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OPERATORS MANUAL

B-63494EN/01

No part of this manual may be reproduced in any form. All specifications and designs are subject to change without notice.

In this manual we have tried as much as possible to describe all the various matters. However, we cannot describe all the matters which must not be done, or which cannot be done, because there are so many possibilities. Therefore, matters which are not especially described as possible in this manual should be regarded as impossible.

B-63494EN/01

SAFETY PRECAUTIONS

SAFETY PRECAUTIONS
This manual includes safety precautions for protecting the user and preventing damage to the machine. Precautions are classified into Warning and Caution according to their bearing on safety. Also, supplementary information is described as a Note. Read the Warning, Caution, and Note thoroughly before attempting to use the machine.

WARNING Applied when there is a danger of the user being injured or when there is a damage of both the user being injured and the equipment being damaged if the approved procedure is not observed. CAUTION Applied when there is a danger of the equipment being damaged, if the approved procedure is not observed. NOTE The Note is used to indicate supplementary information other than Warning and Caution.
- Read this manual carefully, and store it in a safe place.

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TABLE OF CONTENTS

TABLE OF CONTENTS
SAFETY PRECAUTIONS PRECAUTIONS................................ ................................................................ ................................................................................................ ....................................................................................... ....................................................... s-1 s-1 1 OVERVIEW OVERVIEW................................ EW................................................................ ................................................................................................ ................................................................................................ ......................................................................... ......................................... 1

1.1

DIRECTIVE AND STANDARDS ..................................................................................................... 3

1.1.1 1.1.2 1.1.3 1.1.4 1.2 1.2.1 1.2.2 1.3 1.3.1 1.3.2
1.3.2.1 1.3.2.2 1.3.2.3 1.3.2.4 1.3.2.5

Directives.................................................................................................................................... 3 Related Safety Standards.......................................................................................................... 3 Risk Analysis and Evaluation................................................................................................... 3 Certification Test ....................................................................................................................... 4 General Definition of Terms ..................................................................................................... 5 Definition of Terms Related to the Safety Function................................................................ 5 Features of Dual Check Safety ................................................................................................. 6 Compliance with the Safety Standard (EN954-1, Category 3) ............................................... 7
Latent error detection and cross-check ...........................................................................................8 Safety monitoring cycle and cross-check cycle ................................................................................9 MCC off Test .....................................................................................................................................9 Error analysis .................................................................................................................................10 Remaining risks..............................................................................................................................10

DEFINITION OF TERMS ................................................................................................................ 5

BASIC PRINCIPLE OF DUAL CHECK SAFETY .......................................................................... 6

1.4
2 3

GENERAL INFORMATION........................................................................................................... 12

SYSTEM CONFIGURATION CONFIGURATION ................................................................ ................................................................................................ ........................................................................... ........................................... 14 SAFETY FUNCTIONS ................................................................ ................................................................................................ ..................................................................................... ..................................................... 16

3.1 3.2

APPLICATION RANGE ................................................................................................................. 17 BEFORE USING THE SAFETY FUNCTION............................................................................... 20

3.2.1 3.2.2 3.3 3.3.1 3.3.2 3.3.3 3.4 3.5 3.6 3.7

Important Items to Check Before Using the Safety Function .............................................. 20 MCC off Test of the Safe Stop Function ................................................................................. 20 Stopping the Spindle Motor .................................................................................................... 21 Stopping the Servo Motor........................................................................................................ 22 Stop States ............................................................................................................................... 22

STOP ................................................................................................................................................ 21

SAFE-RELATED I/O SIGNAL MONITORING ............................................................................ 24 EMERGENCY STOP ...................................................................................................................... 29 SAFE SPEED MONITORING........................................................................................................ 30 SAFE MACHINE POSITION MONITORING .............................................................................. 31

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TABLE OF CONTENTS
3.8
4

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MCC OFF TEST .............................................................................................................................. 32

INSTALLATION INSTALLATION ................................................................ ................................................................................................ ............................................................................................... ............................................................... 33

4.1

OVERALL CONNECTION DIAGRAM ......................................................................................... 35

4.1.1 4.1.2 4.2 4.3

For One-path............................................................................................................................ 35 For Two-path............................................................................................................................ 37

DI/DO CONNECTION (VIA THE PMC) ....................................................................................... 40 DI/DO CONNECTION (VIA THE FSSB) ...................................................................................... 41

4.3.1 4.3.2 4.3.3


5

FSSB I/O Connection............................................................................................................... 41 FSSB I/O Attachment.............................................................................................................. 43 FSSB I/O Specification List..................................................................................................... 47

I/O SIGNALS ................................................................ ................................................................................................ ................................................................................................ .................................................................... .................................... 48

5.1 5.2 5.3 5.4 5.5

OVERVIEW ..................................................................................................................................... 49 SIGNALS ......................................................................................................................................... 50 SIGNAL ADDRESSES.................................................................................................................... 55 SAFETY SIGNAL MODES............................................................................................................. 56 NOTES ON MULTI-PATH CONTROL ......................................................................................... 57

5.5.1 5.5.2 5.5.3 5.5.4 5.5.5


6

Two-CPU Two-Path Control (Without Axis Change between Paths)................................... 57 Two-CPU Two-Path Control (With Axis Change between Paths) ........................................ 58 One-CPU Two-Path Control.................................................................................................... 59 Two-CPU Three-Path Control................................................................................................. 60 Loader Control ......................................................................................................................... 61

PARAMETERS ................................................................ ................................................................................................ ................................................................................................ ................................................................. ................................. 62

6.1 6.2 6.3 6.4

OVERVIEW ..................................................................................................................................... 63 PARAMETERS ................................................................................................................................ 64 PARAMETERS RELATED TO THE USE OF FSSB I/O UNIT ................................................... 72 FUNCTIONS THAT REQUIRE SPECIAL PARAMETER SETTINGS....................................... 74

6.4.1 6.4.2 6.4.3


7

Tandem Control ....................................................................................................................... 74 Simple Electronic Gear Box and Electronic Gear Box 2-pair ............................................... 74 Multi-path Control................................................................................................................... 74

START-UP ................................................................ ................................................................................................ ................................................................................................ ........................................................................ ........................................ 75

7.1

START-UP OPERATION................................................................................................................ 76

7.1.1 7.1.2
7.1.2.1

Acceptance Test and Report for Safety Functions................................................................. 76 Start-up of the Dual Check Safety Function.......................................................................... 78
Initial start-up ................................................................................................................................78

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Series start-up ................................................................................................................................80

7.1.2.2

7.1.3
8

Troubleshooting ....................................................................................................................... 80

MAINTENANCE ................................................................ ................................................................................................ .............................................................................................. .............................................................. 81

8.1 8.2

SAFETY PRECAUTIONS............................................................................................................... 82 ALARMS AND MESSAGES ........................................................................................................... 86

8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6


9

Overview................................................................................................................................... 86 Servo Alarms............................................................................................................................ 87 Serial Spindle Alarms.............................................................................................................. 91 Alarms Displayed on the Spindle Unit................................................................................... 92 System Alarms ......................................................................................................................... 93 Boot System Alarms ................................................................................................................ 93

DIAGNOSIS ................................................................ ................................................................................................ ................................................................................................ ...................................................................... ...................................... 94

9.1 9.2
10

OVERVIEW ..................................................................................................................................... 95 DIAGNOSIS..................................................................................................................................... 96 SAMPLE SYSTEM CONFI CONFIGURATION GURATION ................................................................ ....................................................................................... ....................................................... 97 SAMPLE CONFIGURATION......................................................................................................... 98

10.1

10.1.1 10.1.2 10.1.3 10.2

For One-path............................................................................................................................ 98 For Two-path (When the main side and sub side use a common MCC)............................... 99 For Two-path (When the main side and sub side use independent MCCs and protection doors) .................................................................................................................... 100

SAMPLE CONNECTIONS ........................................................................................................... 101

10.2.1 10.2.2 10.2.3 10.2.4 10.2.5


11

Emergency Stop Signal (*ESP1, *ESP2).............................................................................. 101 Guard Open Request Signal (ORQ)...................................................................................... 102 Test Mode Signal (OPT) ........................................................................................................ 102 Guard Unlock Signal (*LGD), Guard Lock State Signal (GDL), Guard State Signal (SGD)..................................................................................................... 103 MCC On Enable Signal (MCF), MCC Contact State Signal (*SMC).................................. 105

COMPONENTS LIST ................................................................ ................................................................................................ ................................................................................. ................................................. 106 HARDWARE COMPONENTS ..................................................................................................... 107

11.1

11.1.1 11.1.2 11.1.3 11.2 11.3

Hardware Components for Series 16i/18i/21i/160i/180i/210i/160is/180is/210is-MODEL A107 Hardware Components for Series 16i/18i/21i/160i/180i/210i/160is/180is/210is-MODEL B107 Hardware Components for Other Units............................................................................... 108

SOFTWARE COMPONENTS....................................................................................................... 109 SERVO AMPLIFIER..................................................................................................................... 111

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1.OVERVIEW

OVERVIEW
Setup for machining, which includes attaching and detaching a workpiece to be machined, and moving it to the machining start point while viewing it, is performed with the protection door opened. The dual check safety function provides a means for ensuring a high level of safety with the protection door opened. The simplest method of ensuring safety when the protection door is open is to shut off power to the motor drive circuit by configuring a safety circuit with a safety relay module. In this case, however, no movements can be made on a move axis (rotation axis). Moreover, since the power is shut off, some time is required before machining can be restarted. This drawback can be corrected by adding a motor speed detector to ensure safety. However, the addition of an external detector may pose a response problem, and the use of many safety relay modules results in a large and complicated power magnetics cabinet circuit. With the dual check safety function, two independent CPUs built into the CNC monitor the speed and position of motors in dual mode. An error in speed and position is detected at high speed, and power to the motor is shut off via two independent paths. Processing and data related to safety is cross-checked by two CPUs. To prevent failures from being built up, a safety-related hardware and software test must be conducted at certain intervals time. The dual check safety function need not have an external detector added. Instead, only a detector built into a servo motor or spindle motor is used. This configuration can be implemented only when those motors, detectors built into motors, and amplifiers that are specified by FANUC are used. When an abnormality related to safety occurs, the dual check safety function stops operation safely. The dual check safety function ensures safety with the power turned on, so that an operator can open the protection door to work without turning off the power. A major feature of the dual check safety function is a very short time required from the detection of an abnormality until the power is shut off. A cost advantage of the dual check safety function is that external detectors and safety relays can be eliminated or simplified.

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1.OVERVIEW

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The dual check safety function consists of the following three functions: - Safe-related I/O signal monitoring function - Safe speed monitoring function - Safe machine position monitoring function The safety function operates regardless of the NC mode. Usually, this function should be used in the setup mode. If a position or speed mismatch is detected by a cross-check using two CPUs, power is shut off (MCC off) to the motor drive circuit. The European standard certification organization has certified that this safety function satisfies the European Safety Standard EN954-1 Category 3.

IMPORTANT The dual check safety function cannot monitor the stop state. For details, see the example of system configuration.

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1.OVERVIEW

1.1
1.1.1

DIRECTIVE AND STANDARDS


Directives
Machine tools and their components must satisfy the EC directives listed below. The FANUC CNC systems with the dual check safety function are compatible with all of these directives.
Directive Directive 98/37/EC Directive 89/336/EEC Directive 73/23/EEC

1998 Safety of machinery 1989 Electromagnetic compatibility 1973 Low Voltage Equipment

1.1.2

Related Safety Standards


To be compatible with the directives, especially the machine directive, the international standards and European standards need to be observed.
Important safety standards EN292-1 1991

EN292-2 1991

EN954-1 1996

EN1050 EN60204-1

1996 1997

DIN V VDE0801 (1990) including amendment A1(1994)

Safety of machinery - Basic concepts, general principles for design Part 1: Basic terminology, methodology Safety of machinery - Basic concepts, general principles for design Part 2: Technical principles and specifications Safety of machinery - Safety-related parts of control systems Part 1: General principles for design Safety of machinery - Principles for risk assessment Safety of machinery - Electrical equipment of machines Part 1: General requirements Principles for computers in safetyrelated systems

1.1.3

Risk Analysis and Evaluation


According to the machine directive, the manufacturer of a machine or machine components and a responsible person who supplies a machine or machine components to the market must conduct risk evaluation to identify all risks that can arise in connection with the machine or machine components. Based on such risk analysis and evaluation, a machine and machine components must be designed and manufactured. Risk evaluation must reveal all remaining risks and must be documented.

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1.OVERVIEW

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1.1.4

Certification Test
The German certification organization TUV PS has certified that the dual check safety function satisfies EN954-1 Category 3.

Certification of the dual check safety function

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1.OVERVIEW

1.2
1.2.1

DEFINITION OF TERMS
General Definition of Terms
Reliability and safety are defined by EN292-1 as follows:
Term Reliability Definition Capability of a machine, machine component, or equipment to perform its required function under a specified condition for a specified period Capability of a machine to perform its function without injuring the health under a condition of use for an intended purpose specified in the operator's manual and allow its transportation, installation, adjustment, maintenance, disassembly, and disposal

Reliability and safety

Safety

1.2.2

Definition of Terms Related to the Safety Function


Safe-related I/O signals are input/output signals monitored by two systems. These signals are valid for each feed axis and spindle with a built-in safety function, and are used with each monitoring system. Example: Protection door state signal

Safe-related I/O signal

Safe stop
When a safe stop occurs, power to the drive section is shut off. The drive section can generate neither a torque nor dangerous operation. The following are measures for incorporating the safe stop feature: Contactor between the line and drive system (line contactor) Contactor between the power section and drive motor (motor contactor) If an external force is applied (such as a force applied onto a vertical axis), an additional measure (such as a mechanical brake) must be securely implemented to protect against such a force.

Safe speed
Feature for preventing the drive section from exceeding a specified speed. A measure must be implemented to prevent a set limitation speed from being changed by an unauthorized person.

Safe machine position


When the drive system has reached a specified positional limit, a transition is made to the safe stop state. When a positional limit is set, a maximum move distance traveled until a stop occurs must be considered. A measure must be implemented to prevent a set positional limit from being changed by an unauthorized person.

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1.OVERVIEW

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1.3
1.3.1

BASIC PRINCIPLE OF DUAL CHECK SAFETY


Features of Dual Check Safety
- Two-channel configuration with two or more independent CPUs - Cross-check function for detecting latent errors

Detection
A servo motor detector signal is sent via the servo amplifier and is applied to the CNC through the FSB interface. Then, it is fed to two CPUs: a CNC CPU and a monitor CPU. A spindle motor detector signal is sent via the spindle amplifier and is applied to the CNC connected through the serial interface. Then, it is fed to two CPUs: a CNC CPU and a CPU built into the spindle amplifier.

Evaluation
The safety function is monitored independently by a CNC CPU and monitor CPU or by a CNC CPU and spindle CPU. Each CPU crosschecks data and results at certain intervals.

Response
If the monitoring function detects an error, the CNC CPU and monitor CPU switch off the MCC via independent paths to shut off the power to the feed axis and spindle.

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1.OVERVIEW

1.3.2

Compliance with the Safety Standard (EN954-1, Category 3)


The dual check safety function satisfies the requirements of Category 3 of the safety standard EN954-1. Category 3 requires the following: The safety function of a safety-related portion must not degrade when a single failure occurs. Single errors must be detected at all times when natural execution is possible. To satisfy these requirements, the dual check safety function is implemented using the two-channel configuration shown below. Monitoring of servo motor and spindle motor movement CNC CNC CPU CPU
Motor detector signal Door switch signal

Shut off power

Cross-check of data and results

Magnetic contactor

Monitor Monitor CPU CPU

Shut off power

CNC controller Data output from the detector built into each motor is transferred to the CNC through the amplifier. The safety of this path is ensured by using motors and amplifiers specified by FANUC.

Cross-monitoring using 2 CPUs


Two CPUs built into the CNC are used to cross-monitor the safety function. Each CPU is periodically checked for errors. If one system fails, the servo system and spindle can be stopped safely.

Power shutoff via two paths


If an error is detected, the power is shut off via two power shutoff paths. The paths need to be tested for built-up failures within a certain time.

Input signal safety


Safety-related input signals such as the protection door lock/unlock signal is monitored doubly. If a mismatch between the two occurrences of a signal is detected, the power to the motor drive circuit is shut off. This cross-check is constantly made.

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1.OVERVIEW

B-63494EN/01

Output signal safety


A signal is output (via two paths) to the relay used to shut off the power to the motor drive circuit. An error is detected by a MCC off Test. For detection of built-up failures, a MCC off Test needs to be conducted at certain intervals. This MCC off Test is not mandatory when machining is performed with the protection door closed.

1.3.2.1

Latent error detection and cross-check


This detection function can detect latent software and hardware errors in a system that has a two-channel configuration. So, the safetyrelated portions of the two channels need to be tested at least once within an allowable period of time for latent errors. An error in one monitoring channel causes a mismatch of results, so that a cross-check detects the error.

Detection of latent errors

CAUTION Forced detection of a latent error on the MCC shutoff path must be performed by the user through a MCC off Test (after power-on and at intervals of a specified time (within 24 hours)). When the system is operating in the automatic mode (when the protection door is closed), this detection processing is not requested as mandatory.

Cross-check
A latent safety-related error associated with two-channel monitoring can be detected as a result of cross-checking. For numeric data, an allowable difference between the two channels is set in a parameter. (For example, an allowable cross-checked difference is set for the actual position.)

NOTE An error detected as the result of forced latent error detection or cross-checking leads to a safety stop state. (See Chapter ?.).

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1.OVERVIEW

1.3.2.2

Safety monitoring cycle and cross-check cycle


The safety function is subject to periodical monitoring in a monitoring cycle. Monitoring cycle: 16 ms The cross-check cycle represents a cycle at which all data subject to cross-checking is compared. Cross-check cycle: 16 ms

1.3.2.3

MCC off Test


The MCC is shut off using two CPUs: a CNC CPU and monitor CPU. To detect a latent error in the MCC shutoff paths forcibly, a MCC off Test is conducted. This test is essential to dual check safety. A MCC off Test must be conducted at specified times (after power-on and at intervals of 24 hours) to check that the MCC shutoff paths operate normally. A MCC off Test is conducted once on the CNC side and once on the monitor side. When a MCC off Test becomes necessary, the CNC outputs a MCC off Test execution request signal to the PMC.

NOTE The machine tool builder is to warn and prompt the operator to conduct a MCC off Test when a MCC off Test execution request signal is output. A MCC off Test is executed by turning on the test mode signal.

MCC off Test execution condition


All axes and the spindle must be stopped beforehand. All vertical axes must be secured firmly beforehand.

Select-test termination
When a MCC off Test is completed, the MCC off Test execution request signal is turned off. After the MCC off Test execution request signal is turned off, turn off the test mode signal.

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1.OVERVIEW

B-63494EN/01

1.3.2.4

Error analysis
The table below indicates the results of system error analysis controlled by the dual check safety function. Error analysis when the protection door is open
Error Spindle safety excessive speed Excessive feed axis speed Cause Amplifier or control unit failure, operation error, etc. Action Safety limitation speed monitoring function EN60204-1 Category 1/0 stop Safety limitation speed monitoring function EN60204-1 Category 1/0 stop Safety limitation speed monitoring function EN60204-1 Category 1/0 stop Safety limitation speed monitoring function EN60204-1 Category 1/0 stop

Error analysis

Amplifier or control unit failure, operation error, etc.

Feed axis safety machine position error Input/output signal error

Amplifier or control unit failure, operation error, etc.

Wiring error, control unit failure, etc.

Error analysis when the protection door is closed


Error Input/output signal error Cause Wiring error, control unit failure, etc. Action Safety limitation speed monitoring function EN60204-1 Category 1/0 stop

1.3.2.5

Remaining risks
The machine tool builder is to make a failure analysis in connection with the control system and determine the remaining risks of the machine. The dual check safety function has the following remaining risks: a) The safety function is not active until the control system and drive system have fully powered up. The safety function cannot be activated if any one of the components of the control or drive is not powered on. b) Interchanged phases of motor connections, reversal in the signal of encoder and reversal mounting of encoder can cause an increase in the spindle speed or acceleration of axis motion. If abnormal speed detected, system controlled to brake to zero speed, but no effective for above error. MCC off is not activated until the delay time set by parameter has expired. Electrical faults can also result in the response described above(component failure too).
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1.OVERVIEW
c) d) Faults in the absolute encoder can cause incorrect operation of the safety machine position monitoring function. With a 1-encoder system, encoder faults are detected in a single channel, but by various HW and SE monitoring functions. The parameter related to encoder must be set carefully. Depending on the error type, a category 0 or category 1 stop function according to EN60204-1 is activated. The simultaneous failure of two power transistors in the inverter may cause the axis to briefly(motion depend on number of pole pairs of motor) Example: A 6-pole synchronous motor can cause the axis to move by a maximum of 30 degrees. With a lead-screw that is directly driven by, e.g.20mm per revolution, this corresponds to a maximum linear motion of approximately 1.6mm. When a limit value is violated, the speed may exceed the set value briefly or the axis/spindle overshoot the setpoint position to a greater or lesser degree during the period between error detection and system reaction depending on the dynamic response of the drive and the parameter settings(see Section Safety-Functions) The category 0 stop function according to EN60204-1 (defined as STOP A in Safety Integrated) means that the spindles/axes are not braked to zero speed, but coast to a stop (this may take a very long time depending on the level of kinetic energy involved). This must be noted, for example, when the protective door locking mechanism is opened. Drive power modules and motors must always be replaced by the same equipment type or else the parameters will no longer match the actual configuration and cause Dual check Safety to respond incorrectly. Dual check Safety is not capable of detecting errors in parameterization and programming made by the machine manufacturer. The required level of safety can only be assured by thorough and careful acceptance. There is a parameter that MCC off test is not to be made in the self test mode at power-on as in the case of machine adjustment. This parameter is protected, only changed by authorized person. IF MCC off test is not conducted, MCC may not be off at stop response is measured. Safety machine position monitoring function does not apply to rotation axis. During machine adjustment, an exact motion may be executed incorrectly untie the safety functions setup correctly and confirm test is completely.

e)

f)

g)

h)

i)

j)

k) l)

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1.OVERVIEW

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1.4

GENERAL INFORMATION
The following requirements must be fulfilled for the Dual-Check System: All conditions of the certification report has to be respected. The procedures for the changes in the System (either HW or SW) should be referred to maintenance manual (B-63005). When safety related components are exchanged, confirmation test regarding safety functions can be performed accoding to Chapter 8. Programming in ladder logic should be referred to programming manual (B-61863E).

Training
FANUC Training Center provides versatile training course for the person who is concerned with hardware installation, maintenance and operation. FANUC recommend studying and learning in the training center how efficiently operate FANUC products. There are 3 CNC training course. [CNC ELEMENTARY COURSE] Provides basics of CNC functions, operation and programming. The course is recommended before taking more specialized training courses to gain best effects. MAIN ITEMS OF TRAINING CNC functions Configuration of CNC Configuration and function of servo system Basic programming of CNC Part programming of milling machine Part programming of turning machine Introduction of Custom Macro function [CNC MAINTENANCE COURSE] To master maintenance technique that permits you to maintain and inspect CNC, also how to restore it promptly if a trouble should occur. MAIN ITEMS OF TRAINING Function and configuration of Power Unit Function and configuration of CNC system Include AC servo and AC spindle Self-diagnosis function Interface between CNC and the machine tools Data saving and restoring operation Trouble shooting
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1.OVERVIEW
[CNC SE INTERFACE COURSE] Training course offered to the engineers who design CNC machine tools or CNC application system for the first time. This course is also suitable for customers who provide to retrofitting, to develop an original CNC machine tools or new application of CNC. MAIN ITEMS OF TRAINING Configuration of CNC system Interface between CNC and machine tools Ladder programming of machine control sequence Setting of parameter related to machine Setting of parameter related to servo and spindle More information and course registration Yamanakako-mura, Yamanashi Prefecture : 401-0501, JAPAN Phone : 81-555-84-6030 Fax : 81-555-84-5540 Internet: www.fanuc.co.jp/eschool

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2.SYSTEM CONFIGURATION

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SYSTEM CONFIGURATION
The dual check safety function has the following components.

Applicable CNC
FANUC Series 16i/18i/20i/21i/160is/180is/210is/160i/180i/210i (LCD-mounted type) FANUC Series 16i/18i/21i/160is/180is/210is/160i/180i/210i (stand-alone type)

Number of controlled axes


- Series 20i/21i/210is/210i : - Series 18i/180is/180i : - Series 16i/160is/160i : 4 maximum 6 maximum 8 maximum

Number of spindle controlled axes


- Series 21i/210is/210i - Series 18i/180is/180i - Series 16i/160is/160i : : : 2 maximum 2 maximum 2 maximum

Amplifier
- series servo amplifier - series spindle amplifier - series power supply module - i series servo amplifier - i series spindle amplifier - i series power supply module

Motor
- series servo motor - series spindle motor - series servo motor - i series servo motor - i series spindle motor

I/O
- I/O unit (I/O Link) - I/O module (FSSB)

Software
- Dual check software

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2.SYSTEM CONFIGURATION

Detector system
The detectors below can be used.

