushless motors.
Introduced a new E-type Absolute Position Encoder capable of 163,000 incre/rev.
1984 Okuma and Mitsui established a joint venture company, Okuma Machinery Incorporated
(OMI).
Introduced colored animation display (OSP 5000*-G).
1985 Became the world’s largest Machine Tool builder and second largest
manufacturer of CNC controls.
Introduced the load monitor function, built-in spindle motor, and spindle variable speed
controller (VAC).
1986 Named Japan’s Factory Automation and Industry advancement leader.
Introduced a Die manufacturing system (DMS).
Introduced a Tool monitoring system (MOP-TOOL).
1987 Opened a 163,000 sq ft plant in Charlotte, North Carolina. This company was called
Okuma Machine Tools (OMT).
OMW introduced a wide-range constant output spindle motor and high-speed numerical
control (Hi-NC).
1988 OMI was relocated to Charlotte, North Carolina.
OMI and OMT became Okuma Machine of America (OMA).
Okuma introduced high-speed, high-accuracy NC (Hi²-NC).

3
Okuma America Corporation
Okuma HistoryOkuma History
Okuma HistoryOkuma History
Okuma History
Rev. 8-21-01
1989 Hajime (hah-jee-may) Okuma (son of Takeo) became president of OMT.
John Hendrick became president of OMI.
OMW introduced synchronous control technology.
Introduced the OSP 5020 control.
1990 OMW introduced AI (Artificial Intelligence) based interactive automatic programming
function (one-touch IGF). Opened a new $21 million, 36,000 sq ft R & D Technology
center in Oguchi, Japan.
1991 Okuma (OMW) changed its name to Okuma Corporation of Japan (OCJ).
Yutaka Maeda became president of OCJ.
Opened new 250,000 sq ft plant with 7 FMS’s in Kani, Japan.
Scott Nishio became president of OMT and introduced the “Made In America”
2-axis lathe (Cadet).
Introduced a cam turning function, NC-turret, and NC-ATC.
1992 OMT built their 3000th machine.
1993 OMA is given their largest contract ever by GM Corp., to build 134 machines.
1994 OMA is given their second largest contract ever by GM Corp., 114 machines.
Introduced the OSP 7000 with the Mac Man feature
Opened Okuma Technology Institute, a 53,000 sq ft facility.
1995 Instituted Okuma CARE, a 24 hour-a-day, seven day-a-week customer service support
program for it’s North American customers.
1996 Purchased Plant 2, a 112,000 sq ft facility for manufacturing machining centers. OMA
renamed OAC (Okuma America Corporation)
1997 OTI became the international training center for Okuma. OAC opens a Sales & Service
facility in Sao Paulo, Brazil.

1
Okuma America Corporation
TT
TT
Terminologyerminology
erminologyerminology
erminology
Rev. 1-16-01
The following terms or acronyms pertain to some of the terminology used at
Okuma. Some of the terminology is used throughout the industry while some
pertain only to Okuma machines.
AB0 Axis board
AC1 Axis card
ACC/DEC Acceleration/Deceleration
ACP Animation CRT Processor board
AD Analog to Digital
Address A location of a specific cell in a computers’ memory.
Address bus The wires in a computer that carry signals used to locate a
given memory address.
APT Automatic Programmed Tools
AD-APT Adaption of APT
ALU Arithmetic/Logic Unit
ASCII American Standard Code for Information Interchange
ATC Automatic Tool Changer
APC Automatic Pallet Changer
BB0 Bubble memory section (control software on 5000/5020
series)
BB1 Bubble memory section (part programs on 5000/5020 se-
ries)
BDU Brushless Drive Unit (1st generation Axis drive)
Bit The smallest unit of information in a computer.
BLD Brushless Drive Unit (2nd generation Axis drive)
BLIID Brushless Drive Unit (3rd generation Axis drive)
Bus Set of wires carrying signals around a computer. A conduc-
tor or set of conductors that transmit information between
parts of a computer.
Byte Eight bits
CAD Computer Aided Design
CAM Computer Aided Manufacturing
CAP Computer Aided Program
CCP Communication Control Processor board
CCOP Communication Control Optical card
CIM Computer Integrated Manufacturing

