CNC SYSTEM OSP5020 MC-400H a MAINTENANCE MANUAL (Ist Edition) ME34-015-R13479-E P-(i) TABLE OF CONTENTS TABLE OF CONTENTS PAGE SECTION 1 OUTLINE OF OSPS020M SERIES ......... aw ims B |. Special Features of OSP5020M Series ....., 1 2, Summary of Operation 2 3. Structure of OSP5020M sen 18 34. CPU and Power Supply Unit .. 3 3-2, Electrical Control Unit (Field Network) s 3-3, Servo Drive Unit... 2... ate 4 3-4. Relay and Magnet Circuits... 4 35. Spindle Drive VAC Motor Control 4 3:6. Floppy Disk Drive Unit (optional) ‘ 4 37, Tape Reeder... eee eee cece 3 fi 4 3-8, Control Enclosute 2... eee eves vein hd aEe et Mase 3-9. Operation Panel... 0.2... 2 5 3-10. Absolute Position Feedback Encoders 5 811. Cooling Unit... Bh Piys 8 SECTION 2 MAINTENANCE AND INSPECTION ...... sieovewensg, 6 1. Inspection during Installation 6 11, Installation oo 6 1-2. Environmental Requirements . : 6 1-8. Power Supply Voltage Inspection 7 2. Periodical Inspection... 4 BSG ae teem 7 Operation and Structure of the NG... seresapecsainsemeen) 40 3-4. Example of Operation ...... sedustt oivereere cere tesieed ees AM 3-2. Description on Each Major NC Unit. . 3 1 SECTION TROUBLE ANO TROUBLESHOOTING .....,... te 14 1. Analysis of Trouble... eee ese eee ee eee ediesy deteede peste 1B 2. Loading (For the Model Equipped with the Floppy Disk Drive) oo... ...eeceeees 16: 3, Machine-Mounted Electricals gotuk : 20 3-1. Inspection of Limit Switches by Multimeter ; : 21 3-2, Inspection of Limit Switch by NC Check Display 22 3-8. Inspection of Solenoid by NC Check Display 233479-E Pi) ‘TABLE OF CONTENTS: 10. i Brushless Servomotor Drive Unit. . 44, BDU-A Series 4-1-1. Configuration of BDU-A : 2. Protection and Alarm Monitoring Function (BL-D™A Series) 441-3. Trouble and Troubleshooting ....... 42. BDU-D Series Servo Drive Unit gtisis Protection Functions ........ Trouble and Troubleshooting Precaution to Observe for Maintenance Check Panel F2 Inspection of Position Encoder . . . ayabaleyteate cpu Maj captesveavtayttes 7-1. Operation and Structure of the CPU. 7-2. Checking CPU Operations... 6.2.2. ++ 78, CPU Power Supply EC VO Unit 8-1. Fioldnot Input Photocoupler Card (FIPC) ‘ 8-2. Fieldnet Output High Transistor Card (FOHT) ... +++. eeee ee 8-3. Fieldnet Output Power Transistor Card (FOPT) 8-4 Communication Contol Optical Card (Inside the terminal box) (CCOP) 8-5. Communication Control Optical Card (Inside the control box) (ccoP2, CCOPS) Relay and Magnet Switch Circuits a GH. Operation and Structure ofa Relay and Magnet Switch Circuit 9-2. Inspection of Relays and Magnet Contactors Replacing ECP-II Battery Pack secandagraswesies Inverter Motor (Tool Change Arm Motor). . 11-1. Outline 11-2. Inspection and Maintenance 11-3. Switch Setting. . 41-4, Troubles and Measures to Take... <2 - se see eee nee ees 11-41. Possible Cause of the Trouble. 41-4-2. Cause ofthe Trouble and Measures to Take When the Alarm Lamp (milky white) is Activated 24 2a 26 29 30 36 39 45 46 a7 48 48 50 81 52 53 54 55 58 87 58 6 6 61 62 6a 64 673479-E P.(il) ‘TABLE OF CONTENTS ee PAGE SECTION 4 SPINDLE DRIVE UNIT FOR VAC MOTOR (VACII) 69 4. Outline oss eatekyys 69 2. Periodical Inspection and Maintenance . 69 8. Constructions dg. Pitas das te Hetmstte speaks pe eyes MA 3-1. Arrangement of Major Component Paris 0.2.0.2. 0.cec0ceeeueeseves 7H 4. Operation Status indication itagtegen 7 41. Control PCB Operation Status indicating Lamps 7B 4-2, Operation Status Indicating Lamps oo... 2.2 ...05 is ibiad aaas 4-2-1, Normal Operation Status Indication ..... 80 4 Failure Operation Status Indication . 81 5. Troubleshooting ...... ehascs ths 89 5-1. Confirmation of Power Supply and Connectors 89 5-2, Trouble and Troubleshooting ...-... 0.00. eee eee sere eeseeeereer es 90 5-3. Recovery from Failure Status aus 108 64. Check Terminals 109 6. Fuse Replacement Deane 113 6-1. Fuse Blown Condition... Ras 413 6-2. Inspection and Replacement Procedure for Fuses 114 6-3. Fuse Rating . 116 7. Spare Paris ft stg telat . 16 SECTIONS SELF-DIAGNOSTICS ....... 17 1. Alarm Display and Error Display ........ 2. BARES ASE TEAR ANB 2. Check Data Display. . $$$ No ‘Check the alarm contents on No the CAT, Is CRT display changed over? Check each unit according to YES the contents of the alarm, Check the contents of the block in which the machine has stopped. is the STM lamp No under NG STATUS on the operation panel on? Yes + Display the check || Piease contact The computer does not || Examples of alarm are data on the CAT |] your local Okuma _ || normally operate. shown below: press [F7 tn OP- | reprossintall. 1) Make sure in what |] LOU Overload ERATION mode), and check input! ‘output signals. Sve Section 5, 2. satus the computer is stopped. See 7- 2. in this section. 2) Check the power supply unit for its in- put voltage. See 7- 3. in this section. 3). According to instruc- tions from Okuma, take necessary measures such as control tape loading or replacement of the printed circuit board. 1). Check the servaro- tor for temperature. DA Over 1) Is connection of the position encoder Cannon connector normal? 2) Is the position en- coder normal? Fig. 9-1 Analysis of Trouble9a79-E P16 SECTION 3 TROUBLE AND TROUBLESHOOTING Loading (For the Model Equipped with the Floppy Disk Drive) Bubble momory 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 to the bubble memory becomes necessary. Control software of OSP5020M is delivered by floppy disks. (1) Floppy Disks (3 floppy disks are delivered with the control.) Floppy disk At Basic control software for NC is stored in this floppy disk. When OL the program in this floppy disk is loaded, data having been stored in Oo the bubble memory is cleared and replaced with new program. 0 Floppy disk Az ao Basic control software for EC is stored in this floppy disk 0 Floppy disk B: Used for storing machine data which has been changed after OL delivery 03479-E P17 SECTION 3 TROUBLE AND TROUBLESHOOTING Floppy Disk At OL] oO 0 May or may not be supplied depending on specifications, Control Software Classification FD Mazina BOL (File Name) BIN- BBM Bubble memory initialization NOSH**4,SYS System software MAAQE*-* POL NC main software MAGO****, POL, Graphic, PPC. MAS00-"**.POL NC specification code MAM POL NC message MDUO%.PBU Bubble memory backup (initial values) (Backup by the use of backup function key) MAUO"-"*,PBU, Bubble memory backup (initial values) (Backed up always) MSUO*-**,PBU Servo data MAQ*2*,. ISB Software specific to individual users Maker subprograms (used for autamating functions, etc.) ‘in file name varies depending on software version and machine model Floppy Disk A2: OL4 oO 0 May or may not be supplied depending (on specifications. Control Software Classification beeseecod (File Nara) MEAO™="-*POL EC main software MES00--* POL EC specification code MEM*,POL EC message MEU MPB Backup of EC processor backup area (initial val Software specific to individual users * in fle name varies depending on software version and machine model,3479-E P18 SECTION 3 TROUBLE AND TROUBLESHOOTING. Floppy Disk : Ol Contra! Sottware Oo NE Classification 0 MDUGF>PBU Bubble memory backup (Backup by tho uso of backup function key) MAUOW*PBU Bubble memory backup (Backed up always) MEUOM MP Backup of EC processor backup area **in fle name varies depending on software version and machine model. Files in the floppy disk B stores the backup of the machine data (usually the data at machine delivery).3479-6 P19 SECTION 3 TROUBLE AND TROUBLESHOOTING (2) Control Sottware Loading Procedure Load the control software from the floppy disks A1, A2 and B in this order. Qwew jo oS q eS a Es CI ell jo a) Tum on the LOAD MODE switch b) Push the SYSTEM RESET button. The CRT will display the following message. Control floppy loading wait ©) Sot floppy disk At in the disk drive. For the procedure to set disk A\1 in FDD, refer to. “Floppy Disk Handling” in Section 2, 2 d) Press the LOAD START button. The CAT 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 floppy disk will be loaded in the bubble memory. ‘Miter the completion of the loading, the CAT will display the messages indicated below: Controt floppy