[rotec]

Hello All,

While the lathe was running and in the midst of a sequence restart. The machine stopped and the following alarm came 124 ALARM-A stroke end limit cancel 1 (LS30-N OSP 5000 green )
The panel and CRT was still lit but no buttons and switches would work. Frozen.

I restarted the machine several times and get the same alarm and again the panel wont respond to button presses.

Any help would be much appreciated.

[Algirdas]

check the "stroke end limit cancel" setting ( or /and tumbler ) first. The parameter is intended to use to move axis away from stroke end limit only. Try to move axis with manual knob to check if it is the case.
check the "stroke end limit cancel" switch.
Good ocassion to check stroke end limit switches - easy to do and gives important uderstanding what's .happening. Sometimes samurai is weared and chips collecting there and collection of dirt interferes with stroke end limit sensor. Must be mechanical swith with a little wheel at that machine. This is easy to check.
It's also good to check user stroke end limits in parameters and system stroke end limits in parameters also. Easy to check and narrows the circle of suspection.
If all hardware limit switches checked, parameter limits checked, there is still possibility for error to be in the settings. Check if you get this alarm in manual mode if it depends on axis position.
It's possible that the special parameter allowing to override the stroke end limit is active.

[rotec]

Algirdas,
Thank you! see my response. I have owned this machine for 25 years!

check the "stroke end limit cancel" setting ( or /and tumbler ) first.
PAUL: I cant get to the settings, because as soon as the machine starts the alarm appears and the panel is frozen. No buttons work.

The parameter is intended to use to move axis away from stroke end limit only. Try to move axis with manual knob to check if it is the case.
PAUL: The machine wont move, the panel is frozen, no switches, knobs, wheels or buttons work. So I cant get to the parameters.

check the "stroke end limit cancel" switch.
PAUL: I have never seen this switch, where is it located? Machine is 1982 year. OSP 5000 green screen, LS30-N lathe

Good ocassion to check stroke end limit switches
PAUL: Yes I will look at this, but the machine is clean and there are no chips near the switches, also the axis are mid travel and not near their limits. But I will check the limits switches anyway.

It's also good to check user stroke end limits in parameters and system stroke end limits in parameters also
PAUL: The panel is lit BUT no buttons or switches respond after start up. So I can not get to the parameters.

Check if you get this alarm in manual mode if it depends on axis position.
PAUL: I get to manual mode with the panel frozen on start up.

The machine was running ok then I changed a tool offset to run a second finish pass, on the sequence restart the machine the alarm came.

How do I get to manual mode and the parameters? Why is the machines panel locked on start up?

check the "stroke end limit cancel" setting ( or /and tumbler ) first. The parameter is intended to use to move axis away from stroke end limit only. Try to move axis with manual knob to check if it is the case.
check the "stroke end limit cancel" switch.
Good ocassion to check stroke end limit switches - easy to do and gives important uderstanding what's .happening. Sometimes samurai is weared and chips collecting there and collection of dirt interferes with stroke end limit sensor. Must be mechanical swith with a little wheel at that machine. This is easy to check.
It's also good to check user stroke end limits in parameters and system stroke end limits in parameters also. Easy to check and narrows the circle of suspection.
If all hardware limit switches checked, parameter limits checked, there is still possibility for error to be in the settings. Check if you get this alarm in manual mode if it depends on axis position.
It's possible that the special parameter allowing to override the stroke end limit is active.

[deadlykitten]

I cant get to the settings, because as soon as the machine starts the alarm appears and the panel is frozen. No buttons work.

hy right after power up, open and close the doors (as you would usually do i guess), then try to continue futher : perhaps this will enable some buttons, at least the jog wheel ...

which axis is in overtravel : turret / tailstock ?

[Algirdas]

"chuck clamp" and "chuck unclamp" both are on. I would check the limit switches just in case.

[rotec]

"chuck clamp" and "chuck unclamp" both are on

PAUL: No this is just my camera flash making the LED look on. They are in fact not lit.

"chuck clamp" and "chuck unclamp" both are on. I would check the limit switches just in case.

[rotec]

"chuck clamp" and "chuck unclamp" both are on. I would check the limit switches just in case.

