The machine is equipped with safety devices which serve to protect personnel and the machine itself from
hazards arising from unforeseen accidents. However, operators must not rely exclusively on these safety
devices: they must also become fully familiar with the safety guidelines presented below to ensure accidentfree operation.
This instruction manual and the warning signs attached to the machine cover only those hazards which
Okuma can predict. Be aware that they do not cover all possible hazards.
1.Precautions Relating to Installation
(1) Please be noted about a primary power supply as follows.
Do not draw the primary power supply from a distribution panel that also supplies a major
noise source (for example, an electric welder or electric discharge machine) since this
could cause malfunction of the CNC unit.
If possible, connect the machine to a ground not used by any other equipment. If there is
no choice but to use a common ground, the other equipment must not generate a large
amount of noise (such as an electric welder or electric discharge machine).
(2) Installation Environment
Observe the following points when installing the control enclosure.
Make sure that the CNC unit will not be subject to direct sunlight.
Make sure that the control enclosure will not be splashed with chips, water, or oil.
Make sure that the control enclosure and operation panel are not subject to excessive
vibrations or shock.
The permissible ambient temperature range for the control enclosure is 5 to 40°C (41 to
104°F).
The permissible ambient humidity range for the control enclosure is relative humidity 50%
or less at 40°C (104°F) (no condensation).
The maximum altitude at which the control enclosure can be used is 1000 m (3281ft.).
2.Points to Check before Turning on the Power
(1) Close all the doors of the control enclosure and operation panel to prevent the entry of water,
chips, and dust.
(2) Make absolutely sure that there is nobody near the moving parts of the machine, and that there
are no obstacles around the machine, before starting machine operation.
(3) When turning on the power, turn on the main power disconnect switch first, then the CONTROL
ON switch on the operation panel.
5921-E P-(ii)
SAFETY PRECAUTIONS
3.Precautions Relating to Manual/Continuous Operation
(1) Follow the instruction manual during operation.
(2) Do not operate the machine with the front cover, chuck cover, or another protective cover
removed.
(3) Close the front cover before starting the machine.
(4) When machining the initial workpiece, check for machine operations, run the machine under no
load to check for interference among components, cut the workpiece in the single block mode,
and then start continuous operation.
(5) Ensure your safety before rotating the spindle or moving a machine part.
(6) Do not touch chips or workpiece while the spindle is rotating.
(7) Do not stop a rotating part with hand or another means.
(8) Check that the condition of hydraulic chuck jaws as mounted, operating pressure, and
maximum permissible revolving speed.
(9) Check the condition and location of the cutting tool as mounted.
(10) Check the tool offset value.
(11) Check the zero offset value.
(12) Check that the SPINDLE OVERRIDE and FEEDRATE OVERRIDE dials on the NC operation
panel are set to 100%.
(13) When moving the turret, check the software limits for X- and Z-axes or the locations of limit
switch dogs to prevent interference with the chuck and tailstock.
(14) Check the location of the turret.
(15) Check the location of the tailstock.
(16) Cut workpieces with a transmitted power and torque within the permissible range.
(17) Chuck each workpiece firmly.
(18) Check that the coolant nozzle is properly located.
4.On Finishing Work
(1) On finishing work, clean the vicinity of the machine.
(2) Return the ATC, APC and other equipment to the predetermined retraction position.
(3) Always turn off the power to the machine before leaving it.
(4) To turn off the power, turn off the CONTROL ON switch on the operation panel first, then the
main power disconnect switch.
5921-E P-(iii)
SAFETY PRECAUTIONS
5.Precautions during Maintenance Inspection and When
Trouble Occurs
In order to prevent unforeseen accidents, damage to the machine, etc., it is essential to observe the
following points when performing maitenance inspections or during checking when trouble has
occurred.
(1) When trouble occurs, press the emergency stop button on the operation panel to stop the
machine.
(2) Consult the person responsible for maintenance to determine what corrective measures need
to be taken.
(3) If two or more persons must work together, establish signals so that they can communicate to
confirm safety before proceeding to each new step.
(4) Use only the specified replacement parts and fuses.