loading end Control floppy loading wait ©) Remove floppy disk A1 from the disk drive and place floppy disk A2 instead 1) 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 ta be loaded, the old file is replaced with the new file. 9) Remove floppy disk A2 from the disk drive and place floppy disk B instead. h) Press the LOAD START button. Note: Loading from floppy disk 8 will initialize the machine data (the deta at ma- chine delivery). i) Remove tloppy disk B from the disk drive after the completion of loading, ji) Turn off the LOAD MODE switch k)_ Turn off power supply and then turn it back on, The CPU will start running in several tens seconds.3479- P-20 SECTION 3 TROUBLE AND TROUBLESHOOTING: Machine-Mounted Electricals Mounted on the machine are limit switches, solenoids, motors and other electro-mechanical compo: nents. See the layout diagrams of machine-mountad electricals in Section 7 for their location. As these machine-mounted electricals are placed in a very severe environment affected by chips, cool- ant, oil, dirt and dust, caraful consideration has been given in design to protect these components 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 maintenance technicians. The checking procedures giv: en under Section 3, 9. "Relays and Magnet Switch Circuits” should be also consulted for solving electrical problems. This Section describes the practical method to inspect limit switches and solenoids. For other machine-mounted electricals, check in a similar way.3-1. 3479-E P-2t SECTION 3 TROUBLE AND TROUBLESHOOTING Inspection of Limit Switches by Multimeter Limit switches are used for detecting travel end of individual axes, and on the ATC, APC and spin- dle drive gear box, etc. e ‘The procedure to check travel end limit switches 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 EC control box OFF and rernave the travel end limit switch for the Xaxis. Multimeter Fig. 3-2 LS Check with Tester (1) Disconnect the two electric wires connected to the limit switch (2) Set the multimeter to the resistance range. (8) Apply multimeter probes to the limit switch terminals (C) and (NC). (4) When the multimeter indicator deflects fully to the right on its scalo, there is no problem with the limit switch. After that, press the limit switch actuating lever to check to be sure that the ‘multimeter indicator does not move at all. Then, the limit switch can be judged to be good. When the multimeter probes are applied to the limit switch terminals (C) and (NO), the multi- meter indicator moves in the reverse direction. Namely, when the limit switch actuating lever is not pressed, the multimeter indicator does not move, but when pressed, the multimeter ind cator will deflect to the right,3479-E P22 SECTION 3 TROUBLE AND TROUBLESHOOTING Inspection of Limit Switch by NC Check Display A limit switch is mounted to check that the tool in spindle is unclamped. When this limit switch fails to function, an alarm is given because the tool in spindle unckamp state 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 follows: (1), Display the "MACHINE INPUT* display screen on the CRT, as follows: AUTO OPERATION ° eck para serone eure Pace 18 tem daca BART bits buts bits B1t9 bAez OIE! BARD eartenni-37 See the bit 9 data of No. 13. (2) See the bit 3 data on check No. 13. a) When (NO) and (C) are wired: When the limit switch is tripped, it displays “1” if the limit switch is normal. When itis not pressed, the bit data is “0”. b) When (NC) and (C) are wired: “” whon the limit switch is tripped. "1 when the limit switch is not tripped,3479E P23 SECTION 3 TROUBLE AND TROUBLESHOOTING 3:3. Inspection of Solenoid by NC Check Display Solenoid valves are used to unclamp the tool in spindle When a solenoid is defective, the tool in spindle cannot be unclamped. Whether the solenoid is op: erating or not cannot be known unless voltage is applied and checked with a multimeter. 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 ° SPROUNE OUTPUT PAGE 22 em bit? ING BINS bits BiED BEEZ BIEL BID vins vius vies cers cuts GaHs OLS COL NESS ABKS VERS CRUE FECS NEMS PRS SURS SVES RTCS ‘See check No. 13, bit 1 (2) When bit + of check No. 13 is "1", it indicates that the too! in spindle unclamp signal is active. With “0” display, the tool in spindle will not be unclamped.479-E P-24 SECTION 3 TROUBLE AND TROUBLESHOOTING Brushless Servomotor Drive Unit BDU-A Series Brushless servomotors are employed to control movement of each axis of X,Y, and Z al the fee- drate and in the direction as commanded by the CNG. It is the brushless servo drive unit that ac: curately 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 ODIF between OCON and RAPA is added to the com- manded feedrate and the result, DA is obtained. The brushless servo unit functions ta control the brushless motor, i.e, the present position of each axis so that the ODIF is always zero, ‘The brushless servomotor drive unit BOU-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 commuta- tor brushes, which is the must with DG 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8479-E P-25 SECTION 3 TROUBLE AND TROUBLESHOOTING 4-4-1, Configuration of BDU-A (1) General System Configuration ‘The BDU-A consists of the DC power supply and the servo amplifier unit, A DC power supply can supply power to muliple servo amplifiers (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. DC power supply DC-S'A Servo Sere processor ampiiior board (ist axis) PL nepor (ist and and BLD*A axis) Servo } ampli i (2nd axis) BL si BLD“A \ Servo i processor ' board Servo (Gth and 6th amplifier axis) (6th axis) Blmotot BLD“A Fig. 3:3 BDU-A Configuration3479-E P-26 SECTION 8 TROUBLE AND TROUBLESHOOTING. (2) Configuration of DC Power Supply Unit The DC power supply unit consists of the DC-PS board and the DC-S"A unit Name Table 3-1 Model (Descriotion) DO-PS Board PGB for two-axis control PCB for three-axis control POB for four-axis control POB for five-axis control PGB for six-axis control DC-S'A Unit be-s1at + Conventional DC-82 unit is replaced with the DC-S1A unit after modals. (3) Configuration of Servo Ampiiior The servo amplifier consists of the Name DG-S3A SVC-A board and the BL-D"A unit Table 3-2 Model (Description) ‘SVG-A Board Change DIP switch setting according to motor model. BL-D™A Unit BL-DI5A unit BL-D30A unit BL-D5OA unit BL-D76A unit BL-D150A unit the slight change in3479-E P-27 SECTION 3 TROUBLE AND TROUBLESHOOTING (4) Construction of DC Power Supply, DC-PS Board and DC- "A Unit CNS... .eNt0. ENG cni2 Lo Fig. 3-4 Construction of the DG Power Supply ent iO owo Boga emia LED for alarm indication Fig. 3-5 Arrangement of Major Component Parts of DC-PS Board Rosistan lO ‘MSI sz eas Oo ‘Capacitor O20: oo0°o (2 @ oo gS Rectiior \\_ Transistor Fig. 9-6 Arrangement of Major Component Parts of DC-§3479-E P-28 SECTION 3 TROUBLE AND TROUBLESHOOTING, (5) Construction and Component Part Arrangement of Servo Amplifior Servo Amplifier, SVC-A Board and BL-D“A Unit THe oa cna on on ‘Terminal block NFB Fig. 8-7 Construction of the Servo Amplifier ‘Transformer cna, cna: na | 1 sw? ~ {| SNe ea Fs Fuses co | Transformer] ME _ Sway v Barna i fiir LED's for alarm indication Fig. 3-8 Arrangement of Major Component Parts of SVC-A Board No-luse breaker Resistance *e block 9) 0] Transistors Fig. 3-9 Arrangement of Major Component Parts of BL-D"A Unit3479-E P-29 SECTION 8 TROUBLE AND TROUBLESHOOTING 4-1-2. Protection and Alarm Monitoring Function (BL-D“A Series) Functions Purposes and Contents| 1. [Grounding Protection For grounding problem of the servo amplifier or motor, a high speed ‘no-fuse breaker is tripped to shut off the power immediately, At this time, the motor stops safely with dynamic brake applied, 2 | Base Circuit Protection Alter a breakdown of a power transistor, the fuse connected in the base line protects the base circuit from over voltage. 3. | Motor Overload Protection (Mot) 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. 4 | Abnotmal Temperature Rise of Heat Sink (FOL) It 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, motor stops safely using dynamic brake. 