2
Okuma America Corporation
TT
TT
Terminologyerminology
erminologyerminology
erminology
Rev. 1-16-01
Clock A device usually based on a quartz crystal that gives off
regular pulses used to coordinate a computers’operations.
CMOS Complementary metal-oxide semiconductor
CNC Computerized Numerical Control
CPU Central Processing Unit
CRP CRT Processor board
CRT Cathode-Ray Tube
DA Digital to Analog
Data bus The wires in a computer that carry data to and from
memory locations.
DBR Dynamic Braking Resistor
DCPS Drive Control Power Supply
DDB Digital Data Bus
DMA Direct Memory Access
DMAC Direct Memory Access Controller
DNC Distributed Numerical Control
DRAM Dynamic Random Access Memory
EC/EO I/O board on Okuma Lathes and Grinders
ECP Electrical Control Processor board
I/O control board on Okuma M/C’s
EIA Electronics Industries Association
EEPROM Electrically Erasable Programmable Read Only Memory
EPROM Erasable Programmable Read Only Memory
FCOM Fieldnet Common terminal card
FDC Floppy Disk Controller board
FDD Floppy Disk Drive unit
Fiber Optics The technology of encoding data or pulses of laser
light beamed through thin strands of glass.
FIPC2 Field Input Photocoupler card
FOPT Fieldnet Output Power Transistor card
Flash Memory Flash memory is a combination of EPROM and EEPROM
technology. A non-volatile storage device.
FMS Flexible Machining Systems
FUB-DR Fieldnet Unit Board-Driver/Receiver board
FUB-P4M4 Fieldnet Unit Board-Photocoupler(4 bytes)MOS-FET(4-
bytes)

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Okuma America Corporation
TT
TT
Terminologyerminology
erminologyerminology
erminology
Rev. 1-16-01
FUB-P4R2 Photocoupler(4 bytes)Relay outputs(2 bytes)
GHP Graphics High Power (CPU power supply on 5000*-G)
GLP Graphics Low Power (CPU power supply on 5000*-G)
IC Integrated Circuit
ID Inside Diameter
IF Interface
IGBT Insulated Gate Bipolar Transistor
IGF Interactive Graphics Function
IJP Injection Processor board
IOCM Instantaneous over-current in motor
IOCS Instantaneous over-current in servo
ISO International Standards Organization
ISO 24 Vdc Isolated 24 volts dc
LAP Lathe Automatic Programming
LDU Linear Drive Unit
Long Word 32 bits, 4 bytes, 2 words
MAP Machine Automatic Programming
MB Main board
MC Main Card
MD0: Directory in CMOS (Memory Disk) for parameter backup
files
MD1: Directory in CMOS (Memory Disk) for part programs
MOP-Tool Monitored Overload Protection
MPR Multi-Pole Resolver
NC Numerical Control
NIPS Numerical Instruction Per Second
OCON RCON with Acc/Dec activated
OD Outside diameter
ODIF RDIFF with Acc/Dec activated
OPUS Okuma Processing Unit and System
OSP Okuma Sampling Path
Parallel Several bits (8,16, or 32) of information processed at a
time.
PCB Printed circuit board
PG Pulse Generator
PH Pulse Handle

4
Okuma America Corporation
TT
TT
Terminologyerminology
erminologyerminology
erminology
Rev. 1-16-01
PIP Peripheral Interface Program
PPS Pulse Phase Shift
PTR Paper Tape Reader
PWM Pulse Width Modulation
RAM Random Access Memory
RAPA Actual Position of Axis data (data from A. P. Encoder)
RCON Calculated (Commanded) axis position data
RDIFF The difference between RAPA and
RCON(following error or lag)
RLP Rack Low Power (CPU power supply on 5020)
RHP Rack High Power (Opus power supply on 5020)
RPP RS232C/Printer/Puncher board
RSAPA Axis position when Touchsetter is detected
SAOP Sub Amp Operation
SCSI Serial Communication System Interface
SDU Spindle Drive Unit
SEL Stroke End Limit
SERCOS Serial Realtime Communication System
Serial One bit of information is processed at a time.
SPC Servo Processor Card
SSR Solid State Relay
S.T.M. Spindle, Tool, M Codes
SVP Servo Processor board
TB0 Timing Board
TCC Turret Control Card
TCU Turret Control Unit
TFP Timing Fieldnet Processor board
VAC Spindle Drive on Okumas
Vector Controlled AC Motor Control
Word 16 bits, half a long word, 2 bytes