I had left this machine sit till now! But now I have all the service books and the wiring diagrams and I may have another try. Just for a test is there a way to identify the stroke end limit wiring and for testing purposes connect or override the limit switches so as to trick the machine into moving? Just for a quick test?

[Algirdas]

Looks lke the problem should be described a different way.
According th message on the OSP, the machine is ready to move away from the limit switch ( or system stroke end limit position ). It is normal, that OSP does not respond to any push buttons at this stage. The axis should move by manual knob, however.
I understand, it is not the case. OSP does not respond at all. Right? If hydraulics is stopped as well?
The "Stroke and limit cancel" tumbler can be at the tape reader panel or inside main control cabinet.
The problem is not related to axis movement at all. Check the memory backup battery. Carefull. Okuma designed the special procedure for the backup battery replacement if you do it wrong. "Doing right" means to replace the battery not interrupting the voltage.
Try to call that alarm some other way. Is it possible to start up the control without this alarm?
Is there bar feeder interface installed?

[rotec]

The axis should move by manual knob, however.
PAUL: Yes but does not. Hydraulics is on, drives on machine is otherwise ok. I can not clear the fault with the reset nor use the manual knob.

OSP does not respond at all. Right? If hydraulics is stopped as well?
PAUL: Machine is on, OSP does not respond, Hydraulics are on pump is on pressure is good.

The "Stroke and limit cancel" tumbler can be at the tape reader panel or inside main control cabinet.
PAUL: I looked for this, in the tape reader cabinet, no switch, also looked in the main cabinet, cant find a switch. Ive owned the machine for decades. cant say Ive ever seen this switch? (See pics)

Check the memory backup battery. Careful.
PAUL: The is new to me, where is the battery and how to replace carefully?

Try to call that alarm some other way. Is it possible to start up the control without this alarm?
PAUL: The machine starts fine, but the alarm is always on start up.

Is there bar feeder interface installed?
PAUL: Yes the is a bar feeder panel on the side, we have no bar feeder though. When I switch the manual / auto switch on the bar feed panel the ALARM flickers.

Looks lke the problem should be described a different way.
According th message on the OSP, the machine is ready to move away from the limit switch ( or system stroke end limit position ). It is normal, that OSP does not respond to any push buttons at this stage. The axis should move by manual knob, however.
I understand, it is not the case. OSP does not respond at all. Right? If hydraulics is stopped as well?
The "Stroke and limit cancel" tumbler can be at the tape reader panel or inside main control cabinet.
The problem is not related to axis movement at all. Check the memory backup battery. Carefull. Okuma designed the special procedure for the backup battery replacement if you do it wrong. "Doing right" means to replace the battery not interrupting the voltage.
Try to call that alarm some other way. Is it possible to start up the control without this alarm?
Is there bar feeder interface installed?

[Algirdas]

since hydraulics is still on, looks like the axis movement is not inhibited.
Is it possible to switch to manual mode? I didn't got the "The machine starts fine". Can you switch to manual, to MID-Auto Manual after OSP boot up ? Can You open Parameter after OSP boot up? I guess no.
Check:
- the rapid axis movement override on 50% and try 25% 75% 100%
- the feed axis movement override on 50% and try 25% 75% 100%
- the travel unit 1mm 10µm and 1µm
try to move axis with a knob and try arrow push buttons.

Tape reader picture is poor, can't see what description is on the top of tumbler with "ON' and "OFF". The view of main control cabinet gives no glue about main control unit ( CPU )
The battery. What is the big black with the banner "Fragile" inside in the main control cabinet?
Please, make detailed picture(s) of OSP face.

[rotec]

Is it possible to switch to manual mode?
PAUL: No, I can not switch to manual mode, the panel does not respond, it looks on and AUTO is LIT. But with the stroke end alarm on the panel does not respond.

I didn't got the "The machine starts fine".
PAUL: I should say the machine switches on ok, hyd pumps pumping ok, panel light up ok. But panel is not responding to any button presses (no beeps) The green reset button I can hear the relay clicking but does not clear the alarm.