5 | High/Low Voltage (HV/LY) DG power supply output voltage is monitored to protect 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. 6 |DC Power Supply Short (ioc-s) ‘An overcurrent caused by the short in the inverter DG power supply due to failure of the main circuit elements or control circuit is detected to protect the main circuit elements from secondary breakdown. Whon an alarm is detected, the motor stops safely using dynamic brake. 7 [instantaneous Motor ‘Overcurrent (IOC-M) Instantaneous overcurrent in the motor circuit exceading the preset level is detected to protect motor magnet from demagnetization When an alarm is detected, the motor stops safely using dynamic brake. 8 | 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. 9 | Regenerative Resistor ‘Overheat (OH) ‘Overheating of the regenerative resistor is detected if current 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.3A79- P-30 SECTION 3 TROUBLE AND TROUBLESHOOTING 4-1-3. Trouble and Troubleshooting The troubleshooting procedure is explained below. (1) DC Power Supply Unit No Trouble Causes ‘heck Measures 1 [No-tuse breaker is | Incorrect wiring at | Check wiring. Correct wiring tripped, torminals (VIL, VL) Grounding of output | Check the wiring for | Replace the cable. terminal (VIT, VL) | grounding, cables Grounding of the Check the servo Replace the servo servo ampitior amplifier for grounding. | ampitier. Defeciive DC power | Check that the above | Replace the DC power supply indicated items are all_| supply correct 2 [LED “OH" lights. Defective discharge | Check the power Replace the DC power power transistor transistor. supply Loose connection of | Gheck the connection | Connect the connector connector CN12 of the connector N12 correctly conta. Defective OC power | Check that the above | Replace the DC power supply indicated items are all_| supply. correct. 3. |The "DC PWR ON" _ | Detective DG power Replace the DC power LED is not turned off | supply supply. even alter the power (Before attempting is tumed off. replacement, confirm that the red DC PWR, ON LED is off) (ENS. oun aa LED for alarm nciaton 8 Res © 8 Bn PSON OH ins NFB Fig. 3-103479-E P31 SECTION 3 TROUBLE AND TROUBLESHOOTING (2) Servo Amplifier No. Trouble Causes Check Measures 4 | No-tuse breaker is incorrect wiring at | Check wiring Correct wiring, ‘ripped terminals (U, V, W, E) Grounding of output | Check the wiring for | Replace the cable. terminal (U, V, W, E) | grounding, cables Detective power Check the power Replace the servo transistor transistor, amplifier. Detactive servo Check that the above | Replace the servo amplifier indicated items are all_| amplifier. correct. & [LED “PS-ON" does | Fuse (HM3.2) is Check if the fuse is | Replace the fuse. not light. blown: blown, Loose connection of | Check the connection | Connect the connector connector CN10 of the connector CN10 correctly NiO. Toose conreaon of | Ghack he connoston” | Conect the soar] connector CN2 of the connector CN2._ | CN2 correctly. Defective servo Check that the above | Replace the servo ampiiier indicated items are all_ | amplifier. correct. 6 [LED “LV™ lights. The no-fuse breaker [Check the no-fuse | Turn ON the no-fuse for the servo ampitier | breaker position. breaker. or the DC power supply is OFF. ‘phase input voltage Check the input S- | Check the power is abnormally low. phase power with a | capacity. multimeter. One phase is lost in [Check the input 8- | Check the power the 3-phase input phase power witha | supply cable. power. multimeter. Loose connection of | Check the connection | Connect the connector connector CNS of the connector CN3. | CN3 conectly. Defective servo Check that the above | Replace the servo amplifier indicated iterns are all_ | amplitier. correct. Defective DC power | Check that the above | Replace the DC power supply indicated items are all_ | supply. correct. 7 [LED “VA" lights. Defective SVO-A Replace the SVO-A board board.9479-E P-92 SECTION 8 TROUBLE AND TROUBLESHOOTING No. Trouble Causes Check Measures 8 [LED “iocs* Incorrect setting of [Confirm that SW7 | Re-set SW7 according sw7 seiting is as specified |to the Servo in the Servo Characteristic Chart. Characteristic Chart Incorrect wiring at | Check wiring, Correct wiring. torminals (U, Vy Wy E) Grounding of output | Check the wiring for | Replace the cable. torminal (U, V, W, E) | grounding cables Defective power Check the power Replace the servo transistor transistor. amplifier. Defective servo Check that the above | Replace the servo amplifier indicated items are all_| amplifier. correct. 9 [LED “10CM" lights. incorrect setting ot | Confirm that SW1 and | Re-set SW1 and SW2 SW1 and SW2 SW2 settings are as | according to the Servo specified in the Servo | Characteristic Chart. Characteristic Chart. Incorrect wiring at | Check wiring. Correct wiring. terminals (U, V, W. E) Grounding of ouiput | Check the wiring for | Replace the cable. terminal (U, V, W, E) | grounding. cables Loose connection of || Check the connection | Gonnect the connector connector CNT of the connector CN. | CN1 correctly. Defective SVP board | Check that the above | Replace the SVP indicated items are all_ | board. correct. Defective servo Check that the above | Replace the servo amplifier indicated items are all_| amplifier. correct. Defective motor Check that the above | Replace the motor. indicated items are all correct. 40 [LED “FOL" lights. [Overload operation [Check load with the | Review the cutting oad meter. conditions and cutting tool, Loose connection of connector CN4 Check the connection of the connector CNA, Connect the connector CNA correctly. Defective servo amplifier Check that the above indicated items are all correct, Replace the servo amplifier.3479-E P33 SECTION 3 TROUBLE AND TROUBLESHOOTING. No. Trouble Causes Check Measures 11 [LED “HV" fights. 3:phase input voltage [Check the input 3- | Check the power is abnormally high. | phase power with a | capacity multimeter Defective power Check the power | Replace the DO power transistor of DC power | transistor. supply. supply Defective DC power | Check that the above | Replace the DO power supply indicated items are all_| supply. correct. Defective servo Check that the above | Replace the servo amplifier indicated items are all_| amplifier. correct. 12 |LED "MOL" fights. | Overload operation | Check toad with the | Review the outing load meter. conditions and cutting tool. Loose connection of eonnectar CN11 Check the connection of the connector ont, Connect the connector ON11 correctly, Loose connection of connector CN4 Check the connection of the connector CN4. Connect the connector CN4 correctly. Defective servo amplifier Check that the above indicated items are all correct. == Replace the servo amplifier,3470-6 P-34 SECTION 3 TROUBLE AND TROUBLESHOOTING (3) Others No Trouble Causes ‘Check Measures 19 [DIFFOVER error Incorrect setting of | Confirm that SW1 and | Re-set SW1 and SwW2 occurs. SW1 and SW2 SW2 settings are as | according to the Servo specified in the Servo | Characteristic Chart Characteristic Chart. Incorrect wiring at | Check wiring Correct wiring, terminals (U, V, W, &) Loose connection of | Check the connection | Gonnect the connector connector CN1 of the connector CN1. | CN1 correctly Datective power Check the power Replace the servo transistor transistor. amplifier. Defective servo ‘Check that the above | Replace the servo amplifier indicated items are all_| ampitier correct. Defective motor ‘Check that the above | Replace the motor. indicated items aro all correct. 14 | Motor hunts Loose connection of | Check the connection | Connect the connector connector CN1 of the connector CN1. GNI correctly. Incorrect wiring at terminals (U, V, W, E) heck wiring Correct wiring, Defective power transistor Check the power transistor. Replace the servo ampiiior. Defective servo amplifier Check that the above indicated items are all correct. Replace the servo ampiiier, Defective SVP board or TB board Check that the above indicated items are all correct Replace the SVP board or TB board. Defective encoder Check that the above indicated items are all correct. Replace the encoder. Defective motor Check that the above indicated items are all correct. Replace the motor.3479-6 Pas SECTION 3 TROUBLE AND TROUBLESHOOTING (4) Checking Power Transistor Procedure: 1) Remove the SVC-A board, 2) Disconnect the leads and bus bar for the power transistor to be checked. 