- Feed axis detector


- Servo motor built into 1000, A64, A32 - Separate detector (A/B phase pulse) - A16000i , A1000i, I1000i, A64i - A64B, A32B - 64B, 32B

- Spindle detector
- M sensor - MZ sensor - BZ sensor - Mi sensor - MZi sensor - BZi sensor

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3.SAFETY FUNCTIONS

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SAFETY FUNCTIONS

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3.SAFETY FUNCTIONS

3.1

APPLICATION RANGE
The dual check safety function assumes the following configuration: A) One protective door is provided. B) If the protective door is closed, safety is assured. When the operator makes a request to open the protective door, the safety functions are enabled, and the protective door can be unlocked. While the protective door is open, the active safety functions assure safety. When the request to open the protective door is canceled, the protective door is locked, and the safety functions are disabled. The dual check safety function provides these safety functions while the protective door is open, as described above. Some of the safety functions continue working while the protective door is closed.

WARNING Each machine tool builder should take measures to assure safety while the protective door is closed and to ensure safety related to a rotation axis and travel axis. At the same time, safety measures for the FANUC servo motor or spindle motor need to be taken, while the door is open.
The dual check safety function has the following safety functions:

Safe-related I/O signal monitoring


This function in redundant mode monitors I/O related to safety (emergency stop, protective door lock/open/close state, power-down) in redundant mode. The emergency stop, protective door lock/open/close state, and power-down are checked in redundant mode. If the two corresponding inputs do not match, the system judges that an abnormal event has occurred. The power-down (MCC off) signal is output in redundant mode (from two paths). Whether the two-path output is normal is judged in a MCC off Test.

Safe speed monitoring


This function checks that the rotation speeds of the servo motor and spindle motor are within a predetermined speed range, using two CPUs in redundant mode. If a speed exceeding the range is detected, the system judges that an abnormal event has occurred.

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3.SAFETY FUNCTIONS

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Safe machine position monitoring


This function checks that the position on a servo axis is within a specified range, using two CPUs in redundant mode. If a position exceeding the range is detected, the system judges that an abnormal event has occurred. If an abnormal event (safety error) is found, the dual check safety function shuts off the power to the motor driving circuit, using the two independent CPUs. The state in which the servo or spindle motor stops because of power-down is referred to as the safe stop state. If a safety error results in the safe stop state, the operator must turn off the CNC, remove the cause of the error, then turn on the CNC again. The user must conduct a MCC off Test every 24 hours in order to detect a potential cause of error.

CAUTION This safety function is enabled while the protective door is open after a request to open the protective door is made. If the request to open the protective door is canceled and if the protective door is closed, this safety function is disabled. The dual input check of the safe-related I/O signal monitoring function and the emergency stop function are always active, regardless of whether the protective door is opened or closed.

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3.SAFETY FUNCTIONS
The safe speed of the spindle motor is checked by the CNC CPU and spindle CPU in redundant mode.

CNC
Dual monitoring of emergency stop signal Emergency stop Dual monitoring of protective door state

CNC CPU

Cross-check

Spindle CPU Spindle motor

SPM Protective door

Protective door lock signal

Safe speed monitoring Servo motor SVM

Door lock/ open/close monitoring

Cross-check PSM Monitor CPU Safe speed monitoring Safe machine position monitoring

Dual monitoring of MCC

I/O, safe speed of the servo motor, and machine position are checked by the CNC CPU and monitor CPU in redundant mode.

Powerdown (MCC)
Power-down

Dual monitoring of MCC Dual power-down Detection of potential cause of error by MCC off test

Safety functions
Safe-related I/O signal monitoring Emergency stop input, protective door lock/open/close state, relay state for turning off the MCC Dual signal output Output signal for shutting off the power (turning the MCC off)To detect the potential cause of an abnormal state of this output, a MCC off Test must be made. Spindle motor Safe speed monitoring Servo motor Safe speed monitoring Safe machine position monitoring

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3.SAFETY FUNCTIONS

B-63494EN/01

3.2
3.2.1

BEFORE USING THE SAFETY FUNCTION


Important Items to Check Before Using the Safety Function
When using the safety function for the first time upon assembly of the machine, replacing a part, or changing a safety parameter (such as a safe speed limit or safe range as described in Chapter n), the user must check that all safety parameters are correct and that all safety functions are working normally. A return reference position must be made on each axis. The user must also check the absolute position of the machine. For details, see Chapter 8, "START UP." If an absolute-position detector is used, and reference position return has been performed once, reference position data is stored in the CNC memory. In this case, the user need not make a reference position check. If an incremental pulse coder is being used, reference position data is lost each time the power to the CNC is turned off and then back on. So, after the power is turned on, another reference position return operation must be performed. At the every power on the safety area must be tested. At each power on there is a message: "Please execute safety test" Without this message dual check safety is either not installed or not yet activated (option bit).

3.2.2

MCC off Test of the Safe Stop Function


A MCC off Test of the safe stop function monitors the contact state of the electromagnetic contactor (MCC), compares the state with a command to the electromagnetic contactor, and checks that the safe stop function works normally. The test must be carried out by the user of the machine. This test must be carried out when the CNC is turned on or when 24 hours have elapsed after the previous test is completed. If the CNC is turned on or if 24 hours have elapsed after the previous test is completed, a guard open request (protective door open request) is not accepted until the test is performed.

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3.SAFETY FUNCTIONS

3.3
3.3.1

STOP
Stopping the Spindle Motor
Because the spindle motor is an induction type motor, power-down during rotation causes the motor to continue rotating for a certain amount of time. From a safety standpoint, the motor may have to be stopped immediately. If the CNC detects an error and judges that the spindle can be controlled, it waits until the rotation of the spindle stops, then shuts off the power. This wait period can be specified as a safety parameter. For this safety parameter, two different values can be specified. One value is used when the safety function is active (the door is open), and the other value is used otherwise. The values must be determined in consideration of the stop period calculated from the spindle speed. To implement the function, the CNC CPU and monitor CPU individually incorporate a timer function. Normal operation of the two CPUs are mutually checked to ensure the safety of the timers. To speed down and stop the spindle, the PMC must input the spindle emergency stop signals (*ESPA(G71.1), *ESPB(G75.1), and so on). When this signal is input, the spindle slows down and stops. (A Ladder program for inputting this signal in case of alarm must be created.) The emergency stop input (connector CX4) of the PSM has the same effect. If the emergency stop signal is connected to emergency stop input (connector CX4) of the PSM, the spindle slows down and stops in the emergency stop state. If this processing is not performed, power-down causes the spindle motor to continue rotating at the speed prior to power-down (and eventually stopping in the end).

CAUTION The CNC outputs a DO notifying of an alarm. If necessary, the spindle should be stopped. Because the DO output is not duplicated, this DO may not be output when a single failure is detected. In that case, the speed cannot be reduced, but the MCC is finally shut off and brought into the safe stop state. If a spindle amplifier alarm or any other state in which the spindle motor cannot be controlled is encountered, immediate power-down is carried out.

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3.SAFETY FUNCTIONS

B-63494EN/01

3.3.2

Stopping the Servo Motor


Because the servo motor is a synchronous motor, power-down results in a dynamic brake stop. The dynamic brake stop is electric braking in which the excited rotor is isolated from the power source and the generated electric energy is used up in the winding. Additional braking is provided by an internal resistor. Unlike an induction motor, the servo motor does not coast because of this function. If the input of the emergency stop signal or an error of a safe-related signal or speed monitoring is detected, the CNC automatically specifies a command to zero the speed and reduces the speed to zero (controlled stop). After the motor slows down and stops, the power is turned off, and the motor is brought into the dynamic brake stop state. To slow down and stop the motor, some parameters must be specified in the CNC. If those parameters are not specified, the motor is immediately brought into the dynamic brake stop state. In some circumstances where a controlled stop cannot be made, a dynamic brake stop is unconditionally made.

3.3.3

Stop States
The following stop states are possible:

Safe stop state


The power to the motor is shut off (MCC off state). If the spindle motor can be controlled, the power is shut off after the spindle motor is slowed down to a stop. If the spindle motor cannot be controlled, the power is immediately shut off. If the servo motor can be controlled, the motor is slowed down to a stop and then brought into the dynamic brake stop state. If the motor cannot be controlled, the motor is immediately brought into the dynamic brake stop state. If the power is shut off immediately, the spindle motor continues at the same speed prior to the abnormal event and eventually comes to a stop. If the spindle motor can be slowed down to a stop, the operation is performed as instructed by the PMC and then the power is shut off.

IMPORTANT The time period until the signal for shutting off the power (turning off the MCC) is output depends on the parameter. Different parameters are used in the safety monitoring state and in other states.
Safety parameter number 1947 1948 Name MCC off timer 1 MCC off timer 2 If the protective door is closed If the protective door is opened

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3.SAFETY FUNCTIONS

Controlled stop state


The power to the motor is not shut off. The servo motor and the spindle motor are controlled to stop. In the controlled stop state of either motor, the safety function is active if the condition for enabling the safety function is satisfied (the door is open). If a further abnormal event occurs, the motor is brought into the safe stop state.

WARNING 1 The machine tool builder must design the machine so that the machine is kept in the stop state if the power to the servo motor driving circuit is shut off. Example) Brake mechanism that would not drop the vertical axis after the power is shut off 2 If the power to the spindle motor driving circuit is shut off, the spindle motor continues rotating at the speed before the power-down and eventually comes to a stop. A measure must be taken so that this coasting does not affect safety.

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3.SAFETY FUNCTIONS

B-63494EN/01

3.4

SAFE-RELATED I/O SIGNAL MONITORING


A set of safe-related I/O signals are connected to the I/O Link and the servo FSSB through separate paths. The two independent CPUs individually check the input signals. If a mismatch between two corresponding signals is found, the system enters the safe stop state. The following safe-related I/O signals are monitored or output in redundant mode: Emergency stop input signal Protective door state input signal Lock state input signal Input signal for monitoring the MCC contact state Output signal for turning off the MCC (power-down)

To configure the two-path system, the machine tool builder must connect these signals to both the I/O module and the FSSB I/O.

IMPORTANT If the safety input signals, except for emergency stop input signals, are connected to the I/O module, a Ladder program must be created to establish a oneto-one relationship between the actual input (X) and the input to the CNC (G).
The duplicated input signals are always checked for a mismatch, regardless of whether the safety function is active or not. When a signal state changes, the pair of signals may not match for some period because of a difference in response. The dual check safety function checks whether a mismatch between the two signals continues for a certain period of time, so that an error resulting from the difference in response can be avoided. The check period must be specified as a safety parameter.
Parameter No. 1945 Name Safe-related input signal check timer

The following signals are not defined as safe-related I/O signals and are not duplicated. The signals, however, are necessary for the system. - Input signal for making a protective door open request - Input signal for starting the test mode - Output signal for specifying a command to lock the protective door - Output signal for requesting a MCC off Test This section briefly describes the signals. For details, see Chapter 5, "OPERATION." For specific connections, see the sample system configuration in Chapter 10.
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3.SAFETY FUNCTIONS

CNC

I/O I/O LINK

UNIT DI DO

Machine

CNC CPU

Cross check

FSSB I/O DI

Monitor CPU

FSSB

DO

Duplicated I/O
Symbol *ESP SGD GDL *SMC MCF ORQ OPT *LGD RQT Signal name Emergency stop signal Guard state signal Guard lock state signal MCC contact state signal MCC on enable signal Guard open request signal Test mode signal Guard unlock signal MCC off Test execution request signal I/O address <X008#4> <DI+000#0> <G191#4> <DI+001#4> <G191#5> <DI+001#5> <G191#6> <DI+001#6> <F191#1> <DO+000#1> <G191#3> <G191#2> <F191#0> <F191#2>

Dual input monitoring Dual input monitoring Dual input monitoring Dual input monitoring Duplicated output Input Input Output Output

Safe-related I/O
1. *ESP Emergency stop signal (input)
Emergency stop signal. The signal is monitored in redundant mode. The signal is connected to the *ESP input of the servo amplifier as well.

2. SGD

Guard state signal (input)


The signal is provided for double monitoring of the protective door state. The signal is connected so that it is normally set to 1 while the protective door is closed and locked (door open) and set to 0 otherwise (door close). These states are implemented by the combination of the safety door and safety relays. The CNC monitors these states. If the safe speed range is exceeded in the door open state, the system enters the safe stop state.

3. GDL

Guard lock state signal (input)


This signal is not usually used.

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3.SAFETY FUNCTIONS 4. *SMC MCC contact state signal (input)

B-63494EN/01

The MCC contact state is monitored in redundant mode. In normal operation, the MCC is active, and whether the contact of a relay is closed cannot be detected. In the test mode, a closed contact of a relay can be detected.

5. MCF

MCC on enable signal (output)


With this signal, the MCC is shut off from both the I/O Link side and the FSSB side.

Signals other than safe-related I/O


The following signals are not safe-related signals (are not checked in redundant mode) but are important signals in the system. The machine tool builder must create an appropriate Ladder program.

IMPORTANT The Ladder program cannot be checked for an error. Check the safety function (see Chapter 7). 6. ORQ Guard open request signal (input)
When this signal is input, the CNC checks the machine position and speed. If both the machine position and speed are within the safe range, the guard unlock signal (*LGD) is set to 1 (guard unlock enabled). The machine tool builder must provide an output signal that opens the actual protective door through the PMC. Connect the signal output.

7. OPT

Test mode signal (input)


When the signal is input, a MCC off Test is executed. The MCC off Test checks whether the contact of the MCC is closed. When carrying out the MCC off Test manually, execute a MCC off Test by the PMC and make necessary corrections before inputting this signal.

8. *LGD

Guard unlock signal (output)


If this signal is set to 1, the protective door can be unlocked. Then, a signal to unlock the actual protective door should be output through the PMC. If the protective door is unlocked while the signal is set to 0, an alarm occurs and brings the motor into the safe stop state.

CAUTION When the signal is set to 1, there is a time delay (depending on the Ladder program) before the signal to unlock the actual protective door is output. Meanwhile, the protective door is locked, and safety is ensured. If an error is found as a result of speed check or machine position check during that period, *LGD becomes 0. If a single failure occurs in this state and if the actual protective door is unlocked, an alarm occurs.
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B-63494EN/01

3.SAFETY FUNCTIONS
When the safety function of the CNC is enabled, this signal is output. If the signal is output, the signal to unlock the actual protective door should be output through the PMC.

9. RQT

MCC off Test execution request signal (output)


If the execution of a MCC off Test is required, this signal is output. At power-on, this signal is output. If this signal is output, a MCC off Test must be executed.

Guard open request signal and guard unlock signal


Door open request 24V X Ladder ORQ-I LGD G ORQ F Ladder Y LGD-O Protective door CNC (PMC)

The figure shows a sample connection of the protective door open request switch and the guard unlock signal. In the normal state, the following state transition takes place before the safety monitoring state is established.

State transition
A B C D ORQ-I 0 1 1 1 ORQ 0 0 1 1 *LGD 0 0 0 1 *LGD-O 0 0 0 0 A protective door open request is not made, and the door is locked. A guard open request is made. The request is transferred to the CNC. A safe speed check and a machine position check prove that there is no failure and that the CNC can enter the safe state. The actual safety door is unlocked. Operations can be performed with the door open. The door is closed and locked again. The guard open request is canceled. The request is transferred to the CNC. The CNC exits from the safe state. Normal operating state

E D F G A

1 1 0 0 0

1 1 1 0 0

1 1 1 1 0

1 0 0 0 0

Safety function enabled

IMPORTANT If the CNC detects that the protective door is open (SGD is set to 0) while ORQ is set to 0, the CNC judges that an abnormal event has occurred and enters the safe stop state. This can occur, for instance, when the door happens to open (or to be unlocked) while machining is in progress with the protective door open

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3.SAFETY FUNCTIONS

B-63494EN/01

Timing diagram from door close state to door open state


The following diagram shows the timings at which the door is opened and closed again.
ORQ_P

ORQ

*LGD

*LGD_P1 (Actual door unlock signal) SGD_P SGD2

Actual door status

Door closed

Door opened t (5)

Door closed

(1)

(2)

(3)

(4)

(1) When the guard open request signal (ORQ) is input, it checks that the machine position and speed are within safe ranges. Then, the guard unlock signal (*LGD) is turned on. (2) When *LGD goes on, the Ladder program turns on the unlock signal. This example assumes that the protective door has an electromagnetic lock mechanism. While the door is open, the unlock signal is turned off. (3) The door is open. (4) The protective door is closed and locked. After this, the guard open request signal (ORQ) must be turned off.

CAUTION Reserve a time of 100 ms or longer (t in the figure) from when the door is closed (locked) until the guard open request signal (ORQ) goes off. If this time requirement is not satisfied, an alarm may be raised when the door is closed (locked).
(5) When ORQ goes off, the CNC turns *LGD off.

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3.SAFETY FUNCTIONS

3.5

EMERGENCY STOP
The emergency stop signal is monitored in redundant mode. When the emergency stop is input, the servo motor slows down to a stop (*) and enters the dynamic brake stop. The spindle slows down to a stop(*) as instructed by the PMC, and the power is shut off.

CAUTION To enable the function to slow down and stop the servo motor, the corresponding parameter must be specified. If the parameter is not specified, the motor immediately enters the dynamic brake stop state. The spindle motor slows down and stops as instructed by the PMC (Ladder program). If the PMC does not instruct this, the motor maintains the high speed prior to the power-down and coasts. If an illegal speed is specified because of a failure on the PMC side while the safety function is active (the protective door is open), the CNC enters the safe stop state. WARNING In the emergency stop state, the guard unlock signal becomes 1 (the door opens). In the emergency stop state, the processing to open or close the protective door depends on the Ladder program created by the machine tool builder. For instance, if the protective door should not be opened in the emergency stop state, a Ladder program of the processing must be created.
When the emergency stop is canceled, an alarm may occur, depending on the state. For instance, if the emergency stop state is canceled with the protective door open and if no door open request is made, the CNC judges that an error has occurred and enters the safe stop state.

IMPORTANT Emergency Stop Button must fulfil the Standard IEC60947-5-1. This is mandatory.

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3.SAFETY FUNCTIONS

B-63494EN/01

3.6

SAFE SPEED MONITORING


When the guard open request signal is input, the dual check safety function starts monitoring whether a safe speed is kept on each feed axis and spindle. If the speed does not exceed the safe speed range and if the machine position is in within the safe range, the guard unlock signal is enabled. If the safe speed range is exceeded while the protective door is open, the dual check safety function immediately enters the safe stop state. For each feed axis and spindle, a single safe speed range is specified in a safety parameter.

CAUTION If an illegal speed is detected, the MCC is shut off after the time specified in the parameter. IMPORTANT 1 The period from when an error is detected until the MCC is shut off can be specified in a parameter. The period is reserved to stop the spindle safely. A large value means that a long time is needed to shut off the MCC. In this parameter, different values can be specified and used when the safety function is enabled (the protective door is open) and disabled (normal operation is performed). The value of the parameter for the former case must be carefully specified. 2 A gear ratio, ball screw, and the like must be carefully selected so that a safe speed can be kept on the feed axis. 3 Before inputting the guard open request signal, reduce each axial speed and spindle speed to a safe speed range or below. If a speed exceeds the limit, the guard open request signal is not accepted (the door is not unlocked). If the door is forced open, the power to the driving circuit is shut off (safe stop state). WARNING The safe speed monitoring function monitors whether the traveling speed exceeds a specified limit. The function cannot monitor the stop state (zero speed). If an error causes a movement on the feed axis at a speed lower than the safe speed range while the protective door is open, for instance, the function cannot detect this state. The machine must be designed so that this state does not affect the safety of the machine system.

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3.SAFETY FUNCTIONS

3.7

SAFE MACHINE POSITION MONITORING


While the door is open, the dual check safety function checks whether the position on each feed axis is within the safe machine position range defined by safety parameters. If it detects a machine position beyond the safety range, the dual check safety function immediately enters the safe stop state. The user of the machine must first carry out a reference position return in order to obtain the initial position. If the reference position return is not carried out, the check function is disabled. This check function is enabled after the reference position is established. (The function cannot be disabled by any means after the reference position is established.) A safe machine position limit on each feed axis is specified in a safety parameter.

CAUTION The safe machine position monitoring function does not keep monitoring the specified range. Only after the function detects that a position on a feed axis exceeds the range, the system enters the safe stop state. Accordingly, in the safe stop state, an overtravel has occurred on the feed axis. The travel distance depends on the traveling speed and other conditions.
At power-on, the safety function does not work. After power-on, the CNC checks whether a reference position return is completed. If the reference position return is completed and if the protective door is open, safe machine position monitoring and safe speed monitoring are performed. Then, the safety functions start working. If the reference position return is not completed, safe machine position monitoring cannot be performed because the coordinates are not set. In this state, the machine position monitoring function is disabled. After a reference position return is made, this function is enabled. Depending on the safety parameter setting, however, an alarm may be raised. To avoid this alarm, specify the safe machine position parameters before making a reference position return.

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3.SAFETY FUNCTIONS

B-63494EN/01

3.8

MCC OFF TEST


A MCC off Test must be carried out in intervals of 24 hours, so that the safety functions would not be damaged by a possible cause of failure. A message telling that the MCC off Test must be carried out is displayed at power-on or when 24 hours have elapsed after the previous MCC off Test. The protective door can be opened only after the MCC off Test is carried out accordingly.

IMPORTANT Carry out the MCC off Test with the protective door closed. Because the test shuts off the MCC, prepare the system for mechanical MCC shut-off before starting the MCC off Test.

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B-63494EN/01

4.INSTALLATION

INSTALLATION
Except FSSB I/O module, the hardware installation such as field wiring, power supply, etc. should be referred to connection manual (B-63003EN) for CNC units and (B-65162E) for servo amplifier. EMC problem should be referred to EMC guideline manual (A72937/E). Degree of IP protection: Servo Motors: IP55 Spindle Motors: IP54 with oil-seal, IP40 without oil-seal Servo and Spindle amplifiers: IP1x CNC and other accessories: Ipxx

NOTE Servo/Spindle amplifiers, CNC are to be installed in IP54 protected cabinets.


The peripheral units and the control unit have been designed on the assumption that they are housed in closed cabinets.

Environmental conditions for CNC units


Condition LCDmounted type control unit and display unit (except unit with data server function) 0C to 58C 20C to 60C Standalone type control unit LCDmounted type control unit with PC and data server functions 5C to 53C

Ambient Temperature of the unit Humidity

Operating Storage Transport Normal

0C to 55C

75% RH or less, no condensation

Vibration Meters above sea level Environment

Short period(less 95% RH or less, no condensation than 1 month) Operating 0.5 G or less Nonoperating 1.0 G or less Operating Up to 1000 m Up to 1000 m Nonoperating Up to 12000 m Up to 12000 m Normal machine shop environment (The environment must be considered if the cabinets are in a location where the density of dust, coolant, and/or organic solvent is relatively high.)

10% to 75% RH, no condensation 10% to 90% RH, no condensation

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4.INSTALLATION

B-63494EN/01

Environmental conditions for servo amplifier


The servo amplifier series must be installed in a sealed type cabinet to satisfy the following environmental requirements: (1) Ambient Temperature Ambient temperature of the unit : 0 to 55C (at operation) -20 to 60C (at keeping and transportation) (2) Humidity Normally 90% RH or below, and condensation-free (3) Vibration In operation : Below 0.5G (4) Atmosphere No corrosive or conductive mists or drops should deposit directly on the electronic circuits.

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B-63494EN/01

4.INSTALLATION

4.1
4.1.1
LCD display unit

OVERALL CONNECTION DIAGRAM


For One-path
Mother board

24V-IN(CP1A) 24V-OUT(CP1B) MDI UNIT CK2 CK1

24 VDC supply

power

To I/O device

Soft key cable MDI(CA55)

R232(JD36A) R232(JD36B)

RS-232C I/O device RS-232C I/O device Touch panel

HDI(JA40)

High-speed skip input

Distribution-type I/O board 24VDC I/O-LINK(JD1A) CPD1 JD1 JD1 I/O unit, etc. 24VDC CPD1 JD1 JD1 JA3

Manual pulse generator Operator's panel

Power magnetics cabinet

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4.INSTALLATION

B-63494EN/01

Mother board

LCD display unit

SPDL(JA41)

JA7B JA7A Second spindle SPM

JY2 TB2 Spindle motor Axis 1 servo motor

FSSB(COP10A)

COP10B COP10A COP10B COP10A COP10B COP10A SVM SVM SVM

TB2 JF1 TB2 JF1 TB2 JF1

Axis 2 servo monitor

Axis 3 servo motor

(This diagram assumes the use of a 1-axis amplifier.)