1
2
3
4
5
6
7
8
9
10
11
12
D12<5
D12<5D12<5
D12<5
?6
?6?6
?6
3?>D5>D
3?>D5>D3?>D5>D
3?>D5>D
C165DI
C165DIC165DI
C165DI
4?3E=5>D1D9?>
4?3E=5>D1D9?>4?3E=5>D1D9?>
4?3E=5>D1D9?>
=1389>54569>9D9?>
=1389>54569>9D9?>=1389>54569>9D9?>
=1389>54569>9D9?>
=1389>5?@5B1D9?>
=1389>5?@5B1D9?>=1389>5?@5B1D9?>
=1389>5?@5B1D9?>
3?>CDBE3D9?>
3?>CDBE3D9?>3?>CDBE3D9?>
3?>CDBE3D9?>
4917>?CD93C
4917>?CD93C4917>?CD93C
4917>?CD93C
@1B1=5D5BC
@1B1=5D5BC@1B1=5D5BC
@1B1=5D5BC
C?6DG1B5
C?6DG1B5C?6DG1B5
C?6DG1B5
C385=1D93CI=2?<C
C385=1D93CI=2?<CC385=1D93CI=2?<C
C385=1D93CI=2?<C
<1D85C385=1D93C
<1D85C385=1D93C<1D85C385=1D93C
<1D85C385=1D93C
=1389>9>735>D5B
=1389>9>735>D5B=1389>9>735>D5B
=1389>9>735>D5B
C385=1D93C
C385=1D93CC385=1D93C
C385=1D93C

.

OSP 5000/5020 CONTROL
SAFETY
ELECTRICAL MAINTENANCE
TRAINING MANUAL EL 501

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Okuma America Corporation
SAFETYSAFETY
SAFETYSAFETY
SAFETY
Rev. 8-21-01
SAFETY PRECAUTIONS
Okuma machines are fully equipped with various safety devices to prevent operators and the
machine itself from accidents. However, operators are urged to operate the machine with safety
in mind. Strict observance of all safety guidelines indicated in the documentation provided with
the machine is essential. The following are some points to observe when working with any
machine tool.
CHECK THE FOLLOWING BEFORE TURNING ON POWER
1) Close the doors of the electric control cabinet and the operation panel.
2) Never place obstacles around the machine.
3) Turn on power to the machine in the following sequence:
Depress the Emergency stop button.
Turn on the Main power disconnect.
CONTROL ON button on the operation panel.
(POWER ON button on the control cabinet on machining centers.)
4) Once the control “boots up”, release E-stop and press the Control On button.
PRECAUTIONS TO OBSERVE WHEN USING A CHUCK
1) Before starting the spindle or cutting operations, close the front door.
2) Strictly observe the allowable spindle speed for the chuck installed. Never exceed the maxi-
mum allowable spindle speed.
3) When a chuck or fixture unique to the user’s applications is used, check the allowable
maximum spindle speed and run the spindle within the allowable range. Pay due attention to
workpiece gripping force and balance.
4) The maximum spindle speed can be limited by inputting the spindle speed with G50. To
ensure safety in operation, input this spindle speed limiting command in the program
(G50S****).
5) If the spindle is operated at a speed close to the allowable maximum speed:
Avoid imbalance in the workpiece clamped in the chuck.
Apply the maximum allowable pressure to grip the workpiece since increased centrifugal
force reduces the chuck’s gripping force.
The maximum allowable spindle speed and applicable pressure for the chuck are indicated
on the name plate attached to the front door as well as on the chuck body. The maximum
allowable speed and the applicable pressure ensure a chucking force larger than one-third the
original chuck gripping force with the standard soft-top jaw set in line with the chuck body’s
outer periphery.
6) When special jaws larger than standard soft-top jaws are used:
Lower the spindle speed because the chuck’s gripping force is reduced due to increased
centrifugal force and lowered efficiency.
If the jaw clamping nut (jaw nut) is outside the chuck’s outer periphery, only one clamping
bolt holds the jaws in place, causing very dangerous conditions. Jaw nuts must always be
located within the chuck body’s outer periphery.
Machine the jaws to the shape of the workpiece.