3) Measure the resistance between terminals using a multimeter. Correct resistance is as in- dicated in Table 9-3, B22 cZer e2 ch Bt Et Fig. 9-11, Transistor Module Terminal Arrangement T i c BI 82 Fig. 9-12 Equivalent Circuit for Transistor Module Table 3-3 Judgment Standard (Multimeter setting: x 10) Transistor Terminals Multimeter Multimeter Correct ‘Abnormal (+) probe (=) probe 1 (C2) E1(E2) | Tens to hundreds of ohms fog, = Et (2) 1 (C2) © 0 to hundreds of ohms c1 (C2) B1 (62) __| Tens to hundreds of ohms on, = 81 (82) 1 (C2) © 0.t0 hundreds of ohms 81 (82) E1(E2) _| Hundreds of ohms one E1(E2) B1 (82) _| Hundreds of ohms on © =i3479-E P-a6 SECTION 3 TROUBLE AND TROUBLESHOOTING 42. BDU-D Series Servo Drive Unit The brushless motor servo drive unit (Type D) is used for the control of the tool magazine and crossrail automatic positioning. (optional) 4-2-1. Protection Functions ‘The BDU-D series servo drive unit has the following protection functions. (1) DC-PS (DC Power Supply) Unit a) Protection function using protection components: Type Indication Contents ‘No-fuse breaker The no-use breaker lever is | Protects the circuits from abnormal tripped to OFF. current flow caused by grounding of DC Light emiting diodes (LED), _| 9UtPUt line er short of output load. “PH, *LV" and “OVER DIS*, light atthe same time. Fuse element is blown. ‘The fuse is blown when secondary side When a tuse is blown, LED vatiogs | af the control transformer is “PH” lights. seoties b) Protection function using circuits in PCB Type Indication Contents Phase-loss alatm LED “PH” lights. ‘When any one of three input phases of ‘AC power supply is lost, the protection function is activated and motor rotation is stopped with dynamic brake applied. Low-voltage alarm | LED “LV* lights The protection function is activated when DC output voltage is lowered below 200 V and motor rotation is stopped with dynamic brake applied High-voltage alarm | LED “HV* lights. ‘The protection function is activated when DC output voltage is increased ‘exceeding 430 V and motor rotation is stopped with dynamic brake applied (Over-discharge alarm | LED “OVER DIS" lights. “The protection function is activated when discharge transistor (TRS) is turned on for longer than the specified period and motor rotation is stopped with dynamic brake applied.3479-6 P37 SECTION 3 TROUBLE AND TROUBLESHOOTING (2) Servo Amplifier Unit 8) Protection function using protectian components: Type Indication Contents No-fuse breaker 1) No-fuse breaker lever is tripped to OFF. 2) LED "LV" lights. (SVC No. 2 board) Protects the circuits fram abnormal current caused by grounding of unit ‘output line or short of loads. Protects the circuits from short of transistor bridge. Fuse {control transformer primary input side) 1) Fuse element is blown, 2) When a fuse is blown, LED "PH? lights, The fuse is blown when secondary side voltage of the control transformer is abnormal. Fuse (secondary side of base circuit) The base circuit protection fuse is blown. Protects the base circuit from high voltage if power transistor is faulty, b) Protection function using circuits in PCB Type. Indication —— Contents Phase-loss alarm LED “PH” lights. When any one of three input phases of (SVC No. 2 board) AC power supply is lost, the protection function is activated and motor rotation is stopped with dynamic brake applied. Low-voltage alarm | LED "LV" lights. The protection function is activated when (SVC No. 2 board) DC input voltage is lowered below 200 V ‘and motor rotation is stopped with dynamic brake applied, Motor overcurrent alarm LED “(OG-M" lights. (SVC No. 2 board) The protection function is activated when overcurrent (more than 120% 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. {SVC No. 2 board) The protection function is activated 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 function is activated when DC input voltage is increased exceeding 490 V and motor rotation is stopped with dynamic brake applied.3479-E P38 SECTION 3 TROUBLE AND TROUBLESHOOTING: Type Indication Contents PCB control power | LED "VA" lights. The protection function is activated when supply alarm £12 V power supply of the contro} circuit lowers below + 10.8 V to generate an alarm and motor rotation is. stopped with dynamic brake applied. Encoder pattern data | LED “Ea” lights. This alarm is detected when data format alarm (SVC No. 1 board) 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 pattern data alarm) Encoder velocity LED “MPR” lights. This alarm is detected when lower digit alarm (SVC No. 1 board) 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 | LED “APA” lights. This alarm is detected when upper digit alarm (SVC No. 4 board) ‘numerical value read from the motor incorporated encoder does nat conform to the numerical value obtained through: the calculation of lower digit numerical value. An alarm is generated and motor rotation is stopped with dynamic brake applied. (Equivalent to SVP APA check data alarm) Encoder alarm LED "ALA" lights. This LED is turned on when any of the (SVC No. 1 board) encoder alarm indicated above is detected. Note: ‘An encoder alarm will be displayed until an alarm reset pulse is input from the ECPII board after power supply is turned on. This alarm display does not indicate actual occurrence of an alarm and may be ignored.3479-E P-38 SECTION 8 TROUBLE AND TROUBLESHOOTING Trouble and Troubleshooting If any problem occurs, locate the cause of the problem referring to the inspection items indicated below (1) DC-PS (DC Power Supply) Unit Problem What to Check Measures to Take No-fuse breaker is tripped. Gonnection at output terminals (VH, VL) for short, grounding and wrong) connection Correct wiring. Reciifier (REG) Replace defective rectifier Fuse is blown. Pin Nos. 1, 2 and 3 of output con- nectors (CNS, 6, 7, 8, 9 and 10) Correct wiring. ‘Wrong fuse Replace fuse. LED “PH” lights up. (Phase-loss alarm) No-fuse breaker Refer to No. # Phase-loss of S-phase input power supply 4) Itany one of throe phases is lost, LED "PH" lights up, 2) If two phases are lost, neither of LED lights up because pow- er is not supplied to control PoB. Check 3-phase input power supply sing a multimeter. Circuit breaker on control box IW circuit breaker tripped to OFF is eset to ON too quickly, LED "PH" might light up. Turn OFF the con- {rol box circuit breaker again then tum it back ON more than five sec- onds later. Connection of connector N12 Check the connector. Malfunction of circuits on PCB Replace the PCB. LED “LV" lights up. (Low-voltage alarm) ‘Abnormally low voltage of 3-phase input power supply Check input voltage with multimeter. Phase-loss of S-phase input power supply Check input voltage with a multimeter. Connection of connector N12 Check the connector. Malfunction of circuits on PCB: Replace the PCB, LED "HV" lights up. (High-voltage alarm) Wire broken in resistor AS2 Replace defective resistor. Transistor (TR) Replace detective transistor. Connection of connector CN12 Check the connector. Malfunction of circuits on PCB. Replace the PCB. LED “OVER DIS" lights up. (Over-discharge alarm) Wire broken in resistor AST Replace defective resistor. Transistor (TR) Replace detective transistor. Connection of connector N12 Check the connector. Malfunction of circuits on PCB: Replace the PCB.3479-E P-40 SECTION 3 TROUBLE AND TROUBLESHOOTING: (2) Servo Amplifier Unit No. Problem What to Check Measures to Take 7 | No-tuse breaker is | Connection at output terminals (U, | Correct wiring. ‘ripped \V, W, and E) for short, grounding and wrong connection Transformer on BOC board Replace defective transformer. Power transistors (TR1 - TR6) Replace defective power transistor. Note: Ita power transistor is faulty, the fuse (base circuit protection fuse, 0.5 A) on the BOC board might be blown, or base cur- rent amplifying transistor (E7206) might be faulty. If this occurs, the BDC board itself must be replaced. @ | Fuse at the primary | Wiring to three BDC board trans- | Correct wiring. side of the control | formers renetoaet ie pte Transformers on BDG board Replace defective transformer. 