Separate detector interface unit 24VDC CP11A COP10B COP10A JF101 JF102 JF103 JF104 JA4A Battery for absolute position detector Linear scale axis 2 Linear scale axis 3

FSSB I/O DC24V CP11A CB155A COP10B CB156A COP10A SV-CHK(CA54) Power magnetics cabinet

Servo check board

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B-63494EN/01

4.INSTALLATION

4.1.2

For Two-path
I/O module for operators panel JD1B CE56 JD1A CE57 Machine operators panel

Main board I/O Link (JD44A)

I/O module for connector panel JD1B CB150 JD1A

Power magnetics cabinet

SPDL (JA41)

To next I/O unit

Safe-related and other signals

FSSB (COP10A-1)

200VAC 2 200VAC 3

PSM CX1A CZ1 CX4

CX3 MCC Emergency stop

TB1 TB1 SPM JA7B JA7A

CXA2A CXA2B JYA2 CZ2

Spindle motor TB1 To next SPM (JA7B) TB1 Axis control card SVM1 COP10B COP10A CXA2B JF1 CZ2 CXA2A

Servo motor To next SVM (COP10B)

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4.INSTALLATION
From previous SVM (COP10A) Separate detector interface unit COP10B JF101 COP10A JF102 JF103 JF104 JA4A

B-63494EN/01

Separate detector Separate detector Separate detector Separate detector Battery Safe-related signals

FSSB I/O module COP10B CB155 COP10A CB156

Power magnetics cabinet

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B-63494EN/01

4.INSTALLATION

Sub CPU board

TB1 SPM SPDL (JA41) JA7B JA7A TB1 To next SPM (JA7B) TB1 Axis control card FSSB (COP10A-1) SVM1 COP10B COP10A

CXA2B

JYA2 CZ2 Spindle motor CXA2A

CXA2B

JF1 CZ2 Servo motor

to next SVM (COP10B) From previous SVM (COP10A) Separate detector interface unit COP10B COP10A JF101 JF102 JF103 JF104 JA4A Separate detector Separate detector Separate detector Separate detector Battery Safe-related signals FSSB I/O module COP10B COP10A CB155 CB156 Power magnetics cabinet

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4.INSTALLATION

B-63494EN/01

4.2

DI/DO CONNECTION (VIA THE PMC)


For DI/DO signals connected via the PMC, the I/O signals of the unit connected to the FANUC I/O Link are to be input to or output from the following addresses, via the PMC:

PMCCNC G008 PMCCNC G191 CNCPMC F191

#7

#6

#5

#4 *ESPG

#3

#2

#1

#0

#7

#6 *SMC1

#5 GDL1 #5

#4 SGD1 #4

#3 ORQ #3

#2 OPT #2 RQT

#1

#0

#7

#6

#1 MCF1

#0 *LGD

For the meaning of each of the above signals, see Chapter 6, "OPERATION." Hatted signals means dual monitoring.

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B-63494EN/01

4.INSTALLATION

4.3
4.3.1

DI/DO CONNECTION (VIA THE FSSB)


For DI/DO signals connected via the FSSB, the I/O signals are to be directly connected to the I/O unit connected to the FSSB.

FSSB I/O Connection

Power supply connection


External power supply

CP11A 1 2 3

+24V 0V

24 VDC stabilized power supply 24 VDC10%

Cable CP11A AMP Japan 1-178288-3 (Housing) 1-175218-5 (Contact) +24V(1) 0V(2)

External power supply

Select a one that matches the pins of the external power supply.

Recommended cable specification:

A02B-0124-K830 (5 m) An M3 crimp terminal is provided on the external power supply side.

The 24 VDC power input to CP11A can be drawn from CP11B for distribution. The connection to CP11B is the same as for CP11A.

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4.INSTALLATION

B-63494EN/01

DI/DO connection
Signal name +24V

Pin No. CB155A(A01) CB155A(B01) CB155A(A02) CB155A(A07) CB155A(B07) CB155A(A08) CB155A(B08) CB155A(A09) CB155A(B09) CB155A(A10)

*ESP2

RV RV RV RV RV

SGD2 GDL2 SMC2

RV RV RV

Pin No. DOCOM CB155A(B06)

Signal name

+24V 0V +24V stabilized power supply CB155A(A11) Relay

DV MCF2 DV CB155A(B11) Relay

CB155A(A17,B17)

For the meanings "OPERATION."

of

the

above

signals,

see

Chapter

6,

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B-63494EN/01

4.INSTALLATION

4.3.2

FSSB I/O Attachment

External dimensions

CP11A CP11B

Upper:CB156A Lower:CB155A

COP10A COP10B

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4.INSTALLATION

B-63494EN/01

Screw attachment

Mounting hole machining diagram

- 44 -

B-63494EN/01

4.INSTALLATION CAUTION When attaching/detaching this unit, a screwdriver is inserted at an angle. So, a sufficiently large working space must be provided on the both sides of this unit. As a guideline, if the front surface of an adjacent unit is flush with or set back from the front surface of this unit, provide about 20 mm between the adjacent unit and this unit. If the front surface of the adjacent stands forward of the front surface of this unit, provide about 70 mm between the adjacent unit and this unit. When installing this unit near the side of the cabinet, provide about 70 mm between this unit and the cabinet.

Working space around the I/O unit

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4.INSTALLATION

B-63494EN/01

Attachment to a DIN rail


Attachment

DIN rail

Detachment

DIN rail

Attachment 1. Hook the unit over the top of the DIN rail. 2. Press the unit down until it snaps into place. Detachment 1. Pull down the lock section with a standard screwdriver. 2. Pull the lower part of the unit toward you.

CAUTION When detaching the unit, be careful not to damage the lock section by applying excessive force. When attaching or detaching the unit, hold the upper and lower parts of the unit, if possible, to prevent force from being applied to the side (where the cooling rents are provided) of the unit.

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B-63494EN/01

4.INSTALLATION

4.3.3

FSSB I/O Specification List


Ambient temperature Operating 0C to 55C of the unit Storage, transportation -20C to 60C Temperature variation 1.1C /minute maximum Normally Relative humidity 75% or less Humidity Short term (no more than one month) Relative humidity 95% or less Vibration Operating 0.5G or less Normal machining plant environment (Check is required if the unit is to be used in an Atmosphere environment exposed to relatively high levels of dust or coolant, or a relatively high concentration of organic solvents.) (1) Use the unit in a completely sealed cabinet. (2) Install the unit on a vertical surface, and Other conditions provide a space of 100 mm or more above and below the unit. Do not install equipment that dissipates much heat under this unit.

Installation conditions

Power supply capacity


Supply voltage 24V10% is fed from the CP11A connector of the basic module. 10% includes momentary variations and ripples. Power supply capacity 0.3A+7.3mAxDI Remarks Number of DI points in DI = ON state

Input signal specifications


Contact capacity Leakage current between open contacts Voltage drop across closed contacts Delay time 30 VDC, 16 mA or more 1 mA or less (when the voltage is 26.4 V) 2 V or less (including a cable voltage decrease) Receiver delay time: 2 ms (MAX) In addition, the FSSB transfer period and ladder scan period need to be considered.

Output signal specifications


Maximum load current at 200 mA or less including momentary ON time variations Saturation voltage at ON 1 V (MAX) when the load current is 200 mA time 24 V +20% or less including momentary Dielectric voltage variations Output leakage current at 20 A or less OFF time Driver delay time: 50 s(MAX) Delay time In addition, the FSSB transfer period and ladder scan period must be considered.

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I/O SIGNALS

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5.I/O SIGNALS

5.1

OVERVIEW
The dual check safety function provides two input paths and two output paths for safe-related signals (safety signals). For input signals (safety input signals), two paths are used: one path for input to the CNC via the PMC, and the other for input to the monitor via the FSSB. The CNC and monitor exchange the safety input signals with each other at all times to check each other. If a mismatch is found between a safety input signal via one path and the same signal via the other path, the signal is assumed to be 0. If such a state lasts for the period set in a parameter or more, the CNC and monitor independently detect an alarm. (Dual-check for safety input signals) For output signals (safety output signals), two paths are used: one path for output from the CNC via the PMC, and the other for output from the monitor via the FSSB. The MCC-on enable signal (MCF) is output via these two paths. When both a signal via one path and the same signal via the other path are 1, the signal is assumed to be 1. If either is 0, the signal is assumed to be 0. That is, if the signal (MCF1) via the PMC and the signal (MCF2) via the FSSB are both 1, the MCC may be turned on. If either is 0, the MCC must be turned off. In Subsection 5.2, a signal name is followed by its symbol and addresses <via PMC> and <via FSSB>. Then, for an input signal, its classification, function, and operation are described, in this order. For an output signal, its classification, function, and output condition are described in this order. For information about the emergency stop mode, MCC off Test mode, and safety signal modes A/B/C/D described in Subsection 5.2, see Subsection 5.2.2.

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5.2

SIGNALS

Emergency stop signal *ESP1 <X008#4>(<X1000#7> for loader control), *ESPG <G008#4>, *ESP2 <DI+000#0>
[Classification] [Function] [Operation] Input signal Stops machine movement immediately in an emergency. When emergency stop signal (*ESP) is set to 0, the CNC is reset, and an emergency stop occurs. In general, emergency stop signal (*ESP) is specified by the pushbutton switch B contact. When an emergency stop occurs, the servo ready signal SA is set to 0. When emergency stop signal (*ESP) is set to 0, the emergency stop mode is set with the dual check safety function. In this mode, the MCC contact state signal (*SMC) is checked. When *SMC = 0 (MCC-on state ), the guard unlock signal (*LGD) is set to 0 (to disable guard unlocking). When *SMC = 1 (MCC-off state), the guard unlock signal (*LGD) is set to 1 (to enable guard unlocking).

CAUTION Emergency stop signals (*ESP) via the PMC <X008#4> (<X1000#7> for loader control) and via the FSSB <DI+000#0> are checked each other (dual-check for safety input signals), but *ESP via the PMC <G008#4> is not checked.

Test mode signal OPT <G191#2>


[Classification] [Function] [Operation] Input signal This signal notifies the CNC that MCC off Test mode is set with the dual check safety function. Test mode signal (OPT) is not input via the FSSB. When test mode signal (OPT) is 1, the CNC performs safety output signal MCC off Test processing. (MCC-on enable signals (MCF1/MCF2) is output in various patterns, and a test is conducted to see if an appropriate MCC contact state signals (*SMC1/*SMC2) pattern is input, respectively.) In the emergency stop state or while a servo or spindle alarm is present, the MCC off test processing is not performed. If a MCC off Test is not completed within the time set in parameter No. 1946, servo alarm No. 488 is issued.

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CAUTION 1 While the MCC off test processing is in progress, avoid bringing the test mode signal (OPT) to 0. 2 If multi-path control is carried out, run an MCC off test on individual paths independently. 3 If different paths under multi-path control share the MCC, avoid carrying out an MCC off test on those paths simultaneously. Never run the MCC off test simultaneously on tool posts 1 and 2 under one-CPU two-path control or on tool posts 2 and 3 under two-CPU three-path control. 4 If the MCC off test processing is in progress on one of different paths sharing the MCC under multi-path control, the remaining paths sharing the MCC should ignore a VRDY OFF alarm by using the following: all-axis VRDY OFF alarm ignore signal (IGNVRY <066#0>) or axial VRDY OFF alarm ignore signals (IGNVRY1 to IGNVRY8 <G192>). 5 MCF2 via the FSSB under one-CPU two-path control is tested by the MCC off test on tool post 1 and is not tested by the MCC off test on tool post 2. MCF2 via the FSSB connected to tool posts 2 and 3 under two-CPU three-path control is tested by the MCC off test on tool post 2 and is not tested by the MCC off test on tool post 3. WARNING While the MCC off test processing is in progress, the MCC-on enable signal (MCF) goes high and low to turn on and off the MCC. Carry out the MCC off test in such a state that the turning on or off of the MCC will not cause a problem.
Test No. MCF1 (PMC) MCF2 (FSSB) *SMC1 (PMC) *SMC2 (FSSB) Timer limit Timer 1 2 3 4 5

Test start

Test completion

Example 1) Timing chart 1 of MCC off test (normal state)

Test No. MCF1 (PMC) MCF2 (FSSB) *SMC1 (PMC) *SMC2 (FSSB) Timer limit Timer

Alarm !!

Test start

Example 2) Timing chart 2 of MCC off test (abnormal state)

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Guard open request signal ORQ <G191#3>


[Classification] [Function] [Operation] Input signal This signal requests the CNC to unlock the guard with the dual check safety function. Guard open request signal (ORQ) is not input via the FSSB. When the guard open request signal (ORQ) is 1, the CNC, monitor and spindle software make a machine position check and safe speed check. If the results of the checks assure safety, guard unlock signal (*LGD) is set to 1 (to enable guard unlocking). When guard open request signal (ORQ) is 0, the CNC and monitor set guard unlock signal (*LGD) to 0 (to disable guard unlocking). (In emergency stop state, however, the guard unlock signal (*LGD) is set to 1.) See Subsection 5.4.

Guard state signal SGD1 <G191#4>, SGD2 <DI+001#4>


[Classification] [Function] Input signal This signal posts the guard open/closed state to the CNC and monitor with the dual check safety function. 0: Guard open state 1: Guard closed state This input signal is used together with safety input signals such as guard open request signal (ORQ) to determine a safety signal mode that specifies the operation of the CNC, monitor, and spindle software. For details, see Subsection 5.4. Input this signal according to the guard state.

[Operation]

IMPORTANT Interlock switch must fulfil the Standard IEC60947-51. This is mandatory.

Guard lock state signal GDL1 <G191#5>, GDL2 <DI+001#5>


[Classification] [Function] Input signal This signal posts the guard lock state to the CNC and monitor with the dual check safety function. 0: Guard unlocked state 1: Guard locked state This signal is usually not used, but please input same signal (GDL1) both via PMC and via FSSB all time because dual-check for guard lock state signal (GDL2) is executed by CNC and monitor.

[Operation]

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MCC contact state signal *SMC1 <G191#6>, *SMC2 <DI+001#6>


[Classification] [Function] Input signal This signal posts the MCC state to the CNC and monitor with the dual check safety function. 0: MCC-on state 1: MCC-off state When the MCC contact state signals (*SMC1 and *SMC2) are 1 in the emergency stop state, the CNC sets the guard unlock signal (*LGD) to 1 (to enable guard unlocking). The MCC contact state signals (*SMC1/*SMC2) is used to check if the MCC-on enable signals (MCF1/MCF2) operates normally in MCC off Test mode. Input this signal according to the MCC state.

[Operation]

Guard unlock signal *LGD <F191#0>


[Classification] [Function] Output signal This signal notifies that guard unlocking is enabled with the dual check safety function. When guard unlock signal (*LGD) is 0, the guard is locked. When *LGD is 1, the guard is unlocked. Guard unlock signal (*LGD) is not output via the FSSB. In the following cases, this signal is set to 1 (to enable guard unlocking): When emergency stop state is set, and MCC contact state signals (*SMC1 and *SMC2) are 1 (MCC-off state) When guard open request signal (ORQ) is 1, the servo and spindle motors rotate within the safe speeds, the machine is positioned within the safety area, and MCC off Test execution request signal (RQT) is 0 In cases other than the above, this signal is set to 0 (to disable guard unlocking).

[Output condition]

MCC-on enable signal MCF1 <F191#1>,MCF2 <DO+000#1>


[Classification] [Function] Output signal This signal posts notification that the MCC can be turned on with the dual check safety function. When either of the MCC on-enable signals (MCF1 and MCF2) is 0, the MCC is turned on. When both MCF1 and MCF2 are 1, the MCC is tuned on. In the following cases, this signal is set to 0 (to prevent the MCC from being turned on): When a safety-related alarm is issued When the emergency stop state is issued In cases other than above, this signal is state to 1 (to enable the MCC to be turned on).

[Output condition]

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MCC off Test execution request signal RQT <F191#2>


[Classification] [Function] Output signal This signal requests that MCC off Test mode be set, and a check is made to determine whether the safety output signals (MCC-on enable signal (MCF)) operate normally. When MCC off Test execution request signal (RQT) is set to 1, set MCC off Test mode and conduct a safety output signal MCC off Test as soon as possible. When MCC off Test execution request signal (RQT) is 1, guard unlock signal (*LGD) is set to 0 to disable guard unlocking even if safety signal mode B (state in which a guard open request is input, and the guard is closed) is set and the conditions including speed are satisfied. When safety signal mode C (state where a guard open request is input, and the guard is open) is set, and MCC off Test execution request signal (RQT) is set to 1, guard unlock signal (*LGD) is 0 to disable guard unlocking until MCC off Test execution request signal (RQT) is set to 0 after the guard is closed once. When MCC off Test execution request signal (RQT) is 1, the warning "PLEASE EXECUTE SAFE TEST" is displayed on a screen such as a parameter screen. (On some screens, no warning is displayed.) MCC off Test execution request signal (RQT) is not output via the FSSB. In the following cases, this signal is set to 1: A MCC off Test is not completed after power-on (when bit 3 of parameter No. 1902 is 0). Twenty-four hours have elapsed since the completion of the last MCC off Test.

[Output condition]

CAUTION 1 If the current date and time lags behind the date and time of the previously completed MCC off Test due to a clock change or the like, it is assumed that 24 hours have elapsed since the previous MCC off Test. 2 From February 28 to March 1, the elapse of 24 hours may be assumed even if 24 hours has not elapsed after the completion of the previous MCC off Test. 3 MCC must have forced guided contacts and must fulfil the Standard IEC60204 and the standard IEC 255.This is mandatory.
In the following case, this signal is set to 0: A MCC off Test is completed.

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5.3

SIGNAL ADDRESSES
#7 X008 (For loader control) X1000 #7 *ESP1 #7 G008 #7 G191 #7 F191 #6 *SMC1 #6 #5 GDL1 #5 #6 #5 #4 *ESPG #4 SGD1 #4 #3 ORQ #3 #2 OPT #2 RQT #1 MCF1 #0 *LGD #1 #0 #3 #2 #1 #0 #6 #5 #6 #5 #4 *ESP1 #4 #3 #2 #1 #0 #3 #2 #1 #0

Via the PMC

Via the FSSB


#7 DI+0000 #7 DI+001 #7 DO+000 #6 *SMC2 #6 #5 GDL2 #5 #4 SGD2 #4 #3 *BRK #2 #1 MCF2 #0 #3 #2 #1 #6 #5 #4 #3 #2 #1 #0 *ESP2 #0

CAUTION 1 The signals of shaded boxes are duplexed. 2 Emergency stop signals (*ESP) via the PMC <X008#4> (<X1000#7> for loader control) and via the FSSB <DI+000#0> are checked each other (dual-check for safety input signals), but *ESP via the PMC <G008#4> is not checked. 3 *ESP1 (<X008#4> or <X1000#7> for loader control) is directly checked by the CNC. All signals via the FSSB are directly processed by the monitor CPU. None of the signals is processed by the PMC.

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5.4

SAFETY SIGNAL MODES


Depending on the safety input signal state, the CNC, monitor, and spindle software internally have one of the six modes (safety signal modes) indicated in the table below.
Safety signal mode Emergency stop mode MCC off Test mode Safety signal mode A Safety signal mode B Safety signal mode C Safety signal mode D Safety signal state *ESP = 0 OPT = 1 ORQ = 0, and SGD = 1 ORQ = 1, and SGD = 1 Machine state

Emergency stop state State for conducting a MCC off Test Normal operation state State in which a guard open request is input, and the guard is closed ORQ = 1, and SGD = 0 State in which a guard open request is input, and the guard is open ORQ = 0, and SGD = 0 Abnormal state (state in which the guard is open although no guard open request is input.)

In general, safety signal mode transitions are made as described below. Usually, safety signal mode A is set. In safety signal mode A, guard unlock signal (*LGD) is 0, and the guard is locked. When an emergency stop is required, emergency stop mode is set. In emergency stop mode, the MCC contact state signal (*SMC) is checked. When *SMC = 0 (MCC-on state), guard unlock signal (*LGD) is set to 0 (to disable guard unlocking). When *SMC = 1 (MCC-off state), guard unlock signal (*LGD) is set to 1 (to enable guard unlocking). When a MCC off Test is to be conducted, MCC off Test mode is set. In MCC off Test mode, safety output signal MCC off Test processing is performed. (MCC-on enable signal (MCF) are output in various patterns, and a test is conducted to determine whether appropriate MCC contact state signal (*SMC) patterns are input respectively.) When the guard is to be opened, safety signal mode B is set. In safety signal mode B, the CNC, monitor, and spindle software check the machine position and the speed on each axis. If safety is assured, guard unlock signal (*LGD) is set to 1 to enable the guard to be opened. When the guard is opended in safety signal mode B after guard unlock signal (*LGD) is set to 1, safety signal mode C is set. In safety signal mode C, the CNC, monitor, and spindle software check the machine position and the speed on each axis. If an abnormality is detected, an alarm is issued, MCC-on enable signal (MCF) is set to 0, and the MCC is turned off. Safety signal mode D represents an abnormal state in which the guard is open although no guard open request is made. In safety signal mode D, an alarm is issued, the MCC-on enable signal (MCF) is set to 0, and the MCC is turned off.

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5.I/O SIGNALS

5.5

NOTES ON MULTI-PATH CONTROL


This section describes cautions about safe-related I/O signals that should be taken in multi-path control.

5.5.1

Two-CPU Two-Path Control (Without Axis Change between Paths)


If there is no axis change between paths under two-CPU two-path control, a single independent group of safety areas can be provided for each path (two groups of safety areas in total). Two FSSB I/O units, that is one unit for each path, are required. (The two FSSB I/O units are required even if just one group of safety areas is provided.) Two groups of safety input signals are cross-checked. The first group consists of a safety signal input to tool post 1 (DI1C: X008#4, G191 in the figure below) and a safety signal input to the FSSB I/O unit connected to tool post 1 (DI1M). The second group consists of a safety signal input to tool post 2 (DI2C: X008#4, G1191) and a safety signal input to the FSSB I/O unit connected to tool post 2 (DI2M). Safety output signals should be provided to the safety areas, as follows: Provide a safety signal output from tool post 1 (DO1C: F191) and a safety signal output from the FSSB I/O unit connected to tool post 1 (DO1M) to the safety area of tool post 1; Provide a safety signal output from tool post 2 (DO2C: F1191) and a safety signal output from the FSSB I/O unit connected to tool post 2 (DO2M) to the safety area of tool post 2.
MAIN BOARD
Path 1

SUB BOARD crosscheck


Path 2

DO1C DI1C

CNC CPU

Monitor CPU

DO1M DI1M

DO2C DI2C

CNC CPU

crosscheck

Monitor CPU

DO2M DI2M

Safety Safetyarea area11 Guard Guard MCC MCC


and so on and so on

Safety Safetyarea area22 Guard Guard MCC MCC


and so on and so on

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5.5.2

Two-CPU Two-Path Control (With Axis Change between Paths)


If there is an axis change between paths under two-CPU two-path control, a single group of safety areas can be provided. Two FSSB I/O units, that is one unit for each path, are required. (The two FSSB I/O units are required although just one group of safety areas is provided.) Two groups of safety input signals are cross-checked. The first group consists of a safety signal input to tool post 1 (DI1C: X008#4, G191) and a safety signal input to the FSSB I/O unit connected to tool post 1 (DI1M). The second group consists of a safety signal input to tool post 2 (DI2C: X008#4, G1191) and a safety signal input to the FSSB I/O unit connected to tool post 2 (DI2M). Because just one group of safety areas is provided, these four safety input signals (DI1C, DI1M, DI2C, and DI2M) should be equal. Safety output signals should be provided to the single group of safety areas, as follows: Provide a safety signal output from tool post 1 (DO1C: F191), safety signal output from tool post 2 (DO2C: F1191), safety signal output from the FSSB I/O unit connected to tool post 1 (DO1M), and safety signal output from the FSSB I/O unit connected to tool post 2 (DO2M) to the single group of safety areas.
MAIN BOARD
Path 1

SUB BOARD crosscheck


Path 2

DO1C DI1C

CNC CPU

Monitor CPU

DO1M DI1M

DO2C DI2C

CNC CPU

crosscheck

Monitor CPU

DO2M DI2M

Safety Safetyarea area Guard Guard MCC MCC


and so on and so on

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5.5.3

One-CPU Two-Path Control


A single group of safety areas can be provided under one-CPU twopath control. A single FSSB I/O unit is required. Two groups of safety input signals are cross-checked. The first group consists of a safety signal input to tool post 1 (DI1C: X008#4, G191) and a safety signal input to the FSSB I/O unit (DIM). The second group consists of a safety signal input to tool post 2 (DI2C: X008#4, G1191) and a safety signal input to the FSSB I/O unit (DIM). Because just a single group of safety areas is provided, these three safety input signals (DI1C, DI2C, and DIM) should be equal. The following three safety output signals should be provided to the single group of safety areas: safety signal output from tool post 1 (DO1C: F191), safety signal output from tool post 2 (DO2C: F1191), and safety signal output from the FSSB I/O unit (DOM).
MAIN BOARD DO1C DI1C DO2C DI2C
Path 1

CNC CPU
Path 2

crosscheck

Monitor CPU

DOM DIM

Safety Safetyarea area Guard Guard MCC MCC


and so on and so on

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5.5.4

Two-CPU Three-Path Control


Under two-CPU three-path control, two groups of safety areas can be provided: one group for tool post 1 and the other group for tool posts 2 and 3. Two FSSB I/O units are required: one unit for tool post 1 and the other unit for tool posts 2 and 3. (The two FSSB I/O units are required although just a single group of safety areas is provided.) Three groups of safety input signals are cross-checked. The first group consists of a safety signal input to tool post 1 (DI1C: X008#4, G191) and a safety signal input to the FSSB I/O unit connected to tool post 1 (DI1M). The second group consists of a safety signal input to tool post 2 (DI2C: X008#4, G1192) and a safety signal input to the FSSB I/O unit connected to tool posts 2 and 3 (DI2M). The third group consists of a safety signal input to tool post 3 (DI3C: X008#4, G2191) and a safety signal input to the FSSB I/O unit connected to tool posts 2 and 3 (DI2M). Because the second and third groups share the same safety area, the three safety input signals (DI2C, DI3C, and DI2M) should be equal. Safety output signals should be provided to the safety areas, as follows: Provide a safety signal output from tool post 1 (DO1C: F191) and a safety signal output from the FSSB I/O unit connected to tool post 1 (DO1M) to the safety area of tool post 1. Provide a safety signal output from tool post 2 (DO2C: F1191), safety signal output from tool post 3 (DO3C: F2191), and safety signal output from the FSSB I/O unit connected to tool posts 2 and 3 (DO2M) to the single group of safety areas of tool posts 2 and 3.
MAIN BOARD
Path 1

SUB BOARD crosscheck DO1M DI1M DO2C DI2C DO3C DI3C


Path 2

DO1C DI1C

CNC CPU

Monitor CPU

CNC CPU
Path 3

crosscheck

Monitor CPU

DO2M DI2M

Safety Safetyarea area11 Guard Guard MCC MCC


and so on and so on

Safety Safetyarea area22 Guard Guard MCC MCC


and so on and so on

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5.5.5

Loader Control
A single group of safety areas can be provided for loader control, independently of that for the machine controlled with the main CPU board and sub-CPU board. Besides the FSSB unit for the machine, a single FSSB unit is required for the loader. (Even if the machine and loader share a single safety area, the single FSSB I/O unit for the loader is required.) The following safety input signals are cross-checked by the loader: a safety signal input to the loader (DILC: X1000#7, G191) and a safety signal input to the FSSB I/O unit connected to the loader (DILM). Provide the following safety output signals to the safety area of the loader: a safety signal output from the loader (DOLC: F191) and a safety signal output from the FSSB I/O unit connected to the loader (DOLM).
MAIN BOARD DO1C DI1C crosscheck DO1M DI1M LOADER BOARD DOLC DILC crosscheck DOLM DILM

CNC CPU

Monitor CPU

CNC CPU

Monitor CPU

Safety Safetyarea area11 Guard Guard MCC MCC


and so on and so on

Safety Safetyarea area22 Guard Guard MCC MCC


and so on and so on

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PARAMETERS

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6.PARAMETERS

6.1

OVERVIEW
The parameters related to the dual check safety function (safety parameters) are protected by a code (No. 3225) for the safety parameters. The value of a safety parameter cannot be modified unless the same value as the code for the safety parameters is set as the key (No. 3226) for the safety parameters. The safety parameters are stored in two locations on the CNC. The CNC, monitor, and spindle software check the matching of the parameters stored at the two locations. If a mismatch is found, an alarm is issued. If the setting of a safety parameter is modified, the power must be turned off then back on. The new setting of the parameter becomes effective after the power is turned back on. For information about emergency stop mode, MCC off Test mode, and safety signal modes A/B/C/D described in this section, see Chapter 5. Section 6.3 describes the parameters related to the use of the FSSB I/O unit. Section 6.4 describes the functions that require special parameter settings.