Can you switch to manual, to MID-Auto Manual after OSP boot up ? Can You open Parameter after OSP boot up? I guess no.
PAUL: No

the rapid axis movement override on 50% and try 25% 75% 100%
- the feed axis movement override on 50% and try 25% 75% 100%
- the travel unit 1mm 10µm and 1µm
try to move axis with a knob and try arrow push buttons.
PAUL: None of the above is possible

Tape reader picture is poor, can't see what description is on the top of tumbler with "ON' and "OFF"
PAUL: See attached pic close view. There is no switch for limit cancel. There is a LED

What is the big black with the banner "Fragile" inside in the main control cabinet?
PAUL: Just a box of old Okuma parts, brushes etc

Please, make detailed picture(s) of OSP face
PAUL: See attached

PAUL: I see the BDU servo drives, have the orange LED, "reset" LIT

since hydraulics is still on, looks like the axis movement is not inhibited.
Is it possible to switch to manual mode? I didn't got the "The machine starts fine". Can you switch to manual, to MID-Auto Manual after OSP boot up ? Can You open Parameter after OSP boot up? I guess no.
Check:
- the rapid axis movement override on 50% and try 25% 75% 100%
- the feed axis movement override on 50% and try 25% 75% 100%
- the travel unit 1mm 10µm and 1µm
try to move axis with a knob and try arrow push buttons.

Tape reader picture is poor, can't see what description is on the top of tumbler with "ON' and "OFF". The view of main control cabinet gives no glue about main control unit ( CPU )
The battery. What is the big black with the banner "Fragile" inside in the main control cabinet?
Please, make detailed picture(s) of OSP face.

[defcom]

Hello I have a same problem, did you manage to solve it ?

[Algirdas]

Tell the story. It doesn't happen out of nowhere?
Did you read the thread? If the "OT Release" switch active?

[defcom]

At first I had a problem with OPUS5000 PSU (power supply unit). It was damaged and I replaced it with another one from a working machine of the same type, same type of power supply. After replacing, this alarm 124 appears and nothing can be done. The alarm appears in AUTO, MDI, NULLPUNKT and TOOL SET modes and cannot be cleared. PARAMTERS and EDIT modes are locked and nothing happens when pressed. When you change to MANUAL mode, the alarm disappears, but all axes are locked and you can't make any movement, turn on rotation or rotate the head. Opening and closing of the jaws and the tailstock works.

https://youtu.be/yFspaWu2jEQ

[rotec]

Tell the story. It doesn't happen out of nowhere?
Did you read the thread? If the "OT Release" switch active?

Algirdas, did you see my update. Take a look at the last posts here, solved.

[rotec]

Hello I have a same problem, did you manage to solve it ?

No! Despite the generous help here I have not yet dug too deep into the issue. The machine is still idle. The machine is currently full of sharp steel chips and frankly I haven't mustered the energy to clean it and dive in.

Tell me does your control panel work, because since this alarm though mine is fully lit and has a display but the whole panel is frozen and not one button or switch or nob functions which I believe even this alarm it should.

[Algirdas]

I would requalify the problem.
Since no axis is on overtravel condition ( we don't know for sure without the screen with system coordinates and axis stroke limit parameter values ) the problem is that "axis overtravel cancel" is on. We don't know how and where. For this age machine it should be a tumbler.
or
The OSP goes to that wrong status by mistake, is frozen but powers on the hydraulic system ...
One more question. Check if the contactor supplying power to spindle drive, the contactor supplying power to ZA drive and the contactor supplying power to XA drive turns on after OSP boot.

[kurmay]

Hi

Probably another alarm is lurking behind alarm 124.

[rotec]

Yep! Because the last Okuma tech left the plugs on one of the boards out of place, I later learned they do this to isolate faults. He fixed that fault then but did not put the plugs back as they should be. So the Alarm A end stroke was a misrepresentation of what was in fact a SBP monitor alarm!

A circuit board in the CRT panel was replaced and the machine is up and running again.

Talk about being thrown a curve ball!!!

[rotec]

I wonder about the wiring to the x servo motor years ago the connectors were bad so we hardwired to fix them. Hmmm