2A X 3 pos.) Wrong fuse Replace fuse. @ | Fuse atthe secon- | Power transistor (TR1 - TR6) Replace defective power transistor. dary side of the base Saints For replacing, refer to No. 7. (0.5 A fuse soldered | Output transistor ET206 Replace defective output transistor ‘on BOG board) E1206. 10 | LED “PH” lights up. | Refer to No. 3. Rafer to No. 3. (Phase-loss alarm) [Fuse (2A) on BDC board Refer to No. 8, Transformers on BDC board Replace defective transformer. Connection of the unit connector | Check connectors. (CN10) and BDC board connector (en7) ‘Malfunction of SVC No. 28D —_| Replace SVC No. 2 BDC board, board 11 [LED “LV" lights up. | Tripping of no-fuse breaker of ser- | Refer to No. 7. (Low-voltage alarm) | vo amplifier LED “LV" of DO-PS unit; is itight- | Flefer to No. 4 ed up? Connection of the BDC connectors (CN, GN6) and SVC No, 2 board connector (CNS) (Check connectors. Malfunction of SVC No. 2 board and BDC board Replace defective board, SVC No. 2 board, or BDC board.3479-E P-4t SECTION 3 TROUBLE AND TROUBLESHOOTING No. Problem What to Check Measures to Take 2 LED “1OC-M" lights vp, (Motor overcurrent alarm) Selling of SWi and SW2 on SVC No. 2 board Re-set SWI, SW2 according to Servo Characteristic Chart Connection at output terminals (U, V, W, and E) for short, grounding and wrong connection Correct wiring. Power transistor (TA1 - TR6) Replace detective power transistor. For replacing, refer to No. 7. Connection of SVG No. 2 board connectors (CN7) Check connectors. Malfunction of SVG No. 1 and No, 2 board Replace defective board, SVC No. 1 board, or No. 2 board. 13 LED “100-S" lights up. (inverter short alarm) Setting of SW7 on BDC board Re-set SW7, according ta Servo Characteristic Chart. Connection at output terminals (U, V, W, and E) for short, grounding, land wrong connection Correct wiring, Power transistor (TA1 - TRG) Replace defective power transistor. For replacing, refer to No. 7. Connection of the BDC board con- rectors (CN9, CN6) and SVC No. 2 board connector (CNS) Check connectors. Malfunction of SVG No. 2 board and BOC board Replace SVC No. 2 board or BDC board. LED *HV" lights up. (High-voltage alarm) Refer to No. 6. Refer to No. 5. Connection of the BDC connectors (CNS, CNS) and SVC No, 2 board connector (CNS) Check connectors. Malfunction of SVC No. 2 board and BDC board Replace SVC No. 2 board or BDC board. 16 LED “VR® lights up. (PCB contro! power supply alarm) Voltage across COM and +12 V, and COM and ~12 Vat check ter- minals of SVC No. 2 board; they must be +12 Vand -12 V, re- spectively. Replace SVC No. 2 board or BDC board, Connection of the BDC connectors (CNS) and SVC No. 2 board con. actor (CNS) ‘Check conneciors. Connection of connectors (CNT, Na) in 5 V power supply (LT=168) mounted on SVC No. 2 board Check connectors.Note 1 9479-6 P-42 SECTION 8 TROUBLE AND TROUBLESHOOTING: How to Check Power Transistors O° oO a 2,8 a 2 E1.c2 2 a 5 O° oO (Screw Terminal Type) (Faston Terminal Type) EI-B1. 2 —) Check voltage across exe2, cp —) these terminals. c19 81 1,2 82 Fig. 3-13 Equivalent Circuit of Power Transistor3479.6 P-43 SECTION 3 TROUBLE AND TROUBLESHOOTING No. Problem What to Check Measures to Take 16 | LED “E68” lights up. | Wiring between connector CN1 at | Check connector and cable. (Encoder pattem SVC No. 1 board and ECP Tl, and | (Mainly, upper digit signal line) data alarm) between CN2 and motor incorpo: rated encoder Malfunction of motor incorporated | Replace motor incorporated encoder (upper digit) encoder. Malfunction of SVC No. t board | Replace SVC No, 1 board. 17 | LED *“MPAY lights | Wiring between connector CNt at | Check connector and cable. up. (Encoder velocity alarm) SVC No. 1 board and ECP II, and between CN2 and motor incorpo- rated encoder (Mainly, MPR signal line) Malfunction of MPR of motor incor- porated encoder Replace motor incorporated encoder. Malfunction of SVC No. 1 board Replace SVC No. 1 board, Motor speed; higher than 3,750 rpm? (speed command voltage normal?) Replace EGP IT board, Check connector and cable. LED “APA" lights up. (Encoder check data alarm) Wiring between connector CNT at SVG No. 1 board and EOP II, and between CN2 and motor incorpo- rated encoder (Check connector and cable, Malfunction of motor incorporated ‘encoder Replace motor incorporated encoder. Malfunction of SVC No. 1 board Replace SVC No. 1 board. Excitation signal from EOP Il for motor incorporated encoder Replace EOP Il card, card 4, or distribution card. Is reset pulse (ALOFF) input to ‘CNS of SVC No. 2 board from ECP UL after power supply is turned on? Check connector and wiring,9479-6 P-44 SECTION 3 TROUBLE AND TROUBLESHOOTING (3) Brushless Servomotor Operations No Problem What to Check Measures to Take 19 | Servomotor does not | Are magnet switches in DC-PS unit |1) Check connector (GN4) in DC- rotate even when a | and servo amplifier unit ON? PS unit PeouTan e aien 2) Check connectors (CNS, 6, 7, 8, 9 and 10) on PCB in DC-PS unit. 8) Check connector (CN10) in servo amplifier unit. Is LED “SAOP* on SVC No. 2 1) Check SWE of SVG No. 2 board off? board. 2) Check connector (CN1) on SVC No. 1 board. 8) Replace the SVC board, Is input signal correct? 1) Check waveform at check terminals on SVC No. 2 board; COM-Iuo, COM-Ivo. 2) Check connector (CN) on SVC No. 1 board, DG-PS unit function Refor to (1). ‘Servo amplifier unit function Refer to (2). Wiring to brushless servomotor | Correct wiring, 20 | Wregular rotation of | Connector (CNS) of SVC No.2 | Chack connector. servomotor board Connection to brushless servomo- | Check wiring tor (loose connection) Malfunction of SVC board and BDC | Replace SVC board, or BDC board. board Matching error between servo am- |1) Lower position loop gain Kv plifier and machine value (VR - VCOM) 2) Change velocity loop gain (VA- VLG) 8) Change velocity feedback amount (VR - VNFB) ‘Malfunctioning position encoder _| Replace defective encoder.3479-6 P-46 SECTION 3 TROUBLE AND TROUBLESHOOTING 4-2-3, a), (2) 3) (4) Precaution to Observe for Maintenance Before operating the no-fuse breaker of the DC power supply unit and servo amplifier unit, al- ‘ways tur off the no-fuse breaker (main circuit breaker) at the control box. Before replacing fuses, or printed circuit boards, or checking terminal screws, alvays turn off the main circuit breaker at the control box and press the discharge pushbutton of the condens- er for above 20 seconds. When replacing the SVC board or BDC board, sel the switches according to the Servo Char: acteristic Char 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 citcuit protection fuse might be blown depending on da- ‘maged mode, and output trensistor ET206 might further be faully. Therefore, check the power transistor and BDC board when carrying out repair.3479-6 P-46 SECTION 3 TROUBLE AND TROUBLESHOOTING 5, Check Panel (Open the tape reader door, and the check panel as illustrated below will be found at the side of the tape reader. EMG. STOP LIMIT Row 2 iw SENSORE APC Oo Tl perurn Fig. 2-14 Check Panel When the emergency limit switch at each end of the X-axis, Y-axis, and Z-axis is tripped, the corre- sponding L. §. EMERGENCY lamp lights up. If any one of these lamps lights up, the servo drive unit power supply units will turn OFF for all axes; but as long as the RETURN button is held down, the servo drive unit power supply unit remains ON. Therefore, if any cause activates the emergen- cy limit switch, press the RESET buiton 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, 50 even if the RETURN bulton is released, the machine will return to the previous normal condition.3470-E P.47 SECTION 3 TROUBLE AND TROUBLESHOOTING 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 procedures. (1) Obtain the CHECK DATA "NC AXIS DATA" page on the CRT. (2) Then, the position detected value of each axis, RAPA, operational