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6.2

PARAMETERS
1023 Servo axis number for each axis

[Data type] [Valid data range]

Byte axis 1, 2, 3, ..., number of controlled axes Set which servo axis corresponds to each controlled axis. Usually, set the same value for a controlled axis number and servo axis number. A controlled axis number represents an array number for an axis type parameter or axis type machine signal. For details of the setting, refer to the description of FSSB setting in the connection manual (function part).

CAUTION To use the dual check safety function, the first servo axis is required. To use the dual check safety function under multi-path control, the first servo axis cannot be changed between paths. Specific requirements are as follows. For one-path control, one-CPU two-path control, and loader control: Tool post 1 (or loader) must have an axis for which parameter No.1023 is set to 1. For two-CPU two-path control and two-CPU threepath control: Tool post 1 must have an axis for which parameter No.1023 is set to 1, and tool post 2 must have an axis for which parameter No.1023 is set to 9.
1829 Positional deviation limit during a stop for each axis

[Data type] [Unit of data] [Valid data range]

Word axis Detection unit 0 to 32767 Set a positional deviation limit for each axis at stop time. If a positional deviation limit during a stop is exceeded at stop time, a servo alarm No.410 is issued, and an immediate stop (same as an emergency stop) is performed. In the dual check safety function, the CNC and monitor always check the position deviation amount on each axis. If the monitor detects that the position deviation limit is exceeded during a stop, a servo alarm No.474 is issued only in safety signal mode C (state in which a guard open request is input and the guard is open).

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6.PARAMETERS
1838 Positional deviation limit during movement for each axis in safety signal mode C

[Data type] [Unit of data] [Valid data range]

2-word axis Detection unit 0 to 99999999 Set a positional deviation limit during movement for each axis in safety signal mode C (state in which a guard open request is input, and the guard is opened) when the dual check safety function is used. If a positional deviation limit during movement is exceeded during movement, a servo alarm No.411 is issued, and an immediate stop (same as an emergency stop) is performed. In the dual check safety function, the CNC and monitor always check the position deviation amount on each axis. If the monitor detects that the position deviation limit is exceeded during moving, a servo alarm No.475 is issued only in safety signal mode C (state in which a guard open request is input and the guard is open). When the guard is open, axis movement is performed at a speed not exceeding the safe speed. So, usually, set a value smaller than a positional deviation limit during movement (parameter No. 1828).
#7 #6 DCE #5 0 #4 #3 STP #2 #1 #0

1902

[Data type] STP

Bit When the power is turned on, a MCC off test is: 0: Conducted. (The warning "PLEASE EXECUTE MCC OFF TEST" is displayed at power-on, and MCC off Test execution request signal (RQT) is output.) 1: Not conducted.

CAUTION 1 The STP parameter is used temporarily, for example, when a MCC off Test is not to be made at power-on as in the case of machine adjustment. Usually, set STP = 0. 2 Even when STP = 1, a MCC off Test is required if the power is turned 24 hours or more after the completion of the previous MCC off Test. WARNING Set STP = 0 after the STP parameter is used temporarily as in the case of machine adjustment.
DCE The dual check safety function is: 0: Disabled. 1: Enabled.

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CAUTION Usually set the DCE = 1 in the dual check safety function. The system cannot start-up because MCCon enable signal (MCF) = 0 when the DCE = 0. WARNING Always set bits 5 and 7 of parameter No.1902 to 0. If one of these bits is set "1", the safety functions may be executed incorrectly.
#7 1904 #6 DCN #5 #4 #3 #2 #1 #0

[Data type] DCN

Bit axis The checks of the target axis by the dual check safety function are: 0: Made. 1: Not made.

CAUTION 1 The DCN bit cannot disable the checks by the dual check safety function for all the controlled axes. 2 Set the DCN bit to 1 for the slave axis under tandem control or for the tool axis of a simple electronic gear box or electronic gear box 2-pair. WARNING The checks by the dual check safety function are not made on an axis for which the DCN bit is set to 1. Set the DCN bit to 0 for normal axes.
1942 Safety speed for each axis

[Data type] [Unit of data] [Valid data range]

2-word axis

Increment system

Unit of data

Valid data range IS-A, IS-B IS-C 0 to 240000 0 to 96000 0 to 240000 0 to 100000 0 to 48000 0 to 100000

Millimeter machine 1 mm/min Inch machine 0.1 inch/min Rotation axis 1 deg/min

Set a safe speed for each axis. The CNC and monitor always check the velocity command of each axis in the dual check safety function. If the safe speed is exceeded on one axis at least, the guard unlock signal (*LGD) is brought to 0, to disable guard unlocking. The state in which the safe speed is not exceeded on any axis is one condition for setting the guard unlock signal (*LGD) to 1 (to enable guard unlocking).
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If the safe speed is exceeded in safety signal mode C (state in which a guard open request is input and the guard is open), a servo alarm No.476 or No.494 is issued for the corresponding axis.

CAUTION The checks are made on the basis of the speed converted to the detection unit. Accordingly, a calculation error may occur.
1943 1944 Safe machine position of each axis (+ direction) Safe machine position of each axis (- direction)

[Data type] [Unit of data]

2-word axis
Increment system IS-A IS-B 0.001 0.0001 IS-C 0.0001 0.00001 Unit mm inch

Millimeter machine 0.01 Inch machine 0.001

[Valid data range]

-99999999 to 99999999 Set a safe machine position for each axis. The CNC and monitor always check the machine position on each linear axis in the dual check safety function. In safety signal mode B (state in which a guard open request is input, and the guard is closed), if there is at least one linear axis whose machine position is not in the safe machine position (safe machine position (- direction) machine position safe machine position (+ direction)), the guard unlock signal (*LGD) is set to 0 to disable guard unlocking. The state in which the machine positions of all linear axes are within the safe machine positions is one condition for setting the guard unlock signal (*LGD) to 1 (to enable guard unlocking). If the machine position on a linear axis exceeds the safe machine position in safety signal mode C (state in which a guard open request is input and the guard is open), a servo alarm No.477 or No.495 is issued.

CAUTION The checks are made on the basis of the machine position to the detection unit. Accordingly, a calculation error may occur. WARNING 1 CNC and monitor check the machine position of each linear axis, and not check it of each rotation axis. 2 CNC and monitor check the machine position of only each axis whose reference position is established, and not check it of each axis whose reference position is not established.
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6.PARAMETERS
1945 Safety input signal check timer

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[Data type] [Unit of data] [Valid data range]

Word ms 0 to 32767 For input signals related to the dual check safety function (safety input signals), two paths are used: one path for input to the CNC via the PMC, and the other for input to the monitor via the FSSB. The CNC and monitor exchange the input signals with each other at all times to check each other. If a mismatch greater than the time set in this parameter is detected between an input signal via one path and the same signal via the other path, a servo alarm No.479 or No.486 is issued. If a value of less than 16 is specified, a specification of 16 ms is assumed.

CAUTION Set identical values in parameters No.1945 for the following: two tool posts under two-CPU two-path control with axis change between paths, two tool posts under one-CPU two-path control, or tool posts 2 and 3 under two-CPU three-path control.
1946 MCC off Test timer

[Data type] [Unit of data] [Valid data range]

Word ms 0 to 32767 When MCC off Test mode is set with the dual check safety function, the CNC conducts a safety output signal MCC off Test. If a MCC off Test is not completed within the time set in this parameter, a servo alarm No.488 is issued. If a value of less than 0 is specified, a specification of 10000 ms is assumed.
MCC-off timer 1 MCC-off timer 2

1947 1948

[Data type] [Unit of data] [Valid data range]

Word ms 0 to 32767 When the MCC-on enable signal (MCF) needs to be set to 0 (MCC off) with the dual check safety function for a cause such as an alarm or emergency stop, the CNC and monitor set MCC-on enable signal (MCF) to 0 when an MCC-off timer value has elapsed after the alarm or emergency stop state. If a spindle alarm is issued, however, the timers are not used. Instead, MCC-on enable signal (MCF) is set to 0 immediately. If the MCC is cut off while the spindle motor is rotating, the spindle motor will continue to rotate (free-run) and stop after time. When the
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6.PARAMETERS
spindle motor should stop as quickly as possible, please use these parameters and control the spindle motor to stop, and after that cut MCC off.
State When a spindle alarm is issued When the guard is closed When the guard is open Timer used No timer is used. MCC-off timer 1 (No. 1947) MCC-off timer 2 (No. 1948)

CAUTION Set identical values in parameters No.1947 for the following: two tool posts under two-CPU two-path control with axis change between paths, two tool posts under one-CPU two-path control, or tool posts 2 and 3 under two-CPU three-path control. Set identical values in parameters No.1948 likewise.
1950 Brake signal timer

[Data type] [Unit of data] [Valid data range]

Word ms 0 to 32767 Set a time period from when the monitor in the dual check safety function detects that the MCC contact state signal (*SMC2) is 0 (MCC on state) until the brake release signal (*BRK) goes 1 (brake release enabled). If a value less than 0 is specified, 2500 ms is assumed. Usually, specify 0.

CAUTION Set identical values in parameters No.1950 for the following: two tool posts under two-CPU two-path control with axis change between paths, two tool posts under one-CPU two-path control, or tool posts 2 and 3 under two-CPU three-path control.
#7 1959 0 #6 0 #5 0 #4 0 #3 0 #2 0 #1 0 #0 0

[Data type]

Bit set all bits to 0.

WARNING Always set all bits of parameter No.1959 to 0. If 1 is set, a safety function is not worked normally.

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6.PARAMETERS
2078 2079 Monitor conversion factor (numerator) of each axis

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Monitor conversion factor (denominator) of each axis

[Data type]

Word axis Set the following values. No.2078/No.2079 = Lowest possible terms of the feedback pulse count of built-in pulse coder per motor revolution over one million

CAUTION 1 The monitor in the dual check safety function takes in the feedback of the built-in pulse coder. Even if a separate position detector is used, set parameters No.2078 and No.2079 to the values calculated on the basis of the feedback pulse count of the built-in pulse coder. 2 Changing parameter No.2078 or No.2079 will not cause a P/S000 alarm (PLEASE TURN OFF POWER). However, when making this change, turn off the power. The changed parameter value takes effect after the power is turned on again. 3 Parameters No.2078 and No.2079 are cleared if the standard servo parameter setting (turning on or off the power when the DGPR bit (bit 1 of parameter No.2000) is set to 0) is selected. After making the standard servo parameter setting, set parameters No.2078 and No.2079 again. 4 Set both parameters No.2078 and No.2079 to 0 for the slave axis under tandem control. 5 Parameters No.2078 and No.2079 are used also for the dual position feedback function.
3225 Code for safety parameters

[Data type] [Valid data range]

2-word 0 to 99999999 Set a code (password) for protecting against modifications to parameters related to the dual check safety function (safety parameters). When a code for safety parameters is set, the parameters are locked. At this time, the setting (code) is not displayed but is blank, and safety parameter input is disabled. If an attempt is made to input data in a locked safety parameter, the result indicated in the table below is produced, depending on the method of input. No attempt is successful.
Input method Result MDI input Warning "WRITE PROTECT" G10 (programmable parameter input) P/S231 FORMAT ERROR IN G10 L50 Input via the reader/puncher interface No alarm is issued, but parameter input is disabled.

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6.PARAMETERS
Input through a window Completion code 7 (write protect)

A code for safety parameters can be set when the safety parameters are not locked, that is, when the code for safety parameters is 0, or when the code for safety parameters is the same as the key for safety parameters (No. 3226). The following safety parameters are protected by a code for safety parameters: No.1023, No.1829, No.1838, No.1902#3, No.1902#5, No.1902 #6, No.1904#0, No.1904#1, No.1904#2, No.1904#3, No.1904#4, No.1904#5, No1904#6, No.1942, No.1943, No.1944, No.1945, No.1946, No.1947, No.1948, No.1950, No.1959, No.3225, No.4372
3226 Key for safety parameters

[Data type] [Valid data range]

2-word 0 to 99999999 When the same value as the code for safety parameters is set in this parameter, the key is opened to enable modifications to the safety parameters. The value set in this parameter is not displayed. When the power is turned off, the value set in this parameter is cleared, resulting in the locked state.

CAUTION Once a key is set, the key must be cancelled or memory must be cleared before the safety parameters can be modified. Moreover, the code for the safety parameters cannot be modified. Be careful when setting a code for safety parameters.
4372 Safe speed of each spindle

[Data type] [Unit of data] [Valid data range]

Word min-1 0 to 32767 Set a safe speed for each spindle in terms of motor speed. With the dual check safety function, the CNC and spindle software always check the speed of each spindle motor. In safety signal mode B (state in which a guard open request is input, and the guard is closed), if there is at least one spindle whose speed is greater than the safe speed, guard unlock signal (*LGD) is set to 0 to disable guard unlocking. The state in which the speeds of all spindle motors are within the safe speeds is one condition for setting guard unlock signal (*LGD) to 1 (to enable guard unlocking). In safety signal mode C (state in which a guard open request is input and the guard is open), if a spindle speed exceeds the safe speed, a spindle alarm No.757 (No.767) or AL-69 is issued for the corresponding spindle.

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6.PARAMETERS

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6.3

PARAMETERS RELATED TO THE USE OF FSSB I/O UNIT


#7 1902 #6 #5 #4 #3 #2 #1 #0 FMD

[Data type] FMD

Bit The FSSB setting mode is: 0: Automatic setting mode. 1: Manual setting 2 mode.

CAUTION When using the dual check safety function, set the FMD bit to 1, to select manual setting 2 mode.
#7 1905 #6 #5 IO2 #4 IO1 #3 #2 #1 #0

[Data type] IO1 IO2

Bit axis A first FSSB I/O unit is: 0: Not used. 1: Used. A second FSSB I/O unit is: 0: Not used. 1: Used.

CAUTION 1 The FSSB I/O unit and separate detector interface unit (pulse module) are handled as units of the same type on the FSSB. The term "first unit" or "second unit" used in the following description means that the unit is the first or second one when counted disregarding the difference between the FSSB I/O unit and separate detector interface unit. If one FSSB I/O unit and one separate detector interface unit are connected and if the separate detector interface unit is closer to the CNC on the FSSB than the FSSB I/O unit, for instance, the FSSB I/O unit is referred to as the "second unit." 2 The FSSB I/O unit is controlled on the first servo axis. Set IO1 (or IO2) to 1 for an axis for which parameter No.1023 is set to 1 (to 9 for tool post 2 under two-CPU two-path control or two-CPU threepath control). For the other axes, set both IO1 and IO2 to 0.

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6.PARAMETERS
1910 1919 1970 1979 Address conversion table value for slave 1 of FSSB channel 1 (ATR)

:
Address conversion table value for slave 10 of FSSB channel 1 (ATR) Address conversion table value for slave 1 of FSSB channel 2 (ATR)

:
Address conversion table value for slave 10 of FSSB channel 2 (ATR)

[Data type] [Valid data range]

Byte 0 to 7, 16, 40, 48 Set the address conversion table values for slaves 1 to 10 of each FSSB channel. "Slave" is a generic term for the FSSB I/O unit, separate detector interface unit, and servo amplifier connected to the CNC by an FSSB optical cable. The slaves are numbered 1 to 10 in ascending order of distance from the CNC. A two-axis amplifier has two slaves. A threeaxis amplifier has three slaves. If a slave is a separate detector interface unit or FSSB I/O unit, set 16 for the first unit and 48 for the second unit.

CAUTION The FSSB I/O unit and separate detector interface unit (pulse module) are handled as units of the same type on the FSSB. The term "first unit" or "second unit" used in the following description means that the unit is the first or second one when counted disregarding the difference between the FSSB I/O unit and separate detector interface unit. If one FSSB I/O unit and one separate detector interface unit are connected and if the separate detector interface unit is closer to the CNC on the FSSB than the FSSB I/O unit, for instance, the FSSB I/O unit is referred to as the "second unit."

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6.PARAMETERS

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6.4
6.4.1

FUNCTIONS THAT REQUIRE SPECIAL PARAMETER SETTINGS


Tandem Control
To use tandem control, set the following parameters. Master axis No special parameter settings are required. Slave axis No.1904#6(DCN)=1 No.2078=0 No.2079=0

6.4.2

Simple Electronic Gear Box and Electronic Gear Box 2-pair


To use a simple electronic gear box or electronic gear box 2-pair, set the following parameters. Workpiece axis No special parameter settings are required. Tool axis (EGB axis) No.1904#6(DCN)=1

6.4.3

Multi-path Control
To use multi-path control, set the following parameters. Two-CPU two-path control (without axis change between paths) No special parameter settings are required. Two-CPU two-path control (with axis change between paths) No.1023 The first servo axis cannot be changed between paths. Accordingly, set parameter No.1023 to 1 for the axis of tool post 1 and to 9 for the axis of tool post 2. No.1945, No.1947, No.1948, No.1950 Set identical values for the two tool posts. One-CPU two-path control No.1023 Set parameter No.1023 to 1 for the axis of tool post 1. No.1945, No.1947, No.1948, No.1950 Set identical values for the two tool posts. Two-CPU three-path control (No axis change can be made between tool post 1 and tool post 2 or 3.) No.1023 Set parameter No.1023 to 9 for the axis of tool post 2. No.1945, No.1947, No.1948, No.1950 Set identical values for tool posts 2 and 3. Loader control No special parameter settings are required.

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START-UP

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7.1

START-UP OPERATION
The machine tool builder has to do tests for insulation and protective bonding. Testing must be performed according to Chapter 19.2 and 19.3 of the standard IEC 60204-1 by an appropriately authorized person and recorded.

Continuity of the protective bonding circuit


When the machine is installed and the electrical connections are complete, including those to the power supply, the continuity of the protective bonding circuit can be verified by a loop impedance test in accordance with 612.6.3 of IEC 60364-6-61. For further details, please refer to Chapter 19.2 of IEC 60204-1.

Insulation resistance tests


The insulation resistance measured at 500 V d.c. between the power circuit conductors and the protective bonding circuit is to be not less than 1M. For further details, please refer to Chapter 19.3 of IEC 60204-1.

7.1.1

Acceptance Test and Report for Safety Functions


The machine tool builder is to conduct a dual check safety function check test during machine start-up operation. In this test, limits need to be exceeded to check that the dual check safety function operates normally.

Acceptance test for Safety function

Acceptance report
A qualified person is to check each dual check safety function and record the test results in a check report.

MOTE When modifying dual check safety function data, conduct an additional check test on the modified dual check safety function and record the test results in a check report.

Safe-related I/O monitoring test


Data cross-check operation is tested with the I/O device connector detached.

MCC off Test check


The test mode signal is used to check that a MCC off Test is conducted. Negative test: Conduct a MCC off Test by disconnecting the MCC contact signal (input). Check that an alarm is issued and the MCC remains to be shut off.
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Safe speed monitoring test


This test checks that when the actual speed exceeds a speed limit, safety stop state is set by a stop response.

Safe machine position monitoring test


A positional limit test is conducted by making many different movements. A positional limit is placed at the center of an axis, and the position is moved at many different speeds in a rapid traverse mode. Thus, the distance traveled on the axis until stop state is set by a stop response is measured. The machine tool builder is to determine a safety limit stop position including a safety margin.

Data modification
The user needs to enter the correct password before setting safety parameters with the system. After a safety parameter is modified, a check test needs to be conducted on the related safety function, and the test results need to be recorded in a report.

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7.1.2
7.1.2.1
Main flow

Start-up of the Dual Check Safety Function Initial start-up


Disable dual check safety function Machine start-up

FSSB I/O setting

Safety parameter input

Step 1
Initial state First, check that the machine starts up normally when the dual check safety function is disabled.
Preparation 1 Preparation 2 Disable the dual check safety function. Disable output (MCF), from I/O, that indicates MCC is turned off. Bit 6 of PRM No. 1902 = 0 Connect the relay for driving based on I/O output

CAUTION When the dual check safety function is disabled, the MCC on enable signal (MCF) is not output. So, make a connection to temporarily disable MCF. To enable the dual check safety function, reset the temporary connection.

Step 2
FSSB I/O setting Make the same settings as for the pulse module. Example: When a two-axis amplifier is set as slave 1, and FSSB I/O unit is set as slave 2 Make the settings indicated in the table below.
Parameter setting Bit 0 of No. 1902 = 1 Bit 4 of No. 1905 = 1 No. 1910 = 0 No. 1911 = 1 No. 1912 = 16 Nos. 1913 to 1919 = 40 Meaning Manually sets the FSSB setting mode. Uses the first FSSB I/O unit. Sets the value of parameter No. 1023 less 1 when the slave is an amplifier Sets the value of parameter No. 1023 less 1 when the slave is an amplifier 16 when the slave is a FSSB I/O unit 40 when there is no slave

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Step 3
Safety parameter input Enable the dual check safety function, and enter the safety parameters.
Preparation 1 Preparation 2 Enable the dual check safety function. Enables output (MCF), from I/O, that indicates MCC is turned off. Bit 6 of PRM No. 1902 =1 Enable I/O output.

Set the safety parameters indicated in the table below.


Parameter setting 1942 1943 1944 1945 1946 1947 1948 1838 2078 2079 4372 Meaning Safe speed on each axis Safe machine position (+ direction) on each axis Safe machine position (- direction) on each axis Timer for safety input signal check Timer for MCC off Test Timer 1 for MCC off Timer 2 for MCC off Positional deviation limit value in mode C Dual position feedback conversion coefficient (numerator) Dual position feedback conversion coefficient (denominator) Safe speed on each spindle

Step 4
If alarm 478 or 496 occurs, set the bit 4 of parameter No.2212 to 1, and reset this bit to 0. Then turn off the power of the entire system (included servo amplifier).

Step 5
Execution of general machine tests Axis and spindle optimization Dual check safety function adjustment (safe speed, safe machine position)

Step 6
Test for checking the safety function Check test execution and report creation

Step 7
Parameter preservation Save all parameters including the safety parameters. The parameters are used to start up the series.

Step 8
Set a password. A password is used to disable unauthorized persons from modifying safety parameters. Before safety parameters of the equipment for which a password (No. 3225) is set can be modified, the password value must be set as the keyword (No. 3226). Only those persons authorized to conduct a check test should know the password value.

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7.1.2.2

Series start-up
The parameters for the safety monitoring function are transferred together with other parameters to the CNC as in the case of normal series start-up. Perform a safety function check test in addition to the normal start-up procedure.

7.1.3

Troubleshooting
Alarms related to the safety function are output on the ALARM screen. Correct the cause of trouble according to the chapter describing alarms and messages in this manual. When a component related to the safety function is to be replaced, an authorized person must conduct a safety function check test.

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8.MAINTENANCE

MAINTENANCE

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8.MAINTENANCE

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8.1

SAFETY PRECAUTIONS
This section describes the safety precautions related to the use of CNC units. It is essential that these precautions be observed by users to ensure the safe operation of machines equipped with a CNC unit (all descriptions in this section assume this configuration). CNC maintenance involves various dangers. CNC maintenance must be undertaken only by a qualified technician. Users must also observe the safety precautions related to the machine, as described in the relevant manual supplied by the machine tool builder. Before checking the operation of the machine, take time to become familiar with the manuals provided by the machine tool builder and FANUC.

CAUTION Maintenance on a live system requires careful planning, adherence to operating and maintenance procedures, and the appropriate permits and permissions. These matters are the responsibility of the owner/operator of the system and are outside the scope of this document.