(5) Always turn the power off before starting inspection or changing parts.
(6) When parts are removed during inspection or repair work, always replace them as they were
and secure them properly with their screws, etc.
(7) When carrying out inspections in which measuring instruments are used - for example voltage
checks - make sure the instrument is properly calibrated.
(8) Do not keep combustible materials or metals inside the control enclosure or terminal box.
(9) Check that cables and wires are free of damage: damaged cables and wires will cause current
leakage and electric shocks.
(10) Maintenance inside the Control Enclosure
a.Switch the main power disconnect switch OFF before opening the control enclosure door.
b.Even when the main power disconnect switch is OFF, there may some residual charge in
the MCS drive unit (servo/spindle), and for this reason only service personnel are permitted
to perform any work on this unit. Even then, they must observe the following precautions.
MCS drive unit (servo/spindle)
The residual voltage discharges two minutes after the main switch is turned OFF.
c.The control enclosure contains the NC unit, and the NC unit has a printed circuit board
whose memory stores the machining programs, parameters, etc. In order to ensure that the
contents of this memory will be retained even when the power is switched off, the memory
is supplied with power by a battery. Depending on how the printed circuit boards are
handled, the contents of the memory may be destroyed and for this reason only service
personnel should handle these boards.
(11) Periodic Inspection of the Control Enclosure
a.Cleaning the cooling unit
The cooling unit in the door of the control enclosure serves to prevent excessive
temperature rise inside the control enclosure and increase the reliability of the NC unit.
Inspect the following points every three months.
Is the fan motor inside the cooling unit working?
The motor is normal if there is a strong draft from the unit.
Is the external air inlet blocked?
If it is blocked, clean it with compressed air.
6.General Precautions
(1) Keep the vicinity of the machine clean and tidy.
(2) Wear appropriate clothing while working, and follow the instructions of someone with sufficient
training.
(3) Make sure that your clothes and hair cannot become entangled in the machine. Machine
operators must wear safety equipment such as safety shoes and goggles.
5921-E P-(iv)
SAFETY PRECAUTIONS
(4) Machine operators must read the instruction manual carefully and make sure of the correct
procedure before operating the machine.
(5) Memorize the position of the emergency stop button so that you can press it immediately at any
time and from any position.
(6) Do not access the inside of the control panel, transformer, motor, etc., since they contain high-
voltage terminals and other components which are extremely dangerous.
(7) If two or more persons must work together, establish signals so that they can communicate to
confirm safety before proceeding to each new step.
7.Symbols Used in This Manual
The following warning indications are used in this manual to draw attention to information of
particular importance. Read the instructions marked with these symbols carefully and follow them.
5921-E P-(v)
SAFETY PRECAUTIONS
5921-E P-(i)
INTRODUCTION
INTRODUCTION
Before using this NC unit, read this manual thoroughly in order to ensure correct use.
This manual explains how to use and maintain the control so that it will deliver its full performance and
maintain accuracy over the long term.
You must pay particular attention to the cautions given in this manual; read them carefully and make sure you
fully understand them before operating the NC.
5921-E P-(i)
TABLE OF CONTENTS
TABLE OF CONTENTS
SECTION 1CLASSIFICATION OF ALARMS ...........................................................1
Alarms related with the OSP are classified into five types such as Alarm P, A, B, C and D.
1-1.Alarm Classifications
5921-E P-1
Alarm
PStops NC operation.All NC functions are inoperative.
A
BThe commands in the active block are
CThe part program being run is executed to
DThis alarm does not have any influence on
Machine Conditions When ALARM Lamp
Comes ON
axis feed
Stops;
Shuts off power supply to X- and Z-axis
servo drives.
Alarm display is displayed on the operation
panel.
Stops;
Shuts off power supply to X- and Z-axis
servo drives.
Alarm display is given on the operation
panel.
completed.
Spindle rotation and coolant supply do not
stop.
Power supply to X- and Z-axis servo drives
is not shut off.
Alarm display is given on the operation
panel.
the end (up to M02 command).
Spindle rotation and coolant supply do not
stop.
Power supply to X- and Z-axis servo drives
is not shut off.