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Okuma America Corporation
SAFETYSAFETY
SAFETYSAFETY
SAFETY
Rev. 8-21-01
7) Tighten the bolts on the chuck body, jaws, and block securely. Clamping force should be
greater than 40 to 50 kg.
CHECKUP AROUND THE MACHINE
1) Before starting daily operations, always check the lubrication oil levels.
2) Always use the specified brand or grade of lubrication oil.
3) For cutting fluid (coolant), use Okuma’s recommendation whenever possible.
4) Change and replenish lubrication oil for each reservoir at the predetermined schedule as
explained in the operation & maintenance manual.
5) Clean the filters periodically according to the schedule explained in the operation & mainte-
nance manual.
6) Check the pressure gauges of the air and hydraulic lines to make sure they all read the correct
values as specified in the operation & maintenance manual.
7) For any work required inside the machine door, turn off power and ensure safety beforehand.
For work done at the back of the machine that requires the operator to enter the machine
operating zone, do not forget to turn off power before attempting any work.
PRECAUTIONS FOR MACHINE OPERATIONS
1) Always follow the instructions given in the operation manuals.
2) Never run the machine without protective covers and doors, such as the front door and chuck
cover.
3) Close the front door first before starting the machine.
4) With a new program, never attempt to start actual cutting operations. First run the program
without setting a workpiece in the machine to check machine operations and interference;
after making sure that the program is completely free of bugs, cut a workpiece in the single
block mode operation. Only after making sure that the workpiece can be cut without prob-
lems in the single block mode operation should the automatic mode operation be started.
5) Before attempting the following, always make sure that untended operation can be accom-
plished safely: Spindle rotation
Turret indexing
Axes movements
6) While the spindle is revolving, never touch chips or the workpiece.
7) Never try to stop a revolving object with hands or tools.
8) Confirm the jaw installation conditions, hydraulic pressure, and allowable maximum speed
for the power chuck.
9) Check the installed conditions and arrangement of the tools.
10)Confirm the tool and zero offset settings.
11) Set the spindle speed and feedrate override dials to 100 %.
12)Before feeding the turret, confirm the soft-limit settings and the emergency limit switch
settings for both X and Z axes.
13)Confirm the position where the turret index or rotation is allowed.
14)Confirm the tailstock position.
15)Make sure that cutting is conducted within the allowable transmission power and torque
ranges.
16)Clamp the workpiece in the chuck or fixture securely.
17)Check the cutting fluid nozzle positions. Set them at positions to supply cutting fluid cor-
rectly to the cutting point.

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Okuma America Corporation
SAFETYSAFETY
SAFETYSAFETY
SAFETY
Rev. 8-21-01
SETUP
1) Always make sure that the setup is complete.
2) After changing the setup, operate the machine step by step to make sure the cutting can be
conducted without problems.
3) Before replacing the chuck and/or chuck jaws, make sure that the new set fit the job in-
tended.
4) When two or more workers work as a group, establish the necessary safety signs, for ex-
ample, when lifting or setting heavy objects confirm with other workers whether or not it’s
“okay” to start the next process.
5) When handling heavy objects use a crane or equivalent tool.
6) When attempting unfamiliar setups check the setup again before going on to the next step.
WORKPIECE LOADING and UNLOADING
1) Load and unload workpieces securely.
2) Retract the turret before loading and unloading a workpiece to a position where the cutting
tools on the turret will not injure the operator’s hands.
3) Before attempting to load or unload a workpiece, make sure the spindle has come to a com-
plete stop.
4) Before running a new program, first rotate only the spindle to make sure the workpiece is
securely clamped in the chuck.
5) To machine irregularly shaped workpieces, make sure the workpiece is clamped in the chuck
securely without imbalance.
6) When handling heavy workpieces, use a crane, hoist, or other tool.
7) Before setting a workpiece in the machine, make sure the workpiece has portions that can be
used for proper chucking.
MACHINING CENTERS
1) Never touch the spindle or tool while the spindle is rotating.
2) Never touch the spindle or tool while the spindle is being oriented, or while it is changing
speed range. The spindle might rotate suddenly.
3) Never start spindle rotations with a tool or any other object mounted in the spindle in such a
way that it could easily come loose.
4) Always wait until the spindle has come to a dead stop before attempting to remove chips
from the tool.
5) Never begin operations without first checking that the workpiece has been securely mounted
on the table.
6) Never start table movements with anyone on the table.
7) The automatic tool changer and automatic pallet changer are particularly dangerous when
they are in operation and all personnel should be kept clear of their operation zone.
8) Inspection or changes of tools in the magazine of the ATC should be carried out only when
the ATC is in the manual operation mode.
9) If, for whatever reason, the ATC or APC should stop moving during an operation and it
should become necessary to inspect them without first cutting off power, always secure an
emergency escape zone and never touch the problem unit directly with your hands.
10)Never attempt to clean the machine or inspect it while it is operating. Always bring it to a
complete stop before conducting such operations.

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Okuma America Corporation
SAFETYSAFETY
SAFETYSAFETY
SAFETY
Rev. 8-21-01
AT THE END OF THE DAY
1) Clean the machine.
2) Locate the turret at the predetermined retraction position.
3) Before leaving the machine, turn off all power switches.
4) Turn off power to the machine in the following sequence:
CONTROL OFF button on the operation panel.
The main power disconnect.
WHEN A PROBLEM OCCURS
1) Stop all spindle (s) and axes movement by pushing the closest EMERGENCY STOP switch.
2) Contact the maintenance person to determine what action to take.
3) Use only the fuses and other replacement parts of the specified rating.
4) Be extra careful when handling the following high-voltage units:
Main Breaker
Servo Drive unit (BL-IID)
VAC drive unit
Power cables
OTHER GENERAL PRECAUTIONS
1) Wear suitable safety clothes.
2) Keep work areas clean as well as the machine.
3) Do not touch controls with wet hands.