TRAINING
FANUC Training Center provides versatile training course for the person who is concerned with hardware and software installation, maintenance and operation. FANUC recommend studying and learning how efficiently operate FANUC products.

QUALIFIED PERSONNEL
Only qualified personnel should be allowed to specify, apply, install, commissioning, operate, maintain, or perform any other function related to the products described in the product manuals. Examples of such qualified persons are defined as follows: System application and design engineers who are familiar with the safety concepts of machine tool. Installation, startup, and service personnel who are trained to install and maintain such machine tool. Operating personnel trained to operate machine tool and trained on the specific safety issues and requirements of the particular equipment.

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MAINTENANCE PARTS TO BE MAINTAINED PERIODICALLY


Memory backup battery replacement

WARNING
When replacing the memory backup batteries, keep the power to the machine (CNC) turned on, and apply an emergency stop to the machine. Because this work is performed with the power on and the cabinet open, only those personnel who have received approved safety and maintenance training may perform this work. When replacing the batteries, be careful not to touch the high-voltage circuits (marked and fitted with an insulating cover). Touching the uncovered high-voltage circuits presents an extremely dangerous electric shock hazard.

NOTE The CNC uses batteries to preserve the contents of its memory, because it must retain data such as programs, offsets, and parameters even while external power is not applied. If the battery voltage drops, a low battery voltage alarm is displayed on the machine operator's panel or CRT screen. When a low battery voltage alarm is displayed, replace the batteries within a week. Otherwise, the contents of the CNC's memory will be lost. To replace the battery, see the procedure described in Section 2.10 of the maintenance manual B63005EN.

WARNINGS RELATED TO CHECK OPERATION


WARNING
1. When checking the operation of the machine with the cover removed (1) The user's clothing could become caught in the spindle or other components, thus presenting a danger of injury. When checking the operation, stand away from the machine to ensure that your clothing does not become tangled in the spindle or other components. (2) When checking the operation, perform idle operation without workpiece. When a workpiece is mounted in the machine, a malfunction could cause the workpiece to be dropped or destroy the tool tip, possibly scattering fragments throughout the area. This presents a serious danger of injury. Therefore, stand in a safe location when checking the operation.

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8.MAINTENANCE
2.

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When checking the machine operation with the power magnetics cabinet door opened. (1) The power magnetics cabinet has a high-voltage section (carrying a mark). Never touch the high-voltage section. The high-voltage section presents a severe risk of electric shock. Before starting any check of the operation, confirm that the cover is mounted on the high-voltage section. When the high-voltage section itself must be checked, note that touching a terminal presents a severe danger of electric shock. (2) Within the power magnetics cabinet, internal units present potentially injurious corners and projections. Be careful when working inside the power magnetics cabinet. Never attempt to machine a workpiece without first checking the operation of the machine. Before starting a production run, ensure that the machine is operating correctly by performing a trial run using, for example, the single block, feedrate override, or machine lock function or by operating the machine with neither a tool nor workpiece mounted. Failure to confirm the correct operation of the machine may result in the machine behaving unexpectedly, possibly causing damage to the workpiece and/or machine itself, or injury to the user. Before operating the machine, thoroughly check the entered data. Operating the machine with incorrectly specified data may result in the machine behaving unexpectedly, possibly causing damage to the workpiece and/or machine itself, or injury to the user. Ensure that the specified feedrate is appropriate for the intended operation. Generally, for each machine, there is a maximum allowable feedrate. The appropriate feedrate varies with the intended operation. Refer to the manual provided with the machine to determine the maximum allowable feedrate. If a machine is run at other than the correct speed, it may behave unexpectedly, possibly causing damage to the workpiece and/or machine itself, or injury to the user.

3.

4.

5.

6. When using a tool compensation function, thoroughly check the direction and amount of compensation. Operating the machine with incorrectly specified data may result in the machine behaving unexpectedly, possibly causing damage to the workpiece and/or machine itself, or injury to the user.

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WARNINGS RELATED TO REPLACEMENT


WARNING
1. Always turn off the power to the CNC and the main power to the power magnetics cabinet. If only the power to the CNC is turned off, power may continue to be supplied to the serve section. In such a case, replacing a unit may damage the unit, while also presenting a danger of electric shock. When a heavy unit is to be replaced, the task must be undertaken by two persons or more. If the replacement is attempted by only one person, the replacement unit could slip and fall, possibly causing injury. After the power is turned off, the servo amplifier and spindle amplifier may retain voltages for a while, such that there is a danger of electric shock even while the amplifier is turned off. Allow at least twenty minutes after turning off the power for these residual voltages to dissipate. When replacing a unit, ensure that the new unit has the same parameter and other settings as the old unit. (For details, refer to the manual provided with the machine.) Otherwise, unpredictable machine movement could damage the workpiece or the machine itself, and present a danger of injury. After replacing a safety related unit such as encoder and I/O module, conduct a check test on the safety related and record the test results in a check report.

2.

3.

4.

5.

WARNINGS RELATED TO PARAMETERS


WARNING
1. When machining a workpiece for the first time after modifying a parameter, close the machine cover. Never use the automatic operation function immediately after such a modification. Instead, confirm normal machine operation by using functions such as the single block function, feedrate override function, and machine lock function, or by operating the machine without mounting a tool and workpiece. If the machine is used before confirming that it operates normally, the machine may move unpredictably, possibly damaging the machine or workpiece, and presenting a risk of injury. The CNC and PMC parameters are set to their optimal values, so that those parameters usually need not be modified. When a parameter must be modified for some reason, ensure that you fully understand the function of that parameter before attempting to modify it. If a parameter is set incorrectly, the machine may move unpredictably, possibly damaging the machine or workpiece, and presenting a risk of injury.
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2.

8.MAINTENANCE

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8.2
8.2.1

ALARMS AND MESSAGES


Overview
Alarms related to the dual check safety function cannot be cancelled by a reset. To cancel the alarms, turn off the power, remove the causes of the alarms, then turn on the power again. For information about emergency stop mode, MCC off Test mode, and safety signal modes A/B/C/D, see Chapter 5.

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8.2.2
No. 364

Servo Alarms
Description The servo control software detected an abnormal data skip in a velocity feedback signal on axis n (axis 1 to axis 8). Replace the pulse coder, or take measures to correct noise on the feedback cable. SERVO ALARM: SV CARD The axis control card is not provided. NOT EXIST This alarm will be issued also if the eight-axis control card dedicated to dual check safety function (5DSP card) is mounted on a machine without the dual check safety function. SERVO ALARM : CARD/SOFT For the axis control card, the correct servo software is not installed in flash MISMATCH memory. When the dual check safety function is used: An incorrect axis control card is mounted. Incorrect servo software is installed in flash memory. Monitor software is not installed in flash memory. Mount the correct axis control card, and install the correct servo software and monitor software in flash memory. SERVO ALARM : n AXIS The CNC detected that the positional deviation during a stop on axis n (axis 1 EXCESS ERR to axis 8) exceeded the setting (parameter No. 1829). Confirm a proper value is set to parameter No. 1829. This alarm can not released by reset function at dual check safety. SERVO ALARM : n AXIS The CNC detected that the positional deviation during movement on axis n EXCESS ERR (axis 1 to axis 8) exceeded the setting in parameter No. 1828 (parameter No. 1838 when the safety signal mode C (state where a guard open request is input, and the guard is open) is set with the dual check safety function). Confirm a proper value is set to parameter No. 1828 or No. 1838. This alarm can not released by reset function at dual check safety. n AXIS:SPC SOFT The servo control software detected an alpha pulse coder signal error on axis DISCONNECT ALARM n (axis 1 to axis 8). Replace the alpha pulse coder. n AXIS:ILLEGAL RAM (MNT) An error occurred in a monitor RAM check. Replace the axis control card. n AXIS:SPC SOFT The monitor detected an alpha pulse coder signal error on axis n (axis 1 to DISCONNECT (MNT) axis 8). Replace the pulse coder. n AXIS:SOFT PHASE The monitor detected an abnormal data skip in a velocity feedback signal on ALARM(INT/MNT) axis n (axis 1 to axis 8). Replace the pulse coder, or take measures to correct noise on the feedback cable. n AXIS:EXCESS ERROR The monitor detected that the positional deviation during a stop on axis n (axis (STOP:MNT) 1 to axis 8) exceeded the setting (parameter No. 1829) in safety signal mode C (state in which a guard open request is input, and the guard is open). Confirm a proper value is set to parameter No. 1829. n AXIS:EXCESS ERROR The monitor detected that the positional deviation during movement on axis n (MOVE:MNT) (axis 1 to axis 8) exceeded the setting (parameter No. 1838) in safety signal mode C (state in which a guard open request is input, and the guard is open). Confirm a proper value is set to parameter No. 1838. Meaning n AXIS: SOFT PHASE ALARM(INT)

402

403

410

411

453

470 471

473

474

475

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8.MAINTENANCE
No. 476

B-63494EN/01

477

478

479

480

481

482

483

Meaning Description n AXIS:ILLEGAL SPEED CMD. The monitor detected that the specified speed on axis n (axis 1 to axis 8) (MNT) exceeded the safe speed (parameter No. 1942) in safety signal mode C (state in which a guard open request is input, and the guard is open). When the guard is open, confirm a proper value is set to parameter No. 1942, and the operation is done within the safe speed. If an alarm is issued in safety signal mode C, the movement of the machine immediately stops, and a pulse for adjusting the coordinates is generated. Accordingly, this alarm can be issued. n AXIS:ILLEGAL MACHINE The monitor detected that the machine position on axis n (axis 1 to axis 8) is POS.(MNT) not in the safety area (parameter No. 1943 and No. 1944) in safety signal mode C (state in which a guard open request is input, and the guard is open). When the guard is open, confirm proper values is set to parameter No. 1943 and No. 1944, and operation is done in the safety area. A machine position check is carried out just on a linear axis on which the reference position has already been established. No machine position check is made on a rotation axis or a linear axis on which the reference position has not yet been established. n AXIS:ILLEGAL AXIS DATA The monitor detected that an error occurred on axis n (axis 1 to axis 8) during (MNT) axis data transfer. If the alarm occurs after performing axis number setting for the servo amplifier, set parameter No.2212#4 to 1, and reset the bit to 0, and then turn off the power of the entire system. In the other case, replace the servo amplifier the alarm occurred. ILLEGAL SAFETY DI (MNT) The monitor detected a mismatch exceeding the set time (parameter No. 1945) between a safety input signal via the PMC and the same signal via the FSSB. Check the safety input signals via the PMC and via the FSSB are equal. n AXIS:ILLEGAL SAFETY The monitor detected that safety signal mode D (state in which the guard is MODE (MNT) open although no guard open request is input) was set, or the guard is open when guard unlock signal (*LGD) is not output. In the former, the alarm is issued for all axes. In the latter, the alarm is issued only for the first servo axis (axis for which parameter No.1023 is set to 1 or, for tool post 2 under two-CPU two-path control or two-CPU three-path control, an axis for which parameter No.1023 is set to 9). Check if the guard state signal(SGD) is correctly connected. If an alarm is issued in safety mode C (state in which a guard open request is input and the guard is open), guard unlocking is disabled. Accordingly, this alarm may be issued. n AXIS:SAFETY PARAM The monitor detected that a safety parameter error occurred with axis n (axis ERROR (MNT) 1 to axis 8). Set the safety parameters again. Relative parameters are as follows. No.1023, No.1829, No.1838, No.1942, No.1943, No.1944, No.1945, No.1947, No.1948, No.1950 n AXIS:AXIS NUMBER NOT The monitor detected that the axis number of axis n (axis 1 to axis 8) is not set SET (MNT) with the servo amplifier. Turn off the power of the entire system. Then an axis number is automatically set. MONITOR SAFETY An error occurred in safety functions of monitor: FUNCTION ERROR 1 Monitor or CNC detected the inexecution of monitor safety functions. 2 A mismatch between the monitor results of the safety functions and the servo software or CNC results of them occurred. 3 An error occurred in a monitor CPU test. Replace the axis control card.

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8.MAINTENANCE

No. 484

486

487

488 489

490

491 492

494

Description An error occurred in safety functions of servo software: 1 Servo software or CNC detected the inexecution of servo software safety functions. 2 A mismatch between the servo software results of the safety functions and the monitor results of them occurred. 3 An error occurred in a servo RAM test. 4 An error occurred in a servo CPU test. Replace the axis control card. ILLEGAL SAFETY DI (CNC) The CNC detected a mismatch exceeding the set time (parameter No. 1945) between a safety input signal input via the PMC and the same signal input via the FSSB. Check the safety input signals via the PMC and via the FSSB are equal. ILLEGAL SAFETY MODE The CNC detected that safety signal mode D (state in which the guard is open (CNC) although no guard open request is input) was set, or the guard is open when guard unlock signal (*LGD) is not output. Check if the guard state signal(SGD) is correctly connected. If an alarm is issued in safety mode C (state in which a guard open request is input and the guard is open), guard unlocking is disabled. Accordingly, this alarm may be issued. SAFE TEST OVER TIME A MCC off Test was not completed within the set time (parameter No. 1946). Check the MCC contact. SAFETY PARAM ERROR The CNC detected a safety parameter error. (CNC) Set the safety parameters again. Relative parameters are as follows. No.1023, No.1829, No.1838, No.1904, No.1942, No.1943, No.1944, No.1945, No.1946, No.1947, No.1948, No.1950, No.4372 CNC SAFETY FUNCTION An error occurred in safety functions of CNC: ERROR 1 CNC or monitor detected the inexecution of CNC safety functions. 2 A mismatch between the CNC results of the safety functions and the monitor or spindle results of them occurred. 3 An error occurred in a CNC RAM test. 4 An error occurred in a CNC CPU test. 5 Test at power-up was not executed. Replace the CPU card. LOCAL BUS TEST ERROR An error occurred in a local bus test. The mother board may be faulty. Replace the mother board. F-BUS TEST ERROR An error occurred in an F-BUS test. The mother board or option board may be faulty. The F-BUS test is carried out if a sub-CPU board or loader board is used. n AXIS:ILLEGAL SPEED CMD. The CNC detected that the specified speed on axis n (axis 1 to axis 8) (CNC) exceeded the setting (parameter No. 1942) in safety signal mode C (state in which a guard open request is input, and the guard is open). When the guard is open, confirm a proper value is set to parameter No. 1942, and the operation is done within the safe speed. If an alarm is issued in safety signal mode C, the movement of the machine immediately stops, and a pulse for adjusting the coordinates is generated. Accordingly, this alarm can be issued.

Meaning n AXIS:SERVO SAFETY FUNCTION ERR

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8.MAINTENANCE
No. 495 Meaning n AXIS:ILLEGAL MACHINE POS.(CNC)

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496

n AXIS:ILLEGAL AXIS DATA (CNC)

497 498

n AXIS:SAFETY PARAM TRANS ERROR n AXIS:AXIS NUMBER NOT SET (CNC)

Description The CNC detected that the machine position on axis n (axis 1 to axis 8) is not in the safety area (parameter No. 1943 and No. 1944) in safety signal mode C (state in which a guard open request is input, and the guard is open). When the guard is open, confirm proper values is set to parameter No. 1943 and No. 1944, and operation is done in the safety area. A machine position check is carried out just on a linear axis on which the reference position has already been established. No machine position check is made on a rotation axis or a linear axis on which the reference position has not yet been established. The CNC detected that an error occurred on axis n (axis 1 to axis 8) during axis data transfer. If the alarm occurs after performing axis number setting for the servo amplifier, set parameter No.2212#4 to 1, and reset the bit to 0, and then turn off the power of the entire system. In the other case, replace the servo amplifier the alarm occurred. A safety parameter transfer error occurred on axis n (axis 1 to axis 8). Replace the CPU card or the axis control card. The CNC detected that the axis number of axis n (axis 1 to axis 8) is not set with the servo amplifier. Turn off the power of the entire system. Then an axis number is automatically set.

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8.MAINTENANCE

8.2.3

Serial Spindle Alarms


Description It is serial communication error while system is executing after power supply on. Check optical cable connection between main CPU board and spindle amplifier printed board. Replace optical cable, main CPU board, option 2 board or spindle amplifier printed board. If this alarm occurs when CNC power supply is turned on or when this alarm can not be cleared even if CNC is reset, turn off the power supply also turn off the power supply in spindle side. An error occurred in any spindle safety functions on the first spindle. 1 CNC detected that some spindle safety functions were not executed. 2 A safety parameter transfer error occurred. Replace the CPU card or spindle amplifier module. For the first spindle, the CNC detected a mismatch between the spindle amplifier connection state and spindle amplifier hardware setting. Check the spindle amplifier connection state and spindle amplifier hardware setting. Replace the CPU card or spindle amplifier module. If this alarm is issued because the spindle amplifier configuration is changed, correct the setting on the spindle amplifier side. For the first spindle, the CNC detected that the speed of the spindle motor exceeded the safe speed (parameter No. 4372) in safety signal mode C (state in which a guard open request is input, and the guard is open). Alternatively, for the first spindle, the CNC detected a mismatch between the CNC and spindle software, as to which of the speed of the spindle motor and the safe speed (parameter No. 4372) is greater. When the guard is open, perform operation at a speed not exceeding the safe speed. Check the safe speed parameter(parameter No.4372). Replace the CPU card or spindle amplifier module. Same as alarm No. 755. (For the second spindle) Same as alarm No. 756. (For the second spindle) Same as alarm No. 757. (For the second spindle) See the description of AL-16 in Subsection 8.2.4. (For the n-th spindle) See the description of AL-69 in Subsection 8.2.4. (For the n-th spindle) See the description of AL-70 in Subsection 8.2.4. (For the n-th spindle) See the description of AL-71 in Subsection 8.2.4. (For the n-th spindle) See the description of AL-72 in Subsection 8.2.4. (For the n-th spindle) See the description of AL-74 in Subsection 8.2.4. (For the n-th spindle) See the description of AL-76 in Subsection 8.2.4. (For the n-th spindle) See the description of AL-77 in Subsection 8.2.4. (For the n-th spindle) See the description of AL-78 in Subsection 8.2.4. (For the n-th spindle)

No. Meaning 749 S-SPINDLE LSI ERROR

755 SPINDLE-1 SAFETY FUNCTION ERROR

756 SPINDLE-1 ILLEGAL AXIS DATA

757 SPINDLE-1 SAFETY SPEED OVER

765 SPINDLE-2 SAFETY FUNCTION ERROR 766 SPINDLE-2 ILLEGAL AXIS DATA 767 SPINDLE-2 SAFETY SPEED OVER 7n16 SPN n :S-SPINDLE ERROR (AL-16) 7n69 SPN n :S-SPINDLE ERROR (AL-69) 7n70 SPN n :S-SPINDLE ERROR (AL-69) 7n71 SPN n :S-SPINDLE ERROR (AL-71) 7n72 SPN n :S-SPINDLE ERROR (AL-72) 7n74 SPN n :S-SPINDLE ERROR (AL-74) 7n76 SPN n :S-SPINDLE ERROR (AL-76) 7n77 SPN n :S-SPINDLE ERROR (AL-77) 7n78 SPN n :S-SPINDLE ERROR (AL-78)

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8.MAINTENANCE

B-63494EN/01

8.2.4

Alarms Displayed on the Spindle Unit


Description An error occurred in a spindle RAM test. Replace spindle amplifier module. The spindle software detected that the speed of the spindle motor exceeded the safe speed (parameter No. 4372) in safety signal mode C (state in which a guard open request is input, and the guard is open). When the guard is open, perform operation at a speed not exceeding the safe speed. Check the safe speed parameter(parameter No.4372). Replace spindle amplifier module. The spindle software detected a mismatch between the spindle amplifier connection state and spindle amplifier hardware setting. If this alarm is issued because the spindle amplifier configuration is changed, correct the setting on the spindle amplifier side. Check the spindle amplifier connection state and spindle amplifier hardware setting. Replace the CPU card or spindle amplifier module. If this alarm is issued because the spindle amplifier configuration is changed, correct the setting on the spindle amplifier side. The spindle software detected a safety parameter error. Set the safety parameter again. Replace the CPU card or spindle amplifier module. Relative parameters are as follows. No.4372 The spindle software detected a mismatch between the CNC result of the motor speed check and the spindle result of it. Replace the CPU card or spindle amplifier module. An error occurred in a spindle amplifier CPU test. Replace spindle amplifier module. An error occurred in a spindle ROM CRC test. Replace spindle amplifier module. Any safety function was not executed. Replace spindle amplifier module. The spindle software detected a mismatch between the CNC result of the axis number check and the spindle result of it. Replace the CPU card or spindle amplifier module. The spindle software detected a mismatch between the CNC result of the safety parameters check and the spindle result of it. Replace the CPU card or spindle amplifier module. The safety functions at power-up for spindle were not executed. Replace the spindle amplifier. Replace spindle amplifier module.

No. Meaning AL-16 RAM Alarm AL-69 Safety speed over

AL-70 Illegal axis data

AL-71 Safety parameter error

AL-72 Mismatch the results of motor speed check AL-74 CPU test alarm AL-75 CRC alarm AL-76 Inexecution of safety functions AL-77 Mismatch the results of axis number check AL-78 Mismatch the results of safety parameters check AL-79 Inexecution of safety functions at power-up

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8.MAINTENANCE

8.2.5

System Alarms
Description Parity error of the CNC, macro, or servo ROM. When the dual check safety function is used: 1 Parity error of the CNC, macro, or servo ROM 2 CRC error of the CNC, servo, or monitor ROM Reinstall the indicated ROM in flash memory. Servo alarm (first to fourth axis). A watchdog alarm condition occurred, or a RAM parity error occurred in the axis control card. In the dual check safety function with 4-axes control card, servo alarm (first/second axis, or monitor). Replace the axis control card. Servo alarm (fifth to eighth axis). A watchdog alarm condition occurred, or a RAM parity error occurred in the axis control card. In the dual check safety function with 6-axes control card, servo alarm (monitor). In the dual check safety function with 8-axes control card, servo alarm (fifth/sixth axis, or monitor). If the 8-axes control card dedicated to dual check safety function (5DSP card) is used with the dual check safety function, a servo alarm (fifth to eight axis) is issued. Replace the axis control card. An NMI of an unknown cause occurred. If the 8-axes control card dedicated to dual check safety function (5DSP card) is used with the dual check safety function, this alarm is issued, even when a servo alarm (monitor) is issued.

No. Meaning 900 ROM PARITY

920 SERVO ALARM (1-4 AXIS)

921 SERVO ALARM (5-8 AXIS)

973 NON MASK INTERRUPT

8.2.6

Boot System Alarms


Message Description Parity error of the CNC basic ROM. When the dual check safety function is used: 1. Parity error of the CNC basic ROM 2. CRC error of the CNC basic ROM Reinstall the CNC basic ROM in flash memory.

ROM PARITY ERROR: NC BASIC. HIT SELECT.

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9.DIAGNOSIS

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DIAGNOSIS

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9.DIAGNOSIS

9.1

OVERVIEW
The information of safety signal mode and safety input signal of the dual check safety function is displayed. For information about emergency stop mode, MCC off Test mode, and safety signal modes A/B/C/D, see Chapter 5.

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9.DIAGNOSIS

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9.2

DIAGNOSIS
#7 Diagnosis No. 376 #6 FMC #5 FGL #4 FGD #3 #2 #1 #0

FGD FGL FMC

The current states of safety signals input via the FSSB are displayed. The state of the guard state signal (SGD2) is displayed. The state of the guard lock state signal (GDL2) is displayed. The state of the MCC contact state signal (*SMC2) is displayed.
#7 #6 PMC #5 PGL #4 PGD #3 PRQ #2 PTS #1 #0

Diagnosis No. 377

PTS PRQ PGD PGL PMC

The current states of safety signals input via the PMC are displayed. The state of the test mode signal (OPT) is displayed. The state of the guard open request signal (ORQ) is displayed. The state of the guard state signal (SGD1) is displayed. The state of the guard lock state signal (GDL1) is displayed. The state of the MCC contact state signal (*SMC1) is displayed.
#7 #6 TST #5 #4 #3 MDD #2 MDC #1 MDB #0 MDA

Diagnosis No. 378

ESP

MDA MDB MDC MDD TST ESP


Diagnosis No. 379

The current safety signal mode is displayed. Safety signal mode A Safety signal mode B Safety signal mode C Safety signal mode D MCC off test mode Emergency stop mode
Test number of MCC off test

The test number of the MCC off test is displayed. Zero is displayed if the system is not in the MCC off test mode. After the MCC off test mode is selected by the input of the test mode signal (OPT), the test number increases by 1 from 0 as the MCC off test proceeds. When the MCC off test is completed, the test number is 128. When the test mode signal (OPT) is set to 0 to clear the MCC off test mode, the test number is cleared to 0.