Alarm display is given on the operation
panel.
the machine operation.
Alarm display is given on the operation
panel.
spindle rotation
coolant supply
axis feedOperations for display are possible.
spindle rotation
coolant supply
Operative NC Functions Thereafter
Concerning the control, cancel the alarm
by turning power on again after turning it
off once.
The machine remains inoperative until
the control is reset and the alarm
canceled.
Operations for display are possible.
The machine remains inoperative until
the control is reset and the alarm
canceled.
Operations for display are possible.
No new program can be run until the
control is reset and the alarm is
canceled.
Operations on the operation panel are all
operative. Alarm cannot be canceled
unless the cause of the alarm is
removed.
SECTION 1 CLASSIFICATION OF ALARMS
LE37006R0100300020001
Display Format of Alarm P, A, B, C and D
ALARM-A
Alarm number
Object number
Alarm level
Alarm message
Object message
Alarm code
Alarm character-string
1-2.Object Number and Object Message
The object number and the object message show the programming system and the control axis
where the alarm has occurred by the number and message as shown in the table blow:
5921-E P-2
Object No.MeaningObject messageNotes
NoneNo classificationNone
01System 1“A side” or “1-A sd”1st spindle and turret A
02System 2“B side” or “1-B sd”1st spindle and turret B
03System 3“2-A sd”2d spindle and turret A
04System 4“2-B sd”2d spindle and turret B
111st X-axis“XAaxis” or “X-axis”
121st Y-axis“YAaxis” or “Y-axis”
131st Z-axis“ZAaxis” or “Z-axis”
161st W-axis“W-axis”
191st C-axis“C-axis” or “Caxis1”
201st S-axis“SPDL” or “SPDL-1”
211st T-axis“TAaxis” or “T-axis”
221st M-axis“MAaxis” or “M-axis”
312d X-axis“XBaxis”
322d Y-axis“YBaxis”
332d Z-axis“ZBaxis”
392d C-axis“Caxis2”
402d S-axis“SPDL-2”Sub spindle, pick-off spindle
412d T-axis“TBaxis”
422d M-axis“MBaxis”
533d Z-axis“ZCaxis”LT series
As indicated above, the object numbers and messages to be used are determined by the machine
specifications.
1-2-1. Alarm Codes
In this manual, alarm codes are explained using such as "X", "XX", and "XXYY".
Explanation is given in the following methods:
(1) The alarm code indicated in this text can be used directly as the key to find the contents of error.
(2) The alarm code indicated in this text should first be converted into bit expression (pattern),
which is then used as the key to find the contents of error.
In the case of 2), the procedure to convert the alarm code into bit pattern is shown below.
The method to find the details of the alarm indicated by the bit pattern is explained below using an
example.
Example:
[Code] XX
XX
bit1->EC I/O power shut off error
bit2->ECC error
bit3->Not used
bit4->Not used
bit5->EDRQ INT signal
bit6->ECP INT signal
bit7->ECP RUN signal
bit0->Battery error
If an alarm occurs, a hexadecimal number is displayed.
If "$C1" is displayed, for example, first convert this "$C1" into bits.
5921-E P-4
SECTION 1 CLASSIFICATION OF ALARMS
After the conversion, it is known that Bit0, Bit6, and Bit7 are ON.
See the information above and you will find that these error codes
correspond to "battery error", "ECP INT signal", and "ECP RUN signal",
respectively.
0995 Machine axis data file ................................................................................... 71
0996 PLC axis data file .......................................................................................... 71
0997 PLC monitor backup data file read ............................................................... 72
0998 PLC sequence program load ........................................................................ 72
0999 Synchronous tap data file read ..................................................................... 73
0700 NC start-up error
An error occurred when NC started up.