value CON, and the Gifference RDIF 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 the pulse handle. Check that the value changes from the smaller digit slowly + Check that no value is o = Check that the digit carry is dono properly, ted and that no value repeats. Normal case: 18 319-320-321 920. Abnormal case: 18 320-921 22 18 919 921 20 lf 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3479-6 P-AB SECTION 8 TROUBLE AND TROUBLESHOOTING 7A 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 NG", and should be referred to. Operation and Structure of the CPU Rofer to Fig. 25. AAs described in Section 2, 3., the main component of the OSPS020M is the CPU, which consists of BOARDs and CARDs added to the BOARD. The CPU employs “Multiprocessing system" in which the axis control processor on the SVP BOARD-II, and the machine cantrol processor and interface provided on the ECP BOARD-II operate under the control of the main processor on the MAIN BOARD-IIB. For each processor, a high-performance microprocessor is used and for the IC memory, @ high-speed very large scale IC memory is used in order to accomplish high-grade NC functions. In addition to the IC memory, a bubble memory for storing machining programs and control program (control software) storage is provided. The bubble memory is a readiarite memory, allowing stored data to be altered as needed. Its memory capacity is up to 6 M bytes. 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 OSPS020M is a computer NC with control programs (control software) designed specially to each user’s specifications, and delivered as control tapes 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 supply unit supplies all power required for the CPU. An AC 200V input direct switching method is employed because it gives high efficiency and causes less heat generation, Refer to Fig. 3-15 for CPU and Power Supply Unit.3479-E P-ag SECTION 8 TROUBLE AND TROUBLESHOOTING a cna] Fan motor connector GL puiary function connector Voltage check terminal CPU power supply unit AC input connector Fig. 2-18 CPU and Power Supply Unit3478-E P-50 SECTION 8 TROUBLE AND TROUBLESHOOTING 72. Checking CPU Operations ‘Simple checking for proper computer functioning can be carried aut by checking if the indication on the CRT scroen operates properly. For example, try to change the page indicated on the CAT screen. the page is actually changed, it can be assumed that the computer works well In order to ‘check what condition the computer remains in, make a check by the CPU operation check indication on the CPU. Refer to Fig. 3-15. Table 3-4 CPU Operation Check Indication Indication Indication Contents. P: POWER Power supplied to PU Re RUN CPU running B: BUS ERROR More than one error occur al the same time. CPU stops running. =: ECC ERROR) Error in more than one bit are caused in the main memory. D: DIA ERROR Errors occur in self diagnostics. L: LOOP ERROR Errors occur when the control software execution is looped. C: OYCLE 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 memory address area not yet defined - Two lamps, POWER and RUN, light in normal condition. = When errors occur For any error except BUS ERROR: ‘The GPU continues running and processes errors, and the CAT 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 olf when the OSPS020M is rosel. To start NC operation again, switch OFF the power and then switch ON again. The computer starts RUN automatically and goes into NC operation several tens of seconds later. If the abnormality is continuous, the error occurs again and the computer stops. When the computer carries out normal NC operation, continue using it and abserve the operation.3479-E P61 SECTION 3 TROUBLE AND TROUBLESHOOTING. CPU Power Supply ‘The power supply for the CPU has the arrangement shown here. r— +5V ‘AC 200V — 41av »| Power supply unit a |— +2ay 1 +24v (iso) AG 200V is input into the power supply unit and this supplies the voltage requited for the CPU. This unit is mounted on the CPU as shown in Fig. 3-16. For the connection with the CPU, input of AC 200, and for connection with other devices, dedicated cables and connectors are used. Each output voltage is supplied for the follawing destinations +8V Power supply for IC's in GPU +12V | Bubble memary, position encoder, spindle pulse generator, manual pulse generator +24V | Bubble memory, tape reader 180+24V | Power supply for EC inputfoutput isolator (Power may be supplied from another power supply.) Voltage check terminals for each output are provided to check these output voltages. A veriable resistor to adjust the voltage is provided for +5V. Refer to Fig. 3-16.3479-E P52 SECTION 3 TROUBLE AND TROUBLESHOOTING This power supply 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 indicated below, and CPU operation stops. Table 3-5 GPU Power Supply Alarm Indication Indication Indication Contents AC INPUT UV ALARM Input voltage (AG 200V) dropped too low OVER TEMP ALARM Power supply unit temperature rose too high UNDER VOLTAGE ‘A voltage dropped too low (including short-circuit) OVER VOLTAGE ‘A voltage rose too high 1s024v +24V ‘The voltage on which UNDER VOLTAGE or OVER +10V VOLTAGE alarm has occurred is indicate +8 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 supplies 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 tum back ON the main breaker after confirming that the alarm indication disappears several tens of seconds later. Then press the POWER ON pushbutton. ‘The CPU starts running automatically and the OSP5020M 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. EC W/O Unit The EC VO unit consists of one communication card and multiple input and output cards. Three types of input and output cards are available as indicated below. The number of output signals and the input/output operation differ depending on their combination. Input Card: - Fieldnet Input Photocoupler (FIPC) Output Card: ldnet Output High Transistor (FOHT) - Fieldnet Output Power Transistor (FOPT) Communication Card: = Communication Control Optical (CCOP) = Communication Control Optical 2 (GCOP2) = Communication Control Optical 3 (GCOPS)3479-6 P53 SECTION 3 TROUBLE AND TROUBLESHOOTING 81. Fieldnet Input Photocoupler Card (FIPC) As illustrated below, one card can handle a total of 16 signals, and two cards (32 input signals) can be used at one child station. This card is used for reading input signals from limit switches, relay contacts, and other switches, The card is used only at the child station inside the terminal box. + e 7B TB K-) 4) De2av N24 P24 Fig. 3-168479-6 P-54 SECTION 3 TROUBLE AND TROUBLESHOOTING: 8-2, Fieldnet Output High Transistor Card (FOHT) As illustrated below, one board can handle a total of 82 output signals. One card can be used for each communication card. This card is used for driving the DC controlled small LEDs and control relays in the control box. This card cannot be used at the child station inside the terminal box since it causes temperature rise in the terminal box. com TB 7B (=) a DC24v N24 P24 Fig. 9-178-3, 8479-6 P55 SECTION 3 TROUBLE AND TROUBLESHOOTING Fieldnet Output Power Transistor Card (FOPT) As illustrated below, one card can handle a total of 8 output signals, and up to four cards can be used for each communication card, This card is used for driving the DC controlled solenoids, relays, and lamps. The card is also used for driving DC controlled small LEDs and control relays at the child station in- side the terminal box. 4 >>To E J Sou i | SOL 2 > 3 > 4 > 5 g ER) , @ = com — com TB TB 6 5 S =) 4] Dezav N24A pe2av Fig. 3-183479-E P-56 SECTION 8 TROUBLE AND TROUBLESHOOTING 8-4, Communication Control Optical Card (Inside the terminal box) (CCOP) This card is used only at the child stations inside the terminal box. One communication card is necessary for each child station, The card serves to convert optical signals to electric signals, 8-5. Communication Control Optical Card (inside the control box) (CcopP2, CCOP3) This card is composed of the CCOP and the FIPC, and is used at the child stations inside the con- trol box. One CCOP2 is used for each child