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10.SAMPLE SYSTEM CONFIGURATION

10

SAMPLE SYSTEM CONFIGURATION

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10.SAMPLE SYSTEM CONFIGURATION

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10.1
10.1.1

SAMPLE CONFIGURATION
For One-path

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10.SAMPLE SYSTEM CONFIGURATION

10.1.2

For Two-path (When the main side and sub side use a common MCC)

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10.SAMPLE SYSTEM CONFIGURATION

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10.1.3

For Two-path (When the main side and sub side use independent MCCs and protection doors)

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10.SAMPLE SYSTEM CONFIGURATION

10.2
10.2.1

SAMPLE CONNECTIONS
Emergency Stop Signal (*ESP1, *ESP2)
+24V I/O-Link I/O UNIT *ESP1 (X008#4)

FSSB I/O UNIT *ESP2 (DI+000#0)

0V

PSM CX4 ESP

NOTES
Use a two-contact emergency stop button with a forced dissociation mechanism. Connect the emergency stop button to the PSM, as illustrated in the figure. When the signal is input, the spindle slows down and stops. Input a power-down factor to [G008#4] other than the signal from the emergency stop button. Create a Ladder program so that [X008#4] becomes a factor of [G008#4].
Machine side I/O-Link I/O UNIT PMC Emergency stop factor Emergency stop button
Emergency stop factor other than emergency stop button

X008#4 Ladder program

X00n#n

*ESPG (G008#4)

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10.SAMPLE SYSTEM CONFIGURATION

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10.2.2

Guard Open Request Signal (ORQ)


+24V Guard open request button I/O-Link I/O UNIT X00n#n PMC Ladder program

ORQ (G191#3)

NOTES
Create a Ladder program of conditions for making a guard open request and then input the program to the PMC side [G191#3]. When the guard open request signal (ORQ) is input and when CNC safety has been confirmed, the guard unlock signal (*LGD) is output. If the CNC is not safe, ORQ input will not result in output of *LGD. If the input of ORQ is canceled while the guard is open, the CNC enters a safely stopped status (state in which the guard is open although the guard open request signal is not input). Close the guard (SGD is set to 1), then cancel this signal.

10.2.3

Test Mode Signal (OPT)


Test start button
+24V

I/O-Link I/O UNIT PMC


X00n#n Ladder program

OPT (G191#2)

NOTES
Create a Ladder program for performing a MCC off Test, then input the program to the PMC side [G191#2].

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10.SAMPLE SYSTEM CONFIGURATION

10.2.4

Guard Unlock Signal (*LGD), Guard Lock State Signal (GDL), Guard State Signal (SGD)

+24V

Guard closed SW1 SW2

Guard-monitoring limit switch SW3

Safety relay RY1 RY1 RY3 RY2 RY2 RY3 0V RY3 RY1 RY2 0V

[Sample control components] SW1/SW2: Guard state monitoring switch with forced dissociation mechanism SW3: Guard lock switch RY1, RY2, RY3: Safety relay

I/O Link I/O UNIT X00n#n

PMC SGD (G191#4) *LGD (F191#0)

Y00n#n

Ladder program

FSSB I/O UNIT SGD (DI+001#4)

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10.SAMPLE SYSTEM CONFIGURATION

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OPERATING PRINCIPLE
This section describes the operation of various guard monitoring limit switches with lock mechanism and safety relays. State transition of components
SW1 1 2 3 Guard closed Guard locked Guard closed Guard unlocked Guard opened Guard unlocked CLOSE CLOSE OPEN SW2 CLOSE CLOSE OPEN SW3 CLOSE OPEN OPEN RY1 ON OFF OFF RY2 ON ON OFF RY3 OFF OFF ON SGD 1 0 0

In a normal operation, the transition of 1, 2, 3, 1, 2, and so on is repeated. RY3 detects whether RY1 and RY2 contacts are made. If an unusual event is detected, SGD input is turned off.

NOTES
This example does not use the guard lock state signal (GDL). If GDL is not used, as in this example, tie [G191#5] and [DI+001#5] to 1. The guard state is monitored, and the guard state signal (SGD) affects the dual check safety function. The guard lock state signal (GDL) only indicates whether an input mismatch is found. The state of the GDL signal does not affect the dual check safety function. The illustrated sample system determines that the guard is open (sets SGD to 0) when the guard is unlocked. When the guard open request signal (ORQ) is accepted and when it has been confirmed that the CNC is in a safe state, the guard unlock signal (*LGD) is output. Based on this signal, use a Ladder program to create a guard unlock signal.

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10.SAMPLE SYSTEM CONFIGURATION

10.2.5

MCC On Enable Signal (MCF), MCC Contact State Signal (*SMC)

+24V

I/O Link I/O UNIT X00n#n

PMC *SMC1 (G191#6)

Y00n#n 0V FSSB I/O UNIT *SMC2 (DI+001#6) MCF (DO+000#1) 0V PSM 200A 200B CX3 MCC

MCF1 (F191#1)

U V W Electromagnetic contactor (MAIN MCC)

NOTES
With the MCF signal of the PMC side, allocate [F191#1] to generalpurpose output. On the FSSB side, directly connect [DO+000#1]. Also connect MCF to PSM, as illustrated in the figure. If an error occurs in the PSM, the PSM turns off the MCC.

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11.COMPONENTS LIST

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11

COMPONENTS LIST

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11.COMPONENTS LIST

11.1
11.1.1
No. 1 2 3 4 5 6

HARDWARE COMPONENTS
Hardware Components for Series 16i/18i/21i/160i/180i/210i/160is/180is/210is-MODEL A
Description Specification number Of primary component A20B-8100-0130 A20B-3300-0170 A17B-3300-0200 A20B-3900-0131 A20B-3900-0060 A20B-3900-0011 Specification number of secondary component A20B-8100-013X A20B-8100-014X A20B-8100-054X A20B-3300-0050 A20B-3300-0070 A20B-3300-0260 A20B-3300-012X A20B-3300-020X A20B-3300-024X A20B-3900-003X A20B-3900-004X A20B-3900-013X A20B-3900-005X A20B-3900-006X A20B-3900-002X A20B-3900-001X A20B-3900-007X Remarks

Main board CPU card Servo card DRAM MODULE SRAM MODULE FROM MODULE

11.1.2
No. 1 2 3 4 5 6 7

Hardware Components for Series 16i/18i/21i/160i/180i/210i/160is/180is/210is-MODEL B


Description Specification number Of primary component A20B-8100-0660 A20B-3300-0311 A20B-3300-0244 A17B-3300-0500 A20B-3900-0160 A20B-8100-0720 A20B-8002-0190 A20B-8100-0830 Specification number of secondary component A20B-8100-066X A16B-3200-042X A20B-8100-079X A20B-3300-031X A20B-3300-029X A20B-3300-024X A20B-3900-016X A20B-3900-018X A20B-8100-0851 A16B-2203-0751 A16B-2203-0740 Remarks

Main board CPU card Servo card FROM/SRAM MODULE Power supply module Sub CPU board Loader control board

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11.COMPONENTS LIST

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11.1.3
No. 1 2

Hardware Components for Other Units


Description Specification number Of primary component A20B-2100-0270 Specification number of secondary component Remarks

FSSB ADDITIONAL DETECTOR INTERFACE I/O module

3 4 5

I/O Unit base module I/O Unit interface module DC digital input module

A20B-9001-0020 A20B-8000-0410 A20B-9000-0901 A20B-9000-0902

DC digital output module

A20B-9000-0921

7 8 9 10 11

DC digital input/output module AC digital input module AC digital output module Relay output module FSSB I/O module A20B-2100-0390

A20B-2100-0150 A20B-2100-0410 A20B-2100-0411 A20B-2002-0470 A20B-2002-0521 A20B-9001-0040 A20B-2000-0510 A20B-8000-0420 A20B-8000-0820 A20B-9000-0970 A20B-9001-0011 A20B-9001-0281 A20B-9000-0972 A20B-9001-0490 A20B-9001-0220 A20B-8000-0440 A20B-9001-0490 A20B-8000-0741 A20B-9001-0681 A20B-8000-0780 A20B-8000-0750 A20B-8000-0730 A20B-8000-0341 A20B-8000-0470 A20B-8000-0321 A20B-9001-0200 A20B-8000-0500

A20B-2002-0400 A20B-2002-0401 A20B-2100-0320 A20B-2002-0520 A20B-2000-0550 A20B-8000-0710 A20B-9000-0971 A20B-9001-0010 A20B-8000-0341 A20B-9001-0280 A20B-8000-0510 A20B-8002-0070 A20B-8000-0510 A20B-8000-0740 A20B-9001-0680 A20B-8000-0760 A20B-8000-0751 A20B-8000-0731 A20B-9001-0940 A20B-8000-0480 A20B-8000-0880 A20B-8000-0101

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11.COMPONENTS LIST

11.2

SOFTWARE COMPONENTS
[i series MODEL A CNC software]
Series / Version FS16i-TA FS160i-TA FS160is-TA FS18i-TA FS180i-TA FS180is-TA FS21i-TA FS210i-TA FS210is-TA FS20i-TA FS16i-MA FS160i-MA FS160is-MA FS18i-MA FS180i-MA FS180is-MA FS21i-MA FS210i-MA FS210is-MA FS20i-FA B1F2 B1F4 BEF2 BEF4 DEF2 DEF4 D1F1 B0F2 B0F4 BDF2 BDF4 DDF2 DDF4 D0F1 Functions CNC functions for lathe with up to 8 servo axes and up to 2 spindle axes. CNC functions for lathe with up to 6 servo axes and up to 2 spindle axes. CNC functions for lathe with up to 4 servo axes and up to 2 spindle axes. CNC functions for manual lathe with up to 2 servo axes and up to 1 spindle axis CNC functions for machining center with up to 8 servo axes and up to 2 spindle axes. CNC functions for machining center with up to 6 servo axes and up to 2 spindle axes. CNC functions for machining center with up to 4 servo axes and up to 2 spindle axes. CNC functions for manual milling machine with up to 4 servo axes and up to 1 spindle axis.

[i series MODEL B CNC software]


Series / Version FS16i-TB FS160i-TB FS160is-TB FS18i-TB FS180i-TB FS180is-TB FS21i-TB FS210i-TB FS210is-TB FS16i-MB FS160i-MB FS160is-MB FS18i-MB5 FS180i-MB5 FS180is-MB5 FS18i-MB FS180i-MB FS180is-MB FS21i-MB FS210i-MB FS210is-MB B1H1 Functions CNC functions for lathe with up to 8 servo axes and up to 2 spindle axes. CNC functions for lathe with up to 6 servo axes and up to 2 spindle axes. CNC functions for lathe with up to 4 servo axes and up to 2 spindle axes. CNC functions for machining center with up to 8 servo axes and up to 2 spindle axes. CNC functions for machining center with up to 6 servo axes and up to 2 spindle axes. Simultaneously controlled axes : max 5 axes CNC functions for machining center with up to 6 servo axes and up to 2 spindle axes. Simultaneously controlled axes : max 4 axes CNC functions for machining center with up to 4 servo axes and up to 2 spindle axes.

BEH1

DEH1

B0H1

BDH5

BDH1

DDH1

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11.COMPONENTS LIST
[Monitor software]
Series / Version Monitor Monitor 90A9 / 03 90B9 / 01 Functions

B-63494EN/01

Monitor functions Monitor functions

[Servo control software]


Series / Version Servo Servo Servo 90A5 / 01 90B0 / 09 90B7 / 04 Functions Servo functions Servo functions Learning control

[Spindle software]
Series / Version Spindle Spindle 9D20 / 10 9D50 / 04 Functions Spindle functions Spindle functions

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B-63494EN/01

11.COMPONENTS LIST

11.3
No. 1

SERVO AMPLIFIER
Module Name PSM-5.5 PSM-11 PSM-15 PSM-26 PSM-30 PSM-37 PSM-45 PSM-55 PSM-5.5i PSM-11i PSM-15i PSM-26i PSM-30i PSM-37i PSMR-1 PSMR-3 PSMR-5.5 SVM1-2 SVM1-4 SVM1-12 SVM1-20 SVM1-40S SVM1-40L SVM1-80 SVM1-130 SVM1-130S SVM1-240 SVM1-360 SVM1-20i SVM1-40i SVM1-80i SVM-160i SVM1-360i SVM2-12/12 SVM2-12/20 SVM2-20/20 SVM2-12/40 SVM2-20/40 SVM2-40/40 SVM2-40/80 SVM2-80/80 SVM2-40L/40L SVM2-4/4i SVM2-20/20i SVM2-20/40i SVM2-40/40i SVM2-40/80i Specification number A06B-6077-H106 A06B-6077-H111 A06B-6087-H115 A06B-6087-H126 A06B-6087-H130 A06B-6087-H137 A06B-6087-H145 A06B-6087-H155 A06B-6110-H006 A06B-6110-H011 A06B-6110-H015 A06B-6110-H026 A06B-6110-H030 A06B-6110-H037 A06B-6081-H101 A06B-6081-H103 A06B-6081-H106 A06B-6096-H121 A06B-6096-H122 A06B-6096-H101 A06B-6096-H102 A06B-6096-H103 A06B-6096-H104 A06B-6096-H105 A06B-6096-H106 A06B-6096-H116 A06B-6096-H107 A06B-6096-H108 A06B-6114-H103 A06B-6114-H104 A06B-6114-H105 A06B-6114-H106 A06B-6114-H109 A06B-6096-H201 A06B-6096-H202 A06B-6096-H203 A06B-6096-H204 A06B-6096-H205 A06B-6096-H206 A06B-6096-H207 A06B-6096-H208 A06B-6096-H209 A06B-6114-H201 A06B-6114-H205 A06B-6114-H206 A06B-6114-H207 A06B-6114-H208 Remarks

Description Power Supply Module (Standard)

Power Supply Module (Resister Discharge type) Servo Amplifier Module (1 axis type)

Servo Amplifier Module (2 axes type)

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11.COMPONENTS LIST
No. 4 Description Servo Amplifier Module (2 axes type) Servo Amplifier Module (3 axes type) Module Name SVM2-80/80i SVM2-80/160i SVM2-160/160i SVM3-12/12/12 SVM3-12/12/20 SVM3-12/20/20 SVM3-20/20/20 SVM3-12/12/40 SVM3-12/20/40 SVM3-20/20/40 SVM3-4/4/4i SVM3-20/20/20i SVM3-20/20/40i SPM-2.2-1 SPM-5.5-1 SPM-11-1 SPM-15-1 SPM-22-1 SPM-26-1 SPM-30-1 SPM-45-1 SPM-55-1 SPM-2.2-4 SPM-5.5-4 SPM-11-4 SPM-15-4 SPM-22-4 SPM-26-4 SPM-30-4 SPM-45-4 SPM-55-4 SPM-2.2i SPM-5.5i SPM-11i SPM-15i SPM-22i SPM-26i SPM-30i SPM-2.2i SPM-5.5i SPM-11i SPM-15i SPM-22i SPM-26i SPM-30i Specification number A06B-6114-H209 A06B-6114-H210 A06B-6114-H211 A06B-6096-H301 A06B-6096-H302 A06B-6096-H303 A06B-6096-H304 A06B-6096-H305 A06B-6096-H306 A06B-6096-H307 A06B-6114-H301 A06B-6114-H303 A06B-6114-H304 A06B-6102-H202#H520 A06B-6102-H206#H520 A06B-6102-H211#H520 A06B-6102-H215#H520 A06B-6102-H222#H520 A06B-6102-H226#H520 A06B-6102-H230#H520 A06B-6102-H245#H520 A06B-6102-H255#H520 A06B-6102-H102#H520 A06B-6102-H106#H520 A06B-6102-H111#H520 A06B-6102-H115#H520 A06B-6102-H122#H520 A06B-6102-H126#H520 A06B-6102-H130#H520 A06B-6102-H145#H520 A06B-6102-H155#H520 A06B-6111-H002#H550 A06B-6111-H006#H550 A06B-6111-H011#H550 A06B-6111-H015#H550 A06B-6111-H022#H550 A06B-6111-H026#H550 A06B-6111-H030#H550 A06B-6112-H002#H550 A06B-6112-H006#H550 A06B-6112-H011#H550 A06B-6112-H015#H550 A06B-6112-H022#H550 A06B-6112-H026#H550 A06B-6112-H030#H550

B-63494EN/01

Remarks

Spindle Amplifier Module (SPM HRV Type I )

Spindle Amplifier Module (SPM HRV Type IV )

Spindle Amplifier Module (SPM HRV Type A )

Spindle Amplifier Module (SPM HRV Type B )

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B-63494EN/01

INDEX

INDEX
A
ALARMS AND MESSAGES ............................ 86 Alarms Displayed on the Spindle Unit ........... 92 APPLICATION RANGE................................... 17 For Two-path..................................................... 37 For Two-path (When the main side and sub side use a common MCC) ..................................... 99 For Two-path (When the main side and sub side use independent MCCs and protection doors) ...................................................................... 100 FSSB I/O Attachment....................................... 43 FSSB I/O Connection........................................ 41 FSSB I/O Specification List.............................. 47 FUNCTIONS THAT REQUIRE SPECIAL PARAMETER SETTINGS............................ 74

B
BASIC PRINCIPLE OF DUAL CHECK SAFETY........................................................... 6 BEFORE USING THE SAFETY FUNCTION 20 Boot System Alarms ......................................... 93

C
Certification Test ................................................ 4 Compliance with the Safety Standard (EN954-1, Category 3) ...................................................... 7 COMPONENTS LIST..................................... 106

G
General Definition of Terms .............................. 5 GENERAL INFORMATION ............................ 12 Guard lock state signal..................................... 52 Guard open request signal ............................... 52 Guard Open Request Signal (ORQ) ............... 102 Guard state signal ............................................ 52 Guard unlock signal.......................................... 53 Guard Unlock Signal (*LGD), Guard Lock State Signal (GDL), Guard State Signal (SGD).. 103

D
DEFINITION OF TERMS ................................. 5 Definition of Terms Related to the Safety Function .......................................................... 5 DI/DO CONNECTION (VIA THE FSSB) ....... 41 DI/DO CONNECTION (VIA THE PMC)......... 40 DIAGNOSIS................................................ 94, 96 DIRECTIVE AND STANDARDS ...................... 3 Directives ............................................................ 3

H
HARDWARE COMPONENTS....................... 107 Hardware Components for Other Units........ 108 Hardware Components for Series 16i/18i/21i/160i/180i/210i/160is/180is/210isMODEL A .................................................... 107 Hardware Components for Series 16i/18i/21i/160i/180i/210i/160is/180is/210isMODEL B .................................................... 107

E
EMERGENCY STOP........................................ 29 Emergency stop signal ..................................... 50 Emergency Stop Signal (*ESP1, *ESP2)....... 101 Error analysis ................................................... 10 ety monitoring cycle and cross-check cycle ....... 9

I
I/O SIGNALS .................................................... 48 Important Items to Check Before Using the Safety Function ............................................. 20

F
Features of Dual Check Safety .......................... 6 For One-path............................................... 35, 98

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11.COMPONENTS LIST
Initial start-up .................................................. 78 INSTALLATION............................................... 33

B-63494EN/01

SAFE SPEED MONITORING ......................... 30 SAFETY FUNCTIONS..................................... 16 SAFETY I/O MONITORING............................ 24 SAFETY PRECAUTIONS ............................ 1, 82 Safety Signal Modes ......................................... 56 SAMPLE CONFIGURATION .......................... 98 SAMPLE CONNECTIONS ............................ 101 SAMPLE SYSTEM CONFIGURATION ......... 97 Serial Spindle Alarms....................................... 91 Series start-up................................................... 80 Servo Alarms..................................................... 87 SERVO AMPLIFIER ...................................... 111 Signal Addresses............................................... 55 SIGNALS........................................................... 50 Simple Electronic Gearbox and Two Groups of Electronic Gearboxes .................................... 74 SOFTWARE COMPONENTS ........................ 109 START-UP......................................................... 75 Start-up of the Safety Function ....................... 78 START-UP OPERATION ................................. 76 STOP.................................................................. 21 Stop States ........................................................ 22 Stopping the Servo Motor................................. 22 Stopping the Spindle Motor ............................. 21 System Alarms .................................................. 93 SYSTEM CONFIGURATION .......................... 14

L
Latent error detection and cross-check ............. 8 Loader Control .................................................. 61

M
MAINTENANCE .............................................. 81 MCC contact state signal ................................. 53 MCC off Test ....................................................... 9 MCC OFF TEST ............................................... 32 MCC off Test execution request signal............ 54 MCC off Test of the Safe Stop Function.......... 20 MCC On Enable Signal (MCF), MCC Contact State Signal (*SMC) ................................... 105 MCC-on enable signal ...................................... 53 Multi-path Control............................................ 74

N
NOTES ON MULTI-PATH CONTROL........... 57

O
One-CPU Two-Path Control ............................ 59 OVERALL CONNECTION DIAGRAM........... 35 Overview ........................................................... 86

P
PARAMETERS ........................................... 62, 64 PARAMETERS RELATED TO THE USE OF FSSB I/O UNIT............................................. 72

T
Tandem Control ................................................ 74 Test mode signal ............................................... 50 Test Mode Signal (OPT) ................................. 102 Troubleshooting ................................................ 80 Two-CPU Three-Path Control.......................... 60 Two-CPU Two-Path Control (With Axis Change between Paths) .............................................. 58 Two-CPU Two-Path Control (Without Axis Change between Paths) ................................ 57

R
Related Safety Standards .................................. 3 Remaining risks................................................ 10 Risk Analysis and Evaluation............................ 3

S
SAFE MACHINE POSITION MONITORING 31

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Revision Record

Dual Check Safety OPERATORS MANUAL (B-63494EN)

01

Feb., 2002

Edition

Date

Contents

Edition

Date

Contents

TECHNICAL REPORT (MANUAL)

NO.TMN 00 / 117E

Date: 2000. General Manager of Hardware Laboratory Dual Check Safety USERS MANUAL 1. Communicate this report to: Your information only GE Fanuc-N, GE Fanuc-E FANUC Robotics CINCINNATI MILACRON Machine tool builder Sales agency End user

2. Summary for Sales Documents (Sales guide, Functional comparison list, etc.)

3. Notice

4. Attached Document Drawing No. B-63494EN/01-05

IDE

General Manager

Original section of issue Vice General Department Section Manager Manager Manager

Person in Charge

FANUC

USERS MANUAL

B-63494EN-01 Version 05: 25th of July, 2000

Table of Contents

B-63494EN/01

Table of Contents
1 OVERVIEW.............................................................................................................................................. 1 1.1 DIRECTIVE AND STANDARDS ..................................................................................................... 3 Directives .................................................................................................................................... 3 Related Safety Standards.......................................................................................................... 3 Risk Analysis and Evaluation................................................................................................... 3

1.1.1 1.1.2 1.1.3 1.1.4 1.2 1.2.1 1.2.2 1.3 1.3.1 1.3.2 1.4 2 3

Certification Test.................................................................................................................... 5 General Definition of Terms ................................................................................................... 6 Definition of Terms Related to the Safety Function ......................................................... 6 Features of Dual Check Safety................................................................................................ 8
Compliance with the Safety Standard (EN954-1, Category 3)................................................ 8

DEFINITION OF TERMS ......................................................................................................................... 6

BASIC PRINCIPLE OF DUAL CHECK SAFETY .......................................................................................... 8

GENERAL INFORMATION........................................................................................................... 16

SYSTEM CONFIGURATION ............................................................................................................. 18 SAFETY FUNCTIONS ......................................................................................................................... 20 3.1 3.2 APPLICATION RANGE ................................................................................................................. 21 BEFORE USING THE SAFETY FUNCTION............................................................................... 25 Important Items to Check Before Using the Safety Function ................................................ 25 MCC off Test of the Safe Stop Function.................................................................................. 25 Stopping the Spindle Motor .................................................................................................... 26 Stopping the Servo Motor ........................................................................................................ 27 Stop States................................................................................................................................ 27

3.2.1 3.2.2 3.3 3.3.1 3.3.2 3.3.3 3.4 3.5 3.6 3.7 3.8 4

STOP ................................................................................................................................................ 26

SAFETY I/O MONITORING .......................................................................................................... 30 EMERGENCY STOP ...................................................................................................................... 37 SAFE SPEED MONITORING........................................................................................................ 39 SAFE MACHINE POSITION MONITORING .............................................................................. 41 MCC OFF TEST .............................................................................................................................. 42

INSTALLATION ................................................................................................................................... 43 4.1 4.2 4.3 OVERALL CONNECTION DIAGRAM ......................................................................................... 43 DI/DO CONNECTION (VIA THE PMC) ....................................................................................... 47 DI/DO CONNECTION (VIA THE FSSB) ...................................................................................... 48 FSSB I/O Connection.............................................................................................................. 48

4.3.1

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B-63494EN/01

Table of Contents
FSSB I/O Attachment ............................................................................................................. 49 FSSB I/O Specification List ................................................................................................... 55

4.3.2 4.3.3 5

I/O SIGNALS ......................................................................................................................................... 56 5.1 5.2 OVERVIEW ......................................................................................................................................... 57 SIGNALS ............................................................................................................................................ 58 Signal Addresses...................................................................................................................... 61 Safety Signal Modes ................................................................................................................ 62

5.2.1 5.2.2 6

PARAMETERS...................................................................................................................................... 64 6.1 6.2 OVERVIEW ......................................................................................................................................... 65 PARAMETERS ..................................................................................................................................... 66

MAINTENANCE ................................................................................................................................... 72 7.1 7.2 SAFETY PRECAUTIONS............................................................................................................... 73 ALARMS ............................................................................................................................................. 77 Servo Alarms ............................................................................................................................ 77 Serial Spindle Alarms ............................................................................................................. 81 Alarms Displayed on the Spindle Unit................................................................................... 82 System Alarms ......................................................................................................................... 84 Boot System Alarms................................................................................................................. 84

7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 8

START-UP ............................................................................................................................................. 85 8.1 START-UP OPERATION ......................................................................................................................... 86

8.1.1 8.1.2 8.1.3 9

Acceptance test and report for safety functions ............................................................. 86 Start-up of the Safety Function .......................................................................................... 88 Troubleshooting ....................................................................................................................... 91

SAMPLE SYSTEM CONFIGURATION............................................................................................ 92 9.1 9.2 SAMPLE CONFIGURATION......................................................................................................... 93 SAMPLE CONNECTIONS ............................................................................................................. 94 Emergency Stop Signal (*ESP1, *ESP2)................................................................................ 94 Guard Open Request Signal (ORQ) ........................................................................................... 95 Test Mode Signal (OPT) ............................................................................................................. 95 Guard Unlock Enable Signal (*LGD), MCC On Enable Signal (MCF), Guard Lock State MCC Contact State

9.2.1 9.2.2 9.2.3 9.2.4 9.2.5

Signal (GDL), Guard State Signal (SGD) ............................................................................................. 97 Signal (*SMC) ......................................................................................................................................... 99

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Table of Contents
10

B-63494EN/01

COMPONENTS LIST..................................................................................................................... 100

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B-63494EN/01

1.OVERVIEW

OVERVIEW
Setup for machining, which includes attaching and detaching a workpiece to be machined, and moving it to the machining start point while viewing it, is performed with the protection door opened. The dual check safety function provides a means for ensuring a high level of safety with the protection door opened. The simplest method of ensuring safety when the protection door is open is to shut off power to the motor drive circuit by configuring a safety circuit with a safety relay module. In this case, however, no movements can be made on a move axis (rotation axis). Moreover, since the power is shut off, some time is required before machining can be restarted. This drawback can be corrected by adding a motor speed detector to ensure safety. However, the addition of an external detector may pose a response problem, and the use of many safety relay modules results in a large and complicated power magnetics cabinet circuit. With the dual check safety function, two independent CPUs built into the CNC monitor the speed and position of motors in dual mode. An error in speed and position is detected at high speed, and power to the motor is shut off via two independent paths. Processing and data related to safety is cross-checked by two CPUs. To prevent failures from being built up, a safety-related hardware and software test must be conducted at certain intervals time. The dual check safety system need not have an external detector added. Instead, only a detector built into a servo motor or spindle motor is used. This configuration can be implemented only when those motors, detectors built into motors, and amplifiers that are specified by FANUC are used. When an abnormality related to safety occurs, the dual check safety function stops operation safely. The dual check safety function ensures safety with the power turned on, so that an operator can open the protection door to work without turning off the power. A major feature of the dual check safety function is a very short time required from the detection of an abnormality until the power is shut off. A cost advantage of the dual check safety function is that external detectors and safety relays can be eliminated or simplified.