[Object]
None
[Character-string]
None
[Code]
0x10000000: NC Configuration read error
0x10003000: Spec code read error
0x20000000: ServoLink board initializing error
0x3XXX00YY: NC data file read error
XXX:
0x002: HD backup status file
0x004: Parameter data file
0x008: Machine data file
0x010: PLC backup data file
0x020: PLC-HMI data file
0x040: Alarm History data file
0x080: PLC AXIS data pbu file
0x100: POT TOOL data pbu file (M/C only)
0x200: MOP TOOL Tool data file (M/C only)
0x400: MOP TOOL Parameter file (M/C only)
0x800: Thermal deviation compensation data file
YY:
0x01: File read open error
0x02: File read error
0x03: Version check error
0x04: Check sum error
0x05: Double check sum error
0x06: Backupped Memory error
0x07: File write open error
0x08: File write error
0x40000000: Axis information initializing error
-More than 8 axis
0x50000000: PLC data file read error
-Read failed M code data file
0x60000000: I/O Initializing error
-PLC variable backup file read error
-I/O forced data file read error
0x70000000: ServoLink Initializing error
0x80000000: Operation buffer get error
0x90000000: PBU data file read error
0xA0000000: Shared memory size definition error
0xA1XXXXXX: AlarmService start error
XXXXXX: Error code of AlarmService library function
0xA2400002: Alarm History read error
0xA3000000: Thread monitor initializing error
0xA9000000: Initialization processing of the safety logic was not completed within 20 seconds
0xA9000001: Axis construction definition file open error
0xA9000002: Axis construction definition file read error
0xA9000003: Axis construction definition file mismatch
0xFFFFFFFF: Debug information file read error
5921-E P-10
SECTION 2 ALARM P
0701 P100-Menu initialization failure
An error occurred in P100-Menu while system startup.
[Object]
None
[Character-string]
None
[Code]
1: NC Control file was not found.
2: PLC Control file was not found.
3: NC-HMI was not found
4: 3D real sim file was not found.
5: MacMan file was not found.
6: Version mismatch between P100-Menu and PLC Control
7: Version mismatch between P100-Menu and MacMan
8: Version mismatch between P100-Menu and NC Control
11: Conf-P100-menu read error
12: An error occurred at RTOS
13: An error occurred at UPS Service
21: NC Control start failure
22: Error in obtaining shared objects
23: PLC Control start failure
24: NC-HMI start failure
25: 3D real sim start failure
26: MacMan start failure
101: Startup sequence 0x10 receive failure
200: Startup sequence 0x10 send failure
201: Startup sequence 0x20 receive failure
300: Startup sequence 0x20 send failure
301: Startup sequence 0x30 receive failure
400: Startup sequence 0x30 send failure
401: Startup sequence 0x60 receive failure
500: Startup sequence 0x60 send failure
501: Startup sequence 0x70 receive failure
600: Startup sequence 0x70 send failure
601: Startup sequence 0x7C receive failure
700: Startup sequence 0x7C send failure
701: AlarmService start failure
702: Activation sequence 0x80 receive failure
[Probable Faulty Locations]
1.Execution file name failure
2.Data file name failure
3.RTOS failure
4.UPS function failure
5.Software failure
6.Software Version failure
5921-E P-11
SECTION 2 ALARM P
0702 Power failure upon start-up
[Object]
None
[Character-string]
None
[Code]
None
[Probable Faulty Locations]
1.Power failure during while system startup
2.Power shutoff during while system startup
0703 Load information file not found
A load information file was not found.
[Object]
None
[Character-string]
None
[Code]
None
0704 File load error
An object file was not loaded correctly.
[Object]
None
[Character-string]
None
[Code]
1:A file was not found
2:The attribute of file was not correct.
3:The load address information of file was not correct
4:An error occurred when file was loaded
FFFFFFFF:The details of alarm was displayed by message from OS
XXXXYYYY
XXXX:PLC Control status
YYYY:PLC Control error code
[Probable Faulty Locations]
1.PLC software failure
0718 Real time thread time over
Real time-type thread did not finish within the stated time
[Object]
None
[Character-string]
RT thread name that was exceeded the stated time
[Code]
None
[Probable Faulty Locations]
1.NC software failure
0719 HXCP thread error
An abnormal condition of HXCP thread was detected.
[Object]
None
[Character-string]
None
[Code]
None
[Probable Faulty Locations]
1.NC software failure
0720 AlarmService internal error
An error occurred inside of AlarmService.