station. When the number of input signals exceeds 82, up to three CCOPS can be added. y cA tk Ms 1 PB. at ls 73 73 4] DczaV N24 P24 Fig. 9-19O14, 3479-6 P-57 SECTION 8 TROUBLE AND TROUBLESHOOTING Relay and Magnet Switch Circuits The felay and magnet switch circuits control devices requiring high voltage which cannot be Controlled by semi-conductors, such as motors, clutches, and solencids. Since the relays and magnet switches can be checked visually, the operation chock is relatively easy, Check according to the relay circuit diagrams provided for each machine. Operation and Structure of a Relay and Magnet Switch 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 (NO contact), and turns OFF contact point B which is normally closed (NC contact). ah (o) ‘(normally open) contact paint output Fig. 8-20 Relay Operation When the coil is energized, NO contact (A) is closed and NC contact (B) is opened. On the other hand, when the coil de-energized, NO contact (A) is opened and NC contact (B) is closed. The coil will be energized by either DC voltage or AC voltage. Generally, most small relays are energized 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 number of relays are used.3479-E P.58 SECTION 3 TROUBLE AND TROUBLESHOOTING 9-2. Inspection of Relays and Magnet Contactors Large relays are called magnet contactors. They are mainly used to control motors. a) 2 Operation Check of A Magnet Contactor (MS) @||a|[e||e\|e 13s 8 olouvve 24 6 6M al[a||e||e||e ‘When the magnet contactor is actuated: a If the connection between 1-2 is closed, itis called contact point "A", and indicated in a circuit diagram by the symbol (1). If the connection between 1-2 is opened, itis called contact ® point "B", and in a circuit diagram by the symbol (2). ® When a magnet contactor is actuated (coil is energized), this part is pulled in. When a magnet contactor is actuated, all Connections such as 1-2, 3-4, 6-6, elc., are closed (ON) or opened (OFF). Fig. 3-21, Magnet Contactor Sometimes troubles of a relay are caused. When the coil is energized, a contact point may fail to open and close (due to poor contact or foreign matter clogging), or the Part ® may occa- sionally remain pulled in (fused, etc) even when the coil is not energized. ‘The OSPS020M uses a miniature relay called MY 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 contactor. For contact point Aand B, itis also the same.3479-6 P-58 SECTION 8 TROUBLE AND TROUBLESHOOTING (3) Inspection of Overload Protection Relays and Fuses 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 it. [Retay Pant eo” 6 a" oo” i ow one 6" 6" a" (| / agra contactor 3) i Tost ea, poss he Oo wile pa tor 2s Sheri pes 2 ‘Tis dali latory 2 Do nt aie 3) verted relay Fig. 3-22 Overload Relay3479-E P-60 SECTION 8 TROUBLE AND TROUBLESHOOTING 10. Replacing ECP-II Battery Pack ‘The CPU unit has the ECP-II printed circuit board; the semiconductors on this PCB retain the ma- chine related data. Gonerally, the data saved in semiconductor devices are lost when the power supply is lured off. However, the semiconductors on the EQP-II PCB are backed up by the bat- tery to retain the saved data even ater the power is tured off. When the battery voltage lowers, the following message appears on the screen to give a warning to the operator. Wo3 AlarmD Battery voltage low Battery Replacement Procedure: 4) Tum 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. ECP-II PCB Battery Specification: £5503-490-002 (Okuma part number) Lithium batiory (8.6 V) Toshiba EOP board Battery Connector Fig. 3-23,11-2, S479-E P61 SECTION 3 TROUBLE AND TROUBLESHOOTING Inverter Motor (Tool Change Arm Motor) Outline An inverter motor is used for ATC tool change arm drive, The motor rotation direction, forward or reverse, and the motor speed are controlled by the inverter. The maintenance of the inverter motor is described in this paragraph. Inspection and Maintenance ‘The inverter motor does not require daily inspections. However, to make the most of its outstand- ing performance over a long period of time, check the following inspection items periodically Before starting inspection, turn off the power supply. Then, remove the terminal cover in ten sec fonds after the power has been turned off. (Do not attempt an inspection immediately after the pow- fer has been turned off. Voltage remains in the capacitor inside the inverter motor.) (1) Check the inside of the inverter motor, If dust accumulates, clean it (2) Check the screws used in the terminals and parts for looseness. If they are loose, tighten them securely. (3) Check the wiring accessories and parts. If they are faulty, contact your local Okuma tepresen- tative, (4) Checks the following using a multimeter. a) When checking the external circuit using a multimeter, disconnect all terminals from the in- vertor so that the test voltage is not applied to the inverter. b) When checking the inverter using a multimeter, check only the main circuit as illustrated below, Do not check the control circuit. Use a 500 VDC multimeter. ©) Bo not conduct a continuity test for the control circuit. Input power supply --—— — ie Multimeter Y Grounding terminal Fig. 24S8479-E P-62 SECTION 3 TROUBLE AND TROUBLESHOOTING ‘laren lamp (miky whit) ‘Operation made saloction switches ws) Tp Operation status output selection short plug switches (082 No. 1) Forwardiverse rotation solection shart plug ewiches (082 No. 2) it patorn seloction switch (FDS 3) 11-3. Switch Setting 3 3 Fon cover i Dect in tation fie (OS 2) eclraton Sine sleton Sitch (8 1) Power amp (eo) A, Teint cover a we | is q (eisTa} 4 EEE 4 / teeteeerer |= 4A [o[ololelofel Glee RsTuvW oll, Fig. 3-25 Switch Setting in the Inverter (1) Operation Mode Selection Switches (DS 1) A total of six switches are arranged on the base plate. Switches 3 and 4 are sat at the "ON" position and the others are set at the “OFF” position prior to shipment Irom the factory. To change the setting, use a tool which has a thin top, for example, a ball-point pen. a OF ee ae Fig. 3-25 @ Operation Mode Selaction Switch Setting Forwardireverse Rotation Selection Short Plug Switches (DS 2) As illustrated in Fig. 3-27, three short plugs are arranged. ‘The plug is sot to the left for switch- 95 1 and 3, and itis set to the right for switch 2. Short Piug ~ Fig. 3:27 os Es ps2 Forwardireverse Rotation Selection Short Plug Switches (DS 2)8479-6 P-63 SECTION 3 TROUBLE AND TROUBLESHOOTING. (3) Deceleration Time Selection Switch (RDS 2) Acceleration Time Selection Switch (RDS 1) ‘VA Pattern Selection Switch (RDS 3) As illustrated in Fig. 3-28, these switchos are sel at “0” prior to shipment. RDS1, ADS2 RDS3 Fig. 3-28 Deceleration Time Solection Switch Setting Acceleration Time Selection Switch Setting Vi Pattern Selection Switch Setting3479-E P-84 SECTION 3 TROUBLE AND TROUBLESHOOTING 11-4, Troubles and Measures to Take When a trouble has occurred and the inverter does not function, refer to the chart below to locate the cause of the trouble and to take the necessary measures. ‘When the cause of the trouble cannot be found, contact your local Okuma representative. 11-4-1, Possible Cause of the Trouble (1) The motor does not rotate. Yos The circuit breaker for wiring (MCCB) is ON: No The circuit breaker can be turned on. Short circuit in wiring No The voltages across the falloning terminals are normal. A.