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1.OVERVIEW

B-63494EN/01

The dual check safety function consists of the following three functions: 1. 2. 3. Safety I/O monitoring function Safety limitation speed monitoring function Safety machine position monitoring function

The safety function operates regardless of the NC mode. Usually, this function should be used in the setup mode. If a position or speed mismatch is detected by a crosscheck using two CPUs, power is shut off (MCC off) to the motor drive circuit. The European standard certification organization has certified that this safety function satisfies the European Safety Standard EN954-1 Category 3.

IMPORTANT The dual check safety function cannot monitor the stop state. For details, see the example of system configuration.

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B-63494EN/01

1.OVERVIEW

1.1
1.1.1

DIRECTIVE AND STANDARDS


Directives
Machine tools and their components must satisfy the EC directives listed below. The FANUC CNC systems with the dual check safety function are compatible with all of these directives.

Directive Directive 98/37/EC Directive 89/336/EEC Directive 73/23/EEC

1998 Safety of machinery 1989 Electromagnetic compatibility 1973 Low Voltage Equipment

1.1.2

Related Safety Standards


To be compatible with the directives, especially the

machine directive, the international standards and European standards need to be observed. Important safety standards EN292-1 EN292-2 1991 1991 Safety of machinery - Basic concepts, general principles for design Part 1: Basic terminology, methodology Safety of machinery - Basic concepts, general principles for EN954-1 1996 design Part 2: Technical principles and specifications Safety of machinery - Safety-related parts of control systems Part 1: General principles for design EN1050 EN60204-1 1997 DIN V VDE0801 including amendment A1(1994) 1996 Safety of machinery - Principles for risk assessment Safety of machinery - Electrical equipment of machines Part 1: General requirements (1990) Principles for computers in safety- related systems

1.1.3

Risk Analysis and Evaluation


According to the machine directive, the manufacturer of a machine or machine components and a responsible person who supplies a machine or machine components to the market must conduct risk evaluation to identify all risks that can arise in connection with the machine or machine components. -3-

1.OVERVIEW

B-63494EN/01

Based on such risk analysis and evaluation, a machine and machine components must be designed and manufactured. documented. Risk evaluation must reveal all remaining risks and must be

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B-63494EN/01

1.OVERVIEW

1.1.4

Certification Test

Certification of the dual check safety function The German certification organization TUV PS has certified that the dual check safety function satisfies EN954-1 Category 3.

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1.OVERVIEW

B-63494EN/01

1.2
1.2.1

DEFINITION OF TERMS
General Definition of Terms
Reliability and safety Reliability and safety are defined by EN292-1 as follows: Term Reliability Definition Capability of a machine, machine component, or equipment period Safety Capability of a machine to perform its function without injuring the health under a condition of use for an intended purpose specified in the operator's manual and allow its transportation, installation, adjustment, maintenance, disassembly, and disposal to perform its required function under a specified condition for a specified

1.2.2

Definition of Terms Related to the Safety Function


Safety-related I/O signal Safety-related I/O signals are input/output signals

monitored by two systems. These signals are valid for each feed axis and spindle with a built-in safety function, and are used with each monitoring system. Example: Protection door state signal Safety stop When a safety stop occurs, power to the drive section is shut off. The drive section can generate neither a torque The following are measures for line and drive system (line nor dangerous operation. Contactor between -6the

incorporating the safety stop feature:

B-63494EN/01

1.OVERVIEW
contactor) Contactor between the power section and drive motor (motor contactor) If an external force is applied (such as a force applied onto a vertical axis), an additional measure (such as a mechanical brake) must be securely implemented to protect against such a force. Safety limitation speed Feature for preventing the drive section from exceeding a specified speed. a set A measure must be implemented to prevent speed from being changed by an limitation

unauthorized person. Safety machine position When the drive system has reached a specified positional limit, a transition is made to the safety stop state. until a stop occurs must be considered. changed by an unauthorized person. When a positional limit is set, a maximum move distance traveled A measure must be implemented to prevent a set positional limit from being

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1.OVERVIEW

B-63494EN/01

1.3
1.3.1

BASIC PRINCIPLE OF DUAL CHECK SAFETY


Features of Dual Check Safety

Two-channel configuration with two or more independent CPUs Cross-check function for detecting latent errors

Detection A servo motor detector signal is sent via the servo amplifier and is applied to the CNC through the FSB interface. monitor CPU. A spindle motor detector signal is sent via the spindle amplifier and is applied to the CNC connected through the serial interface. Then, it is fed to two CPUs: a CNC CPU and a CPU built into the spindle amplifier. Evaluation The safety function is monitored independently by a CNC CPU and monitor CPU or by a CNC CPU and spindle CPU. Each CPU cross-checks data and results at certain intervals. Response If the monitoring function detects an error, the CNC CPU and monitor CPU switch off the MCC via independent paths to shut off the power to the feed axis and spindle. Then, it is fed to two CPUs: a CNC CPU and a

1.3.2

Compliance with the Safety Standard (EN954-1, Category 3)


The dual check safety function satisfies the requirements of Category 3 of the safety standard EN954-1. Category 3 requires the following:

The safety function of a safety-related portion must not degrade when a single failure occurs. Single errors must be detected at all times when natural execution is possible.

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B-63494EN/01

1.OVERVIEW
To satisfy these requirements, the dual check safety function is implemented using the two-channel configuration shown below.

CNC CNC CPU CPU


Motor detector signal Door switch signal

Shut off pow er

Cross-check of data and results

Magnetic contactor

Monitor Monitor CPU CPU

Shut off pow er

CNC controller
Monitoring of servo motor and spindle motor movement Data output from the detector built into each motor is transferred to the CNC through the amplifier. The safety of this path is ensured by using motors and amplifiers specified by FANUC. Cross-monitoring using 2 CPUs Two CPUs built into the CNC are used to cross-monitor the safety function. Each CPU is periodically checked for errors. If one system fails, the servo system and spindle can be stopped safely. Power shutoff via two paths If an error is detected, the power is shut off via two power shutoff paths. The paths need to be tested for built-up failures within a certain time. Input signal safety Safety-related input signals such as the protection door lock/unlock signal is monitored doubly. If a mismatch between the two occurrences of a signal is detected, the power to the motor drive circuit is shut off. This crosscheck is constantly made. Output signal safety A signal is output (via two paths) to the relay used to shut off the power to the motor drive circuit. An error is detected by a MCC off Test. For detection of built-up failures, a MCC off Test needs to be conducted at certain intervals. This MCC off Test is not mandatory when machining is performed with the protection door closed.

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1.OVERVIEW

B-63494EN/01

1.3.2.1

Latent error detection and cross-check


Detection of latent errors This detection function can detect latent software and hardware channels errors need to in be a system tested that at has a once two-channel within an configuration. So, the safety-related portions of the two least

allowable period of time for latent errors. An error in one monitoring channel causes a mismatch of results, so that a cross-check detects the error. Caution Forced detection of a latent error on the MCC shutoff path must be performed by the user through a MCC off Test (after power-on and at intervals of a specified time (within 24 hours)). When the system is operating in the automatic mode (when the protection door is closed), this detection processing is not requested as mandatory. Cross-check A latent safety-related error associated with two-channel monitoring can be detected as a result of cross-checking. For numeric data, an allowable difference between the two channels is set in a parameter. (For example, an allowable cross-checked difference is set for the actual position.) Note An error detected as the result of forced latent error detection or cross-checking leads to a safety stop state. (See Chapter ?.).

1.3.2.2

Safety monitoring cycle and cross-check cycle


The safety function is subject to periodical monitoring in a monitoring cycle. Monitoring cycle: 16 ms -10-

B-63494EN/01

1.OVERVIEW

The cross-check cycle represents a cycle at which all data subject to cross-checking is compared. Cross-check cycle: 16 ms

1.3.2.3

MCC off Test

The MCC is shut off using two CPUs: a CNC CPU and monitor CPU. To detect a latent error in the MCC shutoff paths This test is and at A MCC off Test must be (after power-on forcibly, a MCC off Test is conducted. essential to dual check safety. conducted at specified times

intervals of 24 hours) to check that the MCC shutoff paths operate normally. A MCC off Test is conducted once on the CNC side and once on the monitor side. When a MCC off Test becomes necessary, the CNC outputs a MCC off Test execution request signal to the PMC. Note The machine tool builder is to warn and prompt the operator to conduct a MCC off Test when a MCC off Test execution request signal is output. A MCC off Test is executed by turning on the test mode signal. MCC off Test execution condition

All axes and the spindle must be stopped beforehand. All vertical axes must be secured firmly beforehand.

Select-test termination When a MCC off Test is completed, the MCC off Test execution request signal is turned off. test mode signal. After the MCC off Test execution request signal is turned off, turn off the

1.3.2.4

Error analysis

Error analysis The table below indicates the results of system error analysis controlled by the dual check safety function. -11-

1.OVERVIEW

B-63494EN/01

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1.OVERVIEW
Error analysis when the protection door is open Error Cause or control unit Safety failure, etc. or control failure, etc. axis Amplifier operation or control operation Action limitation speed error, monitoring function EN60204-1 Category 1/0 stop unit Safety limitation speed error, monitoring function EN60204-1 Category 1/0 stop unit Safety limitation speed operation error, control error, monitoring function EN60204-1 Category 1/0 stop unit Safety limitation speed monitoring function EN60204-1 Category 1/0 stop Error analysis when the protection door is closed Error Cause Wiring error, control unit Safety failure, etc. Action limitation speed monitoring function EN60204-1 Category 1/0 stop

Spindle safety Amplifier excessive speed

Excessive feed Amplifier axis speed

Feed

safety machine failure, position error etc. Input/output signal error Wiring

failure, etc.

Input/output signal error

1.3.2.5

Remaining risks
The machine tool builder is to make a failure analysis in connection with the control system and determine the remaining risks of the machine. The dual check safety system has the following remaining risks: a) The safety function is not active until the control system and drive system have fully powered up. The safety function cannot be activated if any one of the components of the control or drive is not powered on. b) Interchanged phases of motor connections, reversal in the signal of encoder and reversal mounting of encoder can cause an increase in the spindle speed or acceleration of axis motion. If abnormal speed detected, system controlled to brake to zero speed, but no effective for above error. MCC off is not activated until the delay time set by parameter has expired. Electrical faults can also result in the response -13-

1.OVERVIEW

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described above(component failure too). c) Faults in the absolute encoder can cause incorrect operation of the safety machine position monitoring function. d) With a 1-encoder system, encoder faults are detected in a single channel, but by various HW and SE monitoring functions. The parameter related to encoder must be set carefully. Depending on the error type, a category 0 or category 1 stop function according to EN60204-1 is activated. e) The simultaneous failure of two power transistors in the inverter may cause the axis to briefly(motion depend on number of pole pairs of motor) Example: A 6-pole synchronous motor can cause the axis to move by a maximum of 30 degrees. With a lead-screw that is directly driven by, e.g.20mm per revolution, this corresponds to a maximum linear motion of approximately 1.6mm. f) When a limit value is violated, the speed may exceed the set value briefly or the axis/spindle overshoot the setpoint position to a greater or lesser degree during the period between error detection and system reaction depending on the dynamic response of the drive and the parameter settings(see Section Safety-Functions) g) The category 0 stop function according to EN60204-1 (defined as STOP A in Safety Integrated) means that the spindles/axes are not braked to zero speed, but coast to a stop (this may take a very long time depending on the level of kinetic energy involved). This must be noted, for example, when the protective door locking mechanism is opened. h) Drive power modules and motors must always be replaced by the same equipment type or else the parameters will no longer match the actual configuration and cause Dual check Safety to respond incorrectly. i) Dual check Safety is not capable of detecting errors in parameterization and programming made by the machine manufacturer. The required level of safety can only be assured by thorough and careful acceptance. j) There is a parameter that MCC off test is not to be made in the self test mode at power-on as in the case of machine adjustment. This parameter is protected, only changed by authorized person. IF MCC off test is not conducted, MCC may not be off at stop response is measured. k) Safety machine position monitoring function does not apply to rotation axis. l) During machine adjustment, an exact motion may be executed incorrectly untie the safety functions setup -14-

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1.OVERVIEW
correctly and confirm test is completely.

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1.OVERVIEW

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1.4

GENERAL INFORMATION
The following requirements must be fulfilled for the Dual-Check System: All conditions of the certification report has to be respected. The procedures for the changes in the System (either HW or SW) should be referred to maintenance manual (B-63005). When safety related components are exchanged, confirmation test regarding safety functions can be performed accoding to Chapter 8. Programming in ladder logic should be referred to programming manual (B-61863).

Training
FANUC Training Center provides versatile training course for the person who is concerned with hardware installation, maintenance and operation. FANUC recommend studying and learning in the training center how efficiently operate FANUC products. There are 3 CNC training course. [ CNC ELEMENTARY COURSE ] Provides basics of CNC functions, operation and programming. The course is recommended before taking more specialized training courses to gain best effects. MAIN ITEMS OF TRAINING CNC functions Configuration of CNC Configuration and function of servo system Basic programming of CNC Part programming of milling machine Part programming of turning machine Introduction of Custom Macro function [ CNC MAINTENANCE COURSE ] To master maintenance technique that permits you to maintain and inspect CNC, also how to restore it promptly if a trouble should occur. MAIN ITEMS OF TRAINING Function and configuration of Power Unit Function and configuration of CNC system include AC servo and AC spindle Self-diagnosis function Interface between CNC and the machine tools Data saving and restoring operation Trouble shooting

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1.OVERVIEW
[ CNC SE INTERFACE COURSE ] Training course offered to the engineers who design CNC machine tools or CNC application system for the first time. This course is also suitable for customers who provide to retrofitting, to develop an original CNC machine tools or new application of CNC. MAIN ITEMS OF TRAINING Configuration of CNC system Interface between CNC and machine tools Ladder programming of machine control sequence Setting of parameter related to machine Setting of parameter related to servo and spindle More information and course registration Yamanakako-mura, Yamanashi Prefecture : 401-0501, JAPAN Phone : 81-555-84-6030 Fax : 81-555-84-5540 Internet: www.fanuc.co.jp/eschool

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SYSTEM CONFIGURATION
FANUC Series 16i/18i/20i/21i/160is/180is/210is/160i/180i/210i (LCD-mounted type) FANUC Series 16i/18i/21i/160is/180is/210is/160i/180i/210i (standalone type) Number of controlled axes - Series 20i/21i/210is/210i - Series 18i/180is/180i - Series 16i/160iis/160i Number of spindle controlled axes - Series 21i/210is/210i - Series 18i/180is/180i - Series 16i/160is/160i Amplifier - series servo amplifier - series spindle amplifier - series power supply module Motor - series servo motor - series spindle motor I/O - I/O unit (I/O Link) - I/O module (FSSB) Software - Dual check software DETECTOR SYSTEM The detectors below can be used. Feed axis detector - Servo motor built into 1000 - Separate detector (A/B phase pulse) Spindle detector - M sensor - MZ sensor - BZ sensor
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: : : : : :

4 maximum 6 maximum 6 maximum 2 maximum 3 maximum 4 maximum

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2.SYSTEM CONFIGURATION
CAUTION The dual check safety system can not be used below functions

- I/O Link - SUB CPU - Loader control function - two path control function - EGB function - Spindle switching function - Linear Motor - System of more than twe protectctiv doors - Background graphic function - HRV3 control - Open CNC (LCD-mounted type) - Speed command of the axis control by PMC

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SAFETY FUNCTIONS

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3.SAFETY FUNCTIONS

3.1

APPLICATION RANGE
The dual check safety system assumes the following configuration: A) One protective door is provided. B) If the protective door is closed, safety is assured. When the operator makes a request to open the protective door, the safety functions are enabled, and the protective door can be unlocked. While the protective door is open, the active safety functions assure safety. When the request to open the protective door is canceled, the protective door is locked, and the safety functions are disabled. The dual check safety system provides these safety functions while the protective door is open, as described above. Some of the safety functions continue working while the protective door is closed.

WARNING

Each machine tool builder should take measures to assure safety while the protective door is closed and to ensure safety related to a rotation axis and travel axis. At the same time, safety measures for the FANUC servo motor or spindle motor need to be taken, while the door is open.

The dual check safety system has the following safety functions: Safety I/O monitoring This function in redundant mode monitors I/O related to safety (emergency stop, protective door lock/open/close state, power-down) in redundant mode. The emergency stop, protective door lock/open/close state, and powerdown are checked in redundant mode. If the two corresponding inputs do not match, the system judges that an abnormal event has occurred. The power-down -21-

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(MCC off) signal is output in redundant mode (from two paths). Whether the two-path output is normal is judged in a MCC off Test. Safe speed monitoring This function checks that the rotation speeds of the servo motor and spindle motor are within a predetermined speed range, using two CPUs in redundant mode. If a speed exceeding the range is detected, the system judges that an abnormal event has occurred. Safe machine position monitoring This function checks that the position on a servo axis is within a specified range, using two CPUs in redundant mode. If a position exceeding the range is detected, the system judges that an abnormal event has occurred. If an abnormal event (safety error) is found, the dual check safety system shuts off the power to the motor driving circuit, using the two independent CPUs. The state in which the servo or spindle motor stops because of power-down is referred to as the safe stop state. If a safety error results in the safe stop state, the operator must turn off the CNC, remove the cause of the error, then turn on the CNC again. The user must conduct a MCC off Test every 24 hours in order to detect a potential cause of error.

CAUTION This safety function is enabled while the protective door is open after a request to open the protective door is made. If the request to open the protective door is canceled and if the protective door is closed, this safety function is disabled. The dual input check of the safety I/O monitoring function and the emergency stop function are always active, regardless of whether the protective door is opened or closed.

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3.SAFETY FUNCTIONS

CNC
Dual monitoring of emergency stop signal Emergency stop Dual monitoring of protective door state

The safe speed of the spindle motor is checked by the CNC CPU and spindle CPU in redundant mode.

Spindle CPU

CNC CPU

CrossSPM

Spindle motor

Protective door

Protective door lock signal

Safe speed monitoring Servo motor SVM

Door lock/ open/close monitoring Cross-check

PSM Monitor CPU Powerdown (MCC)


Power-down Dual monitoring of MCC

Safe speed monitoring Safe machine position monitoring

I/O, safe speed of the servo motor, and machine position are checked by the CNC CPU and monitor CPU in redundant mode.

Dual monitoring of MCC Dual power-down Detection of potential cause of error by self test

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3.SAFETY FUNCTIONS
Safety functions

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- Double monitoring of input signals Emergency stop input, protective door lock/open/close state, relay state for turning off the MCC - Dual signal output Output signal for shutting off the power (turning the MCC off)To detect the potential cause of an abnormal state of this output, a MCC off Test must be made. - Spindle motor Safe speed monitoring - Servo motor Safe speed monitoring Safe machine position monitoring

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3.2
3.2.1

BEFORE USING THE SAFETY FUNCTION


Important Items to Check Before Using the Safety Function

When using the safety function for the first time upon assembly of the machine, replacing a part, or changing a safety parameter (such as a safe speed limit or safe range as described in Chapter n), the user must check that all safety parameters are correct and that all safety functions are working normally. A return reference position must be made on each axis. The user must also check the absolute position of the machine. For details, see Chapter 8, "START UP."

If an absolute-position detector is used, and reference position return has been performed once, reference position data is stored in the CNC memory. In this case, the user need not make a reference position check. If an incremental pulse coder is being used, reference position data is lost each time the power to the CNC is turned off and then back on. So, after the power is turned on, another reference position return operation must be performed. At the every power on the safety area must be tested. At each power on there is a message: Please execute safety testWithout this message dual check safety is either not installed or not yet activated (option bit).

3.2.2

MCC off Test of the Safe Stop Function


A MCC off Test of the safe stop function monitors the contact state of the electromagnetic contactor (MCC), compares the state with a command to the electromagnetic contactor, and checks that the safe stop function works normally. The test must be carried out by the user of the machine. This test must be carried out when the CNC is turned on or when 24 hours have elapsed after the previous test is completed. If the CNC is turned on or if 24 hours have elapsed after the previous test is completed, a guard open request (protective door open request) is not accepted until the test is performed.

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3.3
3.3.1

STOP
Stopping the Spindle Motor
Because the spindle motor is an induction type motor, power-down during rotation causes the motor to continue rotating for a certain amount of time. From a safety standpoint, the motor may have to be stopped immediately. If the CNC detects an error and judges that the spindle can be controlled, it waits until the rotation of the spindle stops, then shuts off the power. This wait period can be specified as a safety parameter. For this safety parameter, two different values can be specified. One value is used when the safety function is active (the door is open), and the other value is used otherwise. The values must be determined in consideration of the stop period calculated from the spindle speed. To implement the function, the CNC CPU and monitor CPU individually incorporate a timer function. Normal operation of the two CPUs are mutually checked to ensure the safety of the timers. To speed down and stop the spindle, the PMC must input the *SPEMG signal. When this signal is input, the spindle slows down and stops. (A Ladder program for inputting this signal in case of alarm must be created.) The *EMG input of the PSM has the same effect. If the emergency stop signal is connected to *EMG, the spindle slows down and stops in the emergency stop state. If this processing is not performed, power-down causes the spindle motor to continue rotating at the speed prior to power-down (and eventually stopping in the end). CAUTION The CNC outputs a DO notifying of an alarm. If necessary, the spindle should be stopped. Because the DO output is not duplicated, this DO may not be output when a single failure is detected. In that case, the speed cannot be reduced, but the MCC is finally shut off and brought into the safe stop state. If a spindle amplifier alarm or any other state in -26-

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3.SAFETY FUNCTIONS
which the spindle motor cannot be controlled encountered, immediate power-down is carried out. is

3.3.2

Stopping the Servo Motor


Because the servo motor is a synchronous motor, powerdown results in a dynamic brake stop. The dynamic brake stop is electric braking in which the excited rotor is isolated from the power source and the generated electric energy is used up in the winding. Additional braking is provided by an internal resistor. Unlike an induction motor, the servo motor does not coast because of this function. If the input of the emergency stop signal or an error of a safety signal or speed monitoring is detected, the CNC automatically specifies a command to zero the speed and reduces the speed to zero (controlled stop). After the motor slows down and stops, the power is turned off, and the motor is brought into the dynamic brake stop state. To slow down and stop the motor, some parameters must be specified in the CNC. If those parameters are not specified, the motor is immediately brought into the dynamic brake stop state. In some circumstances where a controlled stop cannot be made, a dynamic brake stop is unconditionally made.

3.3.3

Stop States
The following stop states are possible: Safe stop state The power to the motor is shut off (MCC off state). If the spindle motor can be controlled, the power is shut off after the spindle motor is slowed down to a stop. If the spindle motor cannot be controlled, the power is immediately shut off. If the servo motor can be controlled, the motor is slowed down to a stop and then brought into the dynamic brake stop state. If the motor cannot be controlled, the motor is immediately brought into the dynamic brake stop state. If the power is shut off immediately, the spindle motor continues at the same speed prior to the abnormal event and eventually comes to a stop. If the spindle motor -27-

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can be slowed down to a stop, the operation is performed as instructed by the PMC and then the power is shut off.