[Object]
None
[Character-string]
"ALMS"
[Code]
AlarmService internal error code
[Probable Faulty Locations]
1.NC software failure
2.P100-Menu failure
5921-E P-16
SECTION 2 ALARM P
0721 DeviceNet error
Error occurred on DeviceNet.
[Index]
None
[Character-string]
CH* SC$
* : Channel number where the error occurred.
S : Sequence counter
[Code]
XXYYZZZZ
XX Slave station MacID where the error occurred
YY Slave station
0x00 Normal or nonexistent slave station
0x46 Duplicate MacID error
0x48 Communication stop
0x49 Discrimination information was not compatible with scan list
0x4D Data size was not compatible with scan list
0x4E No response in the connection check.
0x4F Other slave stations are nonexistence on network
0x50 Idle condition
0x53 Error received in the connection check
0x54 Timeout occurred in the connection check
0x56 Turn into the idle mode
0x5B Bus off
0x5C Network power supply off
( XXXX became 0xFFFF,if its not caused by slave station, such as communication delay.)
ZZZZ Scanner error status
bit 0 Memory check error
bit 1 Scan list initialize error
bit 2 Scan list mismatch error(MacID)
bit 3 Scan list mismatch error(Input data)
bit 4 Scan list mismatch error(Output data)
bit 5 Duplicate MacID error
bit 6 Network power supply status error
bit 7 Memory parity error
bit 8 Input data reception error(single)
bit 9 Input data reception error(dowble)
bit10 Output data transmission error(single)
bit11 Output data transmission error(dowble)
bit12 Slave station communication delay error(single)
bit13 Slave station communication delay error(dowble)
bit14 Bus off
bit15 Diagnostic information access error
[Probable Faulty Locations]
1)Hardware failure
2)Software failure
0723 DeviceNet I/O data link file read
The NC failed to read DeviceNet IO data link file.
[Code]
I/O data file load status (in hexadecimal)
2 ->File open error (no file)
3 ->File read error (no data)
4 ->File attribute error (not "PBU1")
5 ->File close error
6 ->File size error (too small)
7 ->File size error (too large)
100->Wrong PLC machine type
200->Wrong PLC class
300->Wrong file version
1002 ->DN SCAN LIST CHANGE FILE OPEN ERROR
1003 ->DN SCAN LIST CHANGE FILE READ ERROR (NO DATA)
1004 ->DN SCAN LIST CHANGE FILE ATTRIBUTE ERROR (NO 'PBU1')
1005 ->DN SCAN LIST CHANGE FILE CLOSE ERROR
1006 ->DN SCAN LIST CHANGE FILE SIZE ERROR (SIZE SMALL)
5921-E P-17
SECTION 2 ALARM P
0725 M code data file
Establishment data of reading M-code file is bad.
[Code]
1->The denial data is bad.
[Character string]
The number is M-code which is established bad data.
[Measures to Take]
Please correct the bad data of M-code.
0726 Safety speed data error
The safety speed data was in abnormal state in the machine without the CE marking safety speed monitor.
[Index]
Axis name or none (spindle)
[Character-string]
None
[Code]
X
X=1:The guard number of the safety speed data was outside the range from -0 to 9.
[Measures to Take]
Change the safety speed monitor data file for axis control.
Relevant specifications:Without CE mark safety speed monitor type
[Related Specifications]
Without CE mark safety speed monitor type
0727 MCS firmware doesn't support POS2 unit
This alarm occurs when the firmware ROM version of the NC axis/ machine(PLC) axis MIV unit is not 511 or later when the new
POS unit is installed.
[Character-string]
None
[Code]
None
0728 FL-net error
An error occurred during startup of the FL-net card.
[Object]
None
[Character-string]
None
[Code]
Y000XXX
Y:0
XXXX:
7F00:System error
7F01:Flash memory error
7F02:DRAM test error
7F03:NICE test error
7F04:EEPROM sum check error
7F05:CPU BUS error
7F06:illegal Instruction
Y:1
XXXX:
0004:Timeout error for 4 sec or longer
Y:F
XXXX:
FFFF: FL-net card is not mounted