-S, S~ LR = The supply is abnormal - Wiring is faulty. ‘Yes (+ 10% of the rated voltage) Yes The POWER lamp (inside the cover) is ON. Tho invertor is Faulty Yes The alarm lamp is ON. of the trouble ard measures to take when the alarm lamp (milky ‘while) is activated.” and take the necessary No There are voltages across the following torminals. U- V, VW, W-U “The inverter is faulty. No Gutput voltages across the following terminals are well-balanced. U- V, V-W, WU. The invertor is faulty. {check without connecting the motor)) ~ The motor is overloaded. = The motor is faulty. = Wiring is faulty Yes (within 3% of the maximum output voltage3479-E P-65 SECTION 3 TROUBLE AND TROUBLESHOOTING —————— (2) Overheat of motor Yos The motor is overloaded, Reduce the motor load Avoid low-speed operation (for example, step [o0¢). The motor has been rotating at & low peed for a long time, rs The inverter is faulty. Output voltages across the following termina are well-balanced. U - V, V-W, W= U Yes (within 3% of the maximum output voltage) Yes Locate the cause and The motor cooling mechanism is disturbed. manek Faulty connection between the motor and the inverter. |_| Connect correctly3479-E P-86 SECTION 3 TROUBLE AND TROUBLESHOOTING (8) The motor does not rotate smoothly. The acceleratingidecelorating time is proper. The motor does not rotate smoothly when itis accolorating/daceleraling, Check the setting of 0S1 Re DS2, and ADSI. (when the motor acceleralesidecelerates intermittent Fleduce the motor load. Output voltages acros the following torminals are ‘wolkbalanced. The inverter is faulty. UV, V=W, W-U, Yes (within 9% of the maximum output voltage) Yes Reduce motor load fluctuation. Backlash of the gear is large ‘Carry out mechanical adjustment. “The inverter is faulty3479-6 P-67 SECTION 8 TROUBLE AND TROUBLESHOOTING 11-4-2, Cause of the Trouble and Measures to Take When white) is Activated the Alarm Lamp (milky When the inverter is faulty, the alarm lamp (milky white) is activated as listed bolow. When the alarm lamp is activated, locate the cause of the trouble from the flickering state of the alarm lamp, and take the necessary measures. Cause of the Trouble and Measures to Take ‘Alarm lamp activation state Possible causes Procedure fo check Measures to take Instanta- | Short circuit or | Disconnect all | Remove the neous | grounding in the | terminals in the | short-circuited or overcur- | output circuit of | output circuit of | ground portion, rent pro- | the inverter the inverter, and tection measure the resistance of the motor. The switch setting | Check the switch | Correct the switch n= umbar.offickerings is wrong. setting. setting. Overload Run the Reduce the motor motor without | load. 1 = two times applying load. = Check the inverter while JUL an running the ‘motor with load. A phase Remove the advancing phase advancing capacitor is capacitor. incorporated in ‘the output circuit of the inverter. Regen- | The switch setting | Check the switch | Correct the switch n= throe times erative | is wrong. setting setting. overvolt- SUUL_IITU. J ace oro: tection insulfi- |=" The power | Measure the Remove the cient volt- |__ supply voltage | power supply ‘cause of low : age pro- is low, voltage and re- | power supply ‘1 = four times tection | ctantaneous. | Stal voltage. JANN. power failure (18 msec or or more)a479-E P-68 SECTION 3 TROUBLE AND TROUBLESHOOTING Alarm lamp activation state Possible causes Procedure to check Measures to take 1 = five times IL Grounding ‘The transistor module is broken Disconnect all terminals and conduct a continuity test between the motor and the Remove the ‘ground portion. n= six times ANN ground. Grounding Check the output | Prevent noise The transistor module is__| circuit of the from being broken inverter for noise ‘sources. generated. Or sot a noise fitter at the primary oF secondary of the inverter. L_ Note 1: When the alarm lamp has been activated, stop the operation and locate the cause of the trouble. Then, turn off the circuit breaker for wiring (MCCB) and the electromag netic contactor. Note 2: When the cause of the trouble cannot be looated, disconnect the wiring between the inverter and the motor. Note 3: Contact your focal Okuma representative if the cause of the trouble cannat be located with all your attempts.3479-E P59 SECTION 4 SPINDLE DRIVE UNIT FOR VAC MOTOR (VACII) SECTION 4 SPINDLE DRIVE UNIT FOR VAC MOTOR (VACII) Outline Okuma VAC motors, providing sufficient pertormance as a spindle driver for machine tools, feature high reliability, wide constant output range, compact construction, etc. Okuma VAC drive unit is @ vector control type driver, using 16-bit micra-processors. It provides quick response and stable control. tenance Periodical Inspection and M: VAC motor and VAC drive unit do not require daily inspection. However, to maintain their high per- formance for a long period, itis recommended to inspact and clean the following points at least ev- ery six months. For each of the inspection items, change inspection intervals depending on contamination degree. Table 4-1 Inspection tems Items to Check How to Check Measures to Take VAC motor Check whether dust is accumulating Clean or blow away with i ‘compressed alr or vacu- VAC drive unit: tal olenoe Cooling fan Fan guard (mesh) Ventilation hole3479 P-70 SECTION 4 SPINDLE DRIVE UNIT FOR VAG MOTOR (VACII) 3. Constructions The VAC drive unit construction is illustrated in Fig. 4-1. Mounting holes (upper: slot * 2, lower round Cover Power supply unit end slot x 2) Gontrol PCB (VAG board II, VAG card 1) Fig. 4-1 VAC Drive Unit Construction (D8, D6, 08) ‘The control PCB and the caver are fixed to the power supply unit door with the screws. The power ‘supply unit door can be opened by removing the screws al the upper and low right sides. ‘Arrangement of major component parts on the control PCB and the power supply unit are shown in Figs. 4-2 to 4-7.3478-E P71 SECTION 4 SPINDLE DRIVE UNIT FOR VAC MOTOR (VACIT) 3-1. Arrangement of Major Component Parts ‘Arrangement of component parts which should be checked at an occurrence of problem is shown in Figs. 4-2 through 4-7, Fig. 4.2 Fig. 43 Fig. 4-4 Fig. 45 Fig. 4-6 Fig. 4-7 ‘Major Component Parts Arrangement on Control PCB - VAC Board IL Major Component Parts Arrangement on Gontrol PCB - VAC Card 1 Major Component Parts Arrangement for Power Supply Unit - DGA, DBA Major Component Parts Arrangement for Power Supply Unit - D11A Major Component Parts Arrangement for Power Supply Unit - D224 Major Component Parts Arrangement for Power Supply Unit - Da7A3479 P-72 SECTION 4 SPINDLE DRIVE UNIT FOR VAC MOTOR (VACIT) Warning fuse ‘Okuma part Heaney, eee. 3 Ne Version No E4809.085-140 st o 3] If} Ragenersve By coe ot §| bo * } = "com wv 2 = Transformer ee PCB nam so ‘stm tse mes el Taare 3 a 18v GND A —— cree § 15y 16a s} po) TRH TAT? ease eeu — = sw swe | veo i a oo = [o. conen MPMBT 29486 [IL] or 1 Los. om oy § CoA WET Sa TOTTI 8 “Traneistor 2 jo ees erst | fs tio mo |e, ° Joho eas cho om ot else ewe. 'S 0's 0S 0 10 MBN” he” Eve § n § o q ° vow vit va vk Oia © 8 é ston seh est ane ons oft wv Mor signal cabo conacton ‘Cort! signal eabio conscior amar Chock trina arable rast Fig. 4-2. Major Component Parts Arrangement on Control PCB - VAG Board It3479-E P-73 SECTION 4 SPINDLE DRIVE UNIT FOR VAC MOTOR (VACII) Manufacturing No. RIE Cd Version No. sas - 2 2 as Peay cin wa] Connector for magne optical pulse neral Connector for optional fiber Fig. 4-3 Major Component Parts Arrangement on Control PCB = VAC Card 18479-6 P-74 SECTION 4 SPINDLE DRIVE UNIT FOR VAC MOTOR (VACII) Door 3 3 Heat sink cooting fan (atthe back) Transistor module Tawa sam Tre awe TaMB awa =, Diode modulo Fuses Neuse broaker ELLE LEI Ey (Power input) SPS PAIE|E | Power input) Terminal block for fan motor cables B Powor supply grounding Terminal block for 1 tominal hol motor power cables | “\ ‘Manufacturing No. Typo \_Version No Fig. 4-4 Major Component Parts Arrangement for Power Supply Unit - DBA, O8A3479-E P-75 SECTION 4 SPINDLE DRIVE UNIT FOR VAC MOTOR (VACII) Heat sink cooing fan (atthe back) Transistor emadule Diode module Fuses ‘No-tuse breakor (Power input) “Touinal block for fenmatr enies a “Terminal block for motor power cables Power supply grouncing terminal hole SS 00 vcraectving No. [yp0 Version No, Fig. 4-5 Major Component Parts Arrangement for Power Supply Unit - D11A,3479-E P-78 SECTION 4 SPINDLE DRIVE UNIT FOR VAC MOTOR (VACII) Heat sink cooling fan (at the back) Door ‘Transistor module TRINA TRMi TANS: raw TANG TAM Hla] a Yoyo Diode module Grounding terminal hole| {for motor power cables Terminal block for motor power cables \ No-fuse breaker (Power input) Terminal block for, §—§ ->==——=————— fan motor cables A t = n Power supply grounding Fuses terminal hole Manufacturing No. Version No. Fig. 4-6 Major Component Parts Arrangement for Power Supply Unit - D22A,