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
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EL 501EL 501
EL 501EL 501
EL 501
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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

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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)