IMPORTANT The time period until the signal for shutting off the power (turning off the MCC) is output depends on the parameter. Different parameters are used in the safety monitoring state and in other states.
Safety number 1947 MCC off timer 1 If the protective door is closed 1948 MCC off timer 2 If the protective door is opened parameter Name

Controlled stop state The power to the motor is not shut off. The servo motor and the spindle motor are controlled to stop. In the controlled stop state of either motor, the safety function is active if the condition for enabling the safety function is satisfied (the door is open). If a further abnormal event occurs, the motor is brought into the safe stop state.

WARNING

- The machine tool builder must design the machine so that the machine is kept in the stop state if the power to the servo motor driving circuit is shut off. Example) Brake mechanism that would not drop the vertical axis after the power is shut off - If the power to the spindle motor driving circuit is shut off, the spindle motor continues rotating at the speed before the power-down and eventually comes to a stop. A measure must be taken so that this coasting does not affect safety.

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3.4

SAFETY I/O MONITORING


A set of safety I/O signals are connected to the I/O Link and the servo FSSB through separate paths. The two independent CPUs individually check the input signals. If a mismatch between two corresponding signals is found, the system enters the safe stop state. The following safety I/O signals are monitored or output in redundant mode: Emergency stop input signal Protective door state input signal Lock state input signal Input signal for monitoring the MCC contact state Output signal for turning off the MCC (power-down)

To configure the two-path system, the machine tool builder must connect these signals to both the I/O module and the FSSB I/O.

IMPORTANT

If the safety input signals, except for emergency stop input signals, are connected to the I/O module, a Ladder program must be created to establish a one-toone relationship between the actual input (X) and the input to the CNC (G).

The duplicated input signals are always checked for a mismatch, regardless of whether the safety function is active or not. When a signal state changes, the pair of signals may not match for some period because of a difference in response. The dual check safety system checks whether a mismatch between the two signals continues for a certain period of time, so that an error resulting from the difference in response can be avoided. The check period must be specified as a safety parameter.
Parameter No. 1945 Name Safety input signal check timer

The following signals are not defined as safety I/O signals and are not duplicated. The signals, however, are necessary for the system. -30-

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- Input signal for making a protective door open request - Input signal for starting the test mode - Output signal for specifying a command to lock the protective door - Output signal for requesting a MCC off Test

This section briefly describes the signals. For details, see Chapter 6, "OPERATION." For specific connections, see the sample system configuration in Chapter n.

CNC CNC CPU I/O

I/O DI DO

Machine

Cross check

FSSB DI

Monitor CPU

FSSB

DO

Duplicated I/O
Symbol Signal name I/O address

*ESP SGD GDL *SMC MCF ORQ OPT *LGD RQT

Emergency stop Guard state signal Guard lock state signal MCC state contact signal MCC off signal Guard open request signal Test mode signal Guard unlock signal MCC off Test execution request signal

<X008#4> <DI+000#0> <G191#4> <DI+001#4> <G191#5> <DI+001#5> <G191#6> <DI+001#6> <F191#1> <DO+000#1> <G191#3> <G191#2> <F191#0> <F191#2>

Dual input monitoring Dual input monitoring Dual input monitoring Dual input monitoring Duplicated output Input Input Output Output

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Safety I/O 1. *ESP (input) Emergency stop signal. The signal is monitored in redundant mode. The signal is connected to the *ESP input of the servo amplifier as well. 2. SGD Guard state signal (input)

The signal is provided for double monitoring of the protective door state. The signal is connected so that it is normally set to 1 while the protective door is closed and locked (door open) and set to 0 otherwise (door close). These states are implemented by the combination of the safety door and safety relays. The CNC monitors these states. If the safe speed range is exceeded in the door open state, the system enters the safe stop state. 3. GDL Lock state signal (input)

This signal is not usually used. 4. *SMC MCC contact signal (input) The MCC contact state is monitored in redundant mode. In normal operation, the MCC is active, and whether the contact of a relay is closed cannot be detected. In the test mode, a closed contact of a relay can be detected. 5. MCF MCC off signal (output) With this signal, the MCC is shut off from both the I/O Link side and the FSSB side. Signals other than safety I/O The following signals are not safety signals (are not checked in redundant mode) but are important signals in the system. The machine tool builder must create an appropriate Ladder program.

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IMPORTANT

The Ladder program cannot be checked for an error. Check the safety function (see Chapter n).

6.

ORQ

Guard open signal

(input)

When this signal is input, the CNC checks the machine position and speed. If both the machine position and speed are within the safe range, the guard unlock signal (*LGD) is set to 1 (guard unlock enabled). The machine tool builder must provide an output signal that opens the actual protective door through the PMC. Connect the signal output. 7. OPT Test mode signal When the signal is input, a MCC off Test is executed. The MCC off Test checks whether the contact of the MCC is closed. When carrying out the MCC off Test manually, execute a MCC off Test by the PMC and make necessary corrections before inputting this signal. 8. *LGD Guard unlock signal If this signal is set to 1, the protective door can be unlocked. Then, a signal to unlock the actual protective door should be output through the PMC. If the protective door is unlocked while the signal is set to 0, an alarm occurs and brings the motor into the safe stop state. CAUTION When the signal is set to 1, there is a time delay (depending on the Ladder program) before the signal to unlock the actual protective door is output. Meanwhile, the protective door is locked, and safety is ensured. If an error is found as a result of speed check or machine position check during that period, *LGD becomes 0. If a single failure occurs in this state and if the actual protective door is unlocked, an alarm occurs. When the safety function of the CNC is enabled, this signal is output. If the signal is output, the signal to unlock the actual protective door should be output -33-

3.SAFETY FUNCTIONS
through the PMC. 9. RQT MCC off Test execution request signal

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If the execution of a MCC off Test is required, this signal is output. At power-on, this signal is output. If this signal is output, a MCC off Test must be executed. Door open request signal and protective door unlock signal

Door open request 24V X Ladder ORQ-I

CNC (PMC)

G ORQ F Ladder LGD-O Y

Protective door

LGD

The figure shows a sample connection of the protective door open request switch and the protective door lock signal. In the normal state, the following state transition takes place before the safety monitoring state is established.

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State transition
ORQ-I ORQ *LGD *LGD-O

A B C D

0 1 1 1

0 0 1 1

0 0 0 1

0 0 0 0

D F G A

1 0 0 0

1 1 0 0

1 1 1 0

0 0 0 0

A protective door open request is not made, and the door is locked. A protective door open request is made. The request is transferred to the CNC. A safe speed check and a machine position check prove that there is no failure and that the CNC can enter the safe state. The actual safety door is unlocked. Operations can be performed with the door open. The door is closed and locked again. The safety door open request is canceled. The request is transferred to the CNC. The CNC exits from the safe state.

Normal operating state

Safety function enabled

IMPORTANT

If the CNC detects that the protective door is open (SGD is set to 0) while ORQ is set to 0, the CNC judges that an abnormal event has occurred and enters the safe stop state. This can occur, for instance, when the door happens to open (or to be unlocked) while machining is in progress with the protective door open

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Timing diagram from door close state to door open state

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The following diagram shows the timings at which the door is opened and closed again.
ORQ P

ORQ

*LGD

*LGD_P1 (Actual door unlock signal) SGD_P SGD2 Door closed Door opened Door closed

Actual door status

(1)

(2)

(3)

(4)

(5)

(1) When the guard open request signal (ORQ) is input, it checks that the machine position and speed are within safe ranges. Then, the guard unlock enable signal (*LGD) is turned on. (2) When *LGD goes on, the Ladder program turns on the unlock signal. This example assumes that the protective door has an electromagnetic lock mechanism. While the door is open, the unlock signal is turned off. (3) The door is open. (4) The protective door is closed and locked. After this, the guard open request signal (ORQ) must be turned off. CAUTION Reserve a time of 100 ms or longer (t in the figure) from when the door is closed (locked) until the guard open request signal (ORQ) goes off. If this time requirement is not satisfied, an alarm may be raised when the door is closed (locked). (5) When ORQ goes off, the CNC turns *LGD off. -36-

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3.5

EMERGENCY STOP
The emergency stop signal is monitored in redundant mode. When the emergency stop is input, the servo motor slows down to a stop (*) and enters the dynamic brake stop. The spindle slows down to a stop(*) as instructed by the PMC, and the power is shut off.

CAUTION To enable the function to slow down and stop the servo motor, the corresponding parameter must be specified. If the parameter is not specified, the motor immediately enters the dynamic brake stop state. The spindle motor slows down and stops as instructed by the PMC (Ladder program). If the PMC does not instruct this, the motor maintains the high speed prior to the power-down and coasts. If an illegal speed is specified because of a failure on the PMC side while the safety function is active (the protective door is open), the CNC enters the safe stop state.

WARNING

In the emergency stop state, the guard unlock enable signal becomes 1 (the door opens). In the emergency stop state, the processing to open or close the protective door depends on the Ladder program created by the machine tool builder. For instance, if the protective door should not be opened in the emergency stop state, a Ladder program of the processing must be created.

When the emergency stop is canceled, an alarm may occur, depending on the state. For instance, if the emergency stop state is canceled with the protective door open and if no door open request is made, the CNC judges that an error has occurred and enters the safe stop state.

IMPORTANT

Emergency Stop Button must fulfil the Standard IEC60947-5-1.


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3.SAFETY FUNCTIONS
This is mandatory.

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3.6

SAFE SPEED MONITORING


When the guard open request signal is input, the dual check safety system starts monitoring whether a safe speed is kept on each feed axis and spindle. If the speed does not exceed the safe speed range and if the machine position is in within the safe range, the guard unlock enable signal is enabled. If the safe speed range is exceeded while the protective door is open, the dual check safety system immediately enters the safe stop state. For each feed axis and spindle, a single safe speed range is specified in a safety parameter.

CAUTION If an illegal speed is detected, the MCC is shut off after the time specified in the parameter.

IMPORTANT The period from when an error is detected until the MCC is shut off can be specified in a parameter. The period is reserved to stop the spindle safely. A large value means that a long time is needed to shut off the MCC. In this parameter, different values can be specified and used when the safety function is enabled (the protective door is open) and disabled (normal operation is performed). The value of the parameter for the former case must be carefully specified.

IMPORTANT A gear ratio, ball screw, and the like must be carefully selected so that a safe speed can be kept on the feed axis.

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Before inputting the guard open request signal, reduce each axial speed and spindle speed to a safe speed range or below. If a speed exceeds the limit, the guard open request signal is not accepted (the door is not unlocked). If the door is forced open, the power to the driving circuit is shut off (safe stop state).

WARNING

The safe speed monitoring function monitors whether the traveling speed exceeds a specified limit. The function cannot monitor the stop state (zero speed). If an error causes a movement on the feed axis at a speed lower than the safe speed range while the protective door is open, for instance, the function cannot detect this state. The machine must be designed so that this state does not affect the safety of the machine system.

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3.7

SAFE MACHINE POSITION MONITORING


While the door is open, the dual check safety checks whether the position on each feed axis is the safe machine position range defined by parameters. If it detects a machine position the safety range, the dual check safety immediately enters the safe stop state. system within safety beyond system

The user of the machine must first carry out a reference position return in order to obtain the initial position. If the reference position return is not carried out, the check function is disabled. This check function is enabled after the reference position is established. (The function cannot be disabled by any means after the reference position is established.) A safe machine position limit on each feed axis is specified in a safety parameter. Note) The safe machine position monitoring function does not keep monitoring the specified range. Only after the function detects that a position on a feed axis exceeds the range, the system enters the safe stop state. Accordingly, in the safe stop state, an overtravel has occurred on the feed axis. The travel distance depends on the traveling speed and other conditions. At power-on, the safety function does not work. After power-on, the CNC checks whether a reference position return is completed. If the reference position return is completed and if the protective door is open, safe machine position monitoring and safe speed monitoring are performed. Then, the safety functions start working. If the reference position return is not completed, safe machine position monitoring cannot be performed because the coordinates are not set. In this state, the machine position monitoring function is disabled. After a reference position return is made, this function is enabled. Depending on the safety parameter setting, however, an alarm may be raised. To avoid this alarm, specify the safe machine position parameters before making a reference position return.

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3.8

MCC OFF TEST


A MCC off Test must be carried out in intervals of 24 hours, so that the safety functions would not be damaged by a possible cause of failure. A message telling that the MCC off Test must be carried out is displayed at power-on or when 24 hours have elapsed after the previous MCC off Test. The protective door can be opened only after the MCC off Test is carried out accordingly.

IMPORTANT Carry out the MCC off Test with the protective door closed. Because the test shuts off the MCC, prepare the system for mechanical MCC shut-off before starting the MCC off Test.

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INSTALLATION
Except FSSB I/O module, the hardware installation such as field wiring, power supply, etc. should be referred to connection manual (B-63003E) for CNC units and (B65162E) for servo amplifier. EMC problem should be referred to EMC guideline manual (A-72937/E).

Degree of IP protection: Servo Motors: IP55 Spindle Motors: IP54 with oil-seal, IP40 without oil-seal Servo and Spindle amplifiers: IP1x CNC and other accessories: Ipxx

Note Servo/Spindle amplifiers, CNC are to be installed in IP54 protected cabinets.


The peripheral units and the control unit have been designed on the assumption that they are housed in closed cabinets.

Environmental conditions for CNC units


Condition LCDmounted type control unit and display unit (except unit with data server function) 0C to 58C 20C to 60C 75% RH condensation 95% RH condensation or Standalone type control unit LCDmounted type control unit with PC and data server functions

Ambient Temperature of the unit Humidity

Operating Storage Transport Normal

0C to 55C

5C to 53C

less,

no

Vibration Meters above sea level Environment

or less, no Short period(less than 1 month) Operating 0.5 G or less Nonoperating 1.0 G or less Operating Up to 1000 m Up to 1000 m Nonoperating Up to 12000 m Up to 12000 m Normal machine shop environment (The environment must be considered if the cabinets are in a location where the density of dust, coolant, and/or organic solvent is relatively high.)

10% to 75% RH, no condensation 10% to 90% RH, no condensation

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Environmental conditions for servo amplifier


The servo amplifier series must be installed in a sealed type cabinet to satisfy the following environmental requirements: (1) Ambient Temperature Ambient temperature of the unit : 0 to 55C (at operation) 20 to 60C (at keeping and transportation) (2) Humidity Normally 90% RH or below, and condensationfree (3) Vibration In operation : Below 0.5G (4) Atmosphere No corrosive or conductive mists or drops should deposit directly on the electronic circuits.

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4.INSTALLATION

4.1
LCD display unit

OVERALL CONNECTION DIAGRAM


Mother board

24V-IN(CP1A) 24V-OUT(CP1B) MDI UNIT Soft key cable MDI(CA55) CK2 CK1

24 VDC supply

power

To I/O device

R232(JD36A) R232(JD36B)

RS-232C I/O device RS-232C I/O device Touch panel

HDI(JA40)

High-speed skip input

Distribution-type I/O board DC24V I/O-LINK(JD1A) CPD1 JD1 JD1 I/O unit, etc. DC24V CPD1 JD1 JD1 JA3

Manual pulse generator

Operator's panel

Power magnetics cabinet

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4.INSTALLATION

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LCD display unit

Mother board

SPDL(JA41)

JA7B JA7A SPM

JY2 TB2 Spindle motor

Second spindle FSSB(COP10A) COP10B COP10A COP10B COP10A COP10B COP10A SVM SVM SVM TB2 JF1 Axis 2 servo monitor Axis 1 servo motor

TB2 JF1

TB2 JF1

Axis 3 servo motor

Six or eight axes maximum, depending on the model (This diagram assumes the use of a 1-axis amplifier.) Separate detector interface unit DC24V CP11A COP10B COP10A JF104 JA4A JF101 JF102 JF103 Linear scale axis 1 Linear scale axis 2 Linear scale axis 3 Linear scale axis 4 Battery for absolute position detector

FSSB I/O DC24V CP11A CB155A COP10B CB156A COP10A Power magnetics cabinet

SV-CHK(CA54)

Servo check board

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4.INSTALLATION

4.2

DI/DO CONNECTION (VIA THE PMC)


For DI/DO signals connected via the PMC, the I/O signals of the unit connected to the FANUC I/O Link are to be input to or output from the following addresses, via the PMC:
PMCCNC G008 PMCCNC #7 G191 CNCPMC #7 F191 *ESPG

#6

#5 *SMC1

#4 GDL1

#3 SGD1

#2 ORQ

#1 OPT

#0

#6

#5

#4

#3

#2

#1 RQT

#0 MCF1 *LGD

For the meaning of each of the above signals, see Chapter 6, "OPERATION." Hatted signals means dual monitoring.

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4.3
4.3.1

DI/DO CONNECTION (VIA THE FSSB)


For DI/DO signals connected via the FSSB, the I/O signals are to be directly connected to the I/O unit connected to the FSSB.

FSSB I/O Connection

Power supply connection


External power supply

24 VDC regulated power supply 24 VDC10%

Cable AMP Japan 1-178288-3 (Housing) 1-175218-5 (Contact)

External power supply


Select a one that matches the pins of the external power supply.

+24V(1) 0V(2)

Recommended cable specification: A02B-0124-K830 (5 m) An M3 crimp terminal is provided on the external power supply side.

The 24 VDC power input to CP11A can be drawn from CP11B for distribution. The connection to CP11B is the same as for CP11A.

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4.INSTALLATION

DI/DO connection
Pin No.
Signal name +24V

CB155A(A01) CB155A(B01) CB155A(A02) CB155A(A07) CB155A(B07) CB155A(A08) CB155A(B08) CB155A(A09) CB155A(B09) CB155A(A10)

*ESP2

SGD2 GDL2 SMC2

Pin No. DOCOM CB155A(B06)

Signal name

0V +24V +24V regulated power supply CB155A(A11)

Relay

MCF2 CB155A(B11) Relay

CB155A(A17,B17)

4.3.2

For the meanings "OPERATION."

of

the

above

signals,

see

Chapter

6,

FSSB I/O Attachment

External dimensions

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CP11A CP11B

Upper:CB156A Lower:CB155A

COP10A COP10B

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4.INSTALLATION

Screw attachment

Mounting hole machining diagram

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CAUTION When attaching/detaching this unit, a screwdriver is inserted at an angle. So, a sufficiently large working space must be provided on the both sides of this unit. As a guideline, if the front surface of an adjacent unit is flush with or set back from the front surface of this unit, provide about 20 mm between the adjacent unit and this unit. If the front surface of the adjacent stands forward of the front surface of this unit, provide about 70 mm between the adjacent unit and this unit. When installing this unit near the side of the cabinet, provide about 70 mm between this unit and the cabinet.

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4.INSTALLATION

Working space around the I/O unit

Attachment to a DIN rail

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4.INSTALLATION

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Attachment

DIN rail

Detachment

DIN rail

Attachment 1. Hook the unit over the top of the DIN rail. 2. Press the unit down until it snaps into place. Detachment 1. Pull down the lock section with a standard screwdriver. 2. Pull the lower part of the unit toward you.

CAUTION When detaching the unit, be careful not to damage the lock section by applying excessive force. When attaching or detaching the unit, hold the upper and lower parts of the unit, if possible, to prevent force from being applied to the side (where the cooling rents are provided) of the unit.

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4.INSTALLATION

4.3.3

FSSB I/O Specification List

Installation conditions
Ambient temperature of the unit Temperature variation Humidity Vibration Atmosphere Operating 055 Storage, transportation 2060 1.1/minute maximum Normally Relative humidity 75% or less Short term (no more than one month) Relative humidity 95% or less Operating 0.5G or less Normal machining plant environment (Check is required if the unit is to be used in an environment exposed to relatively high levels of dust or coolant, or a relatively high concentration of organic solvents.) (1) Use the unit in a completely sealed cabinet. (2) Install the unit on a vertical surface, and provide a space of 100 mm or more above and below the unit. Do not install equipment that dissipates much heat under this unit.

Other conditions

Power supply capacity


Supply voltage 24V10% is fed from the CP11A connector of the basic module. 10% includes momentary variations and ripples. Power supply capacity 0.3A+7.3mAxDI Remarks Number of DI points in DI = ON state

Input signal specifications


Contact capacity Leakage current between open contacts Voltage drop across closed contacts Delay time 30 VDC, 16 mA or more 1 mA or less (when the voltage is 26.4 V) 2 V or less (including a cable voltage decrease) Receiver delay time: 2 ms (MAX) In addition, the FSSB transfer period and ladder scan period need to be considered.

Output signal specifications


Maximum load current at ON time Saturation voltage at ON time Dielectric voltage Output leakage current at OFF time Delay time 200 mA or less including momentary variations 1 V (MAX) when the load current is 200 mA 24 V +20% or less including momentary variations 20 A or less Driver delay time: 50 s(MAX) In addition, the FSSB transfer period and ladder scan period must be considered.

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I/O SIGNALS

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5.I/O SIGNALS

5.1

Overview
The dual-check safety system provides two input paths and two output paths for safety-related signals (safety signals). For input signals (safety input signals), two paths are used: one path for input to the CNC via the PMC, and the other for input to the monitor via the FSSB. The CNC and monitor exchange the safety input signals with each other at all times to check each other. If a mismatch is found between a safety input signal via one path and the same signal via the other path, the signal is assumed to be 0. If such a state lasts for the period set in a parameter or more, the CNC and monitor independently detect an alarm. (Dual-check for safety input signals) For output signals (safety output signals), two paths are used: one path for output from the CNC via the PMC, and the other for output from the monitor via the FSSB. The MCC-on enable signal (MCF) is output via these two paths. When both a signal via one path and the same signal via the other path are 1, the signal is assumed to be 1. If either is 0, the signal is assumed to be 0. That is, if the MCC-on enable signal (MCF) via the PMC and the same signal via the FSSB are both 1, the MCC may be turned on. If either is 0, the MCC must be turned off. In Subsection 5.2, a signal name is followed by its symbol and addresses <via PMC> and <via FSSB>. Then, for an input signal, its classification, function, and operation are described, in this order. For an output signal, its classification, function, and output condition are described in this order. For information about the emergency stop mode, MCC off Test mode, and safety signal modes A/B/C/D described in Subsection 5.2, see Subsection 5.2.2.

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5.2

Signals

Emergency stop signal

*ESP1 <X008#4>, *ESPG <G008#4>, *ESP2 <DI+000#0>


[Classification] [Function] [Operation] Input signal Stops machine movement immediately in an emergency. When emergency stop signal (*ESP) is set to 0, the CNC is reset, and an emergency stop occurs. In general, emergency stop signal (*ESP) is specified by the pushbutton switch B contact. When an emergency stop occurs, the servo ready signal SA is set to 0. When emergency stop signal (*ESP) is set to 0, the emergency stop mode is set with the dual-check safety system. In this mode, the MCC contact state signal (*SMC) is checked. When *SMC = 0 (MCC-on state ), the guard unlock enable signal (*LGD) is set to 0 (to disable guard unlocking). When *SMC = 1 (MCC-off state), the guard unlock enable signal (*LGD) is set to 1 (to enable guard unlocking).

CAUTION Emergency stop signals (*ESP) via the PMC <X008#4> and via the FSSB <DI+000#0> are checked each other (dual-check for safety input signals), but *ESP via the PMC <G008#4> is not checked.

Test mode signal

OPT <G191#2>
[Classification] [Function] [Operation] Input signal This signal notifies the CNC that MCC off Test mode is set with the dual-check safety system. Test mode signal (OPT) is not input via the FSSB. When test mode signal (OPT) is 1, the CNC performs safety output signal MCC off Test processing. (MCC-on enable signal (MCF) is output in various patterns, and a test is conducted to see if an appropriate MCC contact state signal (*SMC) pattern is input, respectively.) In the emergency stop state, however, MCC off Test processing is not performed. If a safety output signal MCC off Test is not completed within the time set in parameter No. 1946, servo alarm No. 488 is issued.

Guard open request signal

ORQ <G191#3>
[Classification] [Function] [Operation] Input signal This signal requests the CNC to unlock the guard with the dual-check safety system. Guard open request signal (ORQ) is not input via the FSSB. When the guard open request signal (ORQ) is 1, the CNC, monitor and spindle software make a machine position check and safety speed
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5.I/O SIGNALS
check. If the results of the checks assure safety, guard unlock enable signal (*LGD) is set to 1 (to enable guard unlocking). When guard open request signal (ORQ) is 0, the CNC and monitor set guard unlock enable signal (*LGD) to 0 (to disable guard unlocking). (In emergency stop state, however, the guard unlock enable signal (*LGD) is set to 1.) See Subsection 5.2.2.

Guard state signal

SGD1 <G191#4>, SGD2 <DI+001#4>


[Classification] [Function] Input signal This signal posts the guard open/closed state to the CNC and monitor with the dual-check safety system. 0: Guard open state 1: Guard closed state This input signal is used together with safety input signals such as guard open request signal (ORQ) to determine a safety signal mode that specifies the operation of the CNC, monitor, and spindle software. For details, see Subsection 5.2.2. Input this signal according to the guard state.

[Operation]

IMPORTANT
Interlock switch must fulfil the Standard IEC60947-5-1. This is mandatory.

Guard lock state signal

GDL1 <G191#5>, GDL2 <DI+001#5>


[Classification] [Function] Input signal This signal posts the guard lock state to the CNC and monitor with the dual-check safety system. 0: Guard unlocked state 1: Guard locked state This signal is usually not used, but please input same signal both via PMC and via FSSB all time because dual-check for guard lock state signal is executed by CNC and monitor.

[Operation]

MCC contact state signal

*SMC1 <G191#6>, *SMC2 <DI+001#6>


[Classification] [Function] Input signal This signal posts the MCC state to the CNC and monitor with the dual-check safety system. 0: MCC-on state 1: MCC-off state
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[Operation]

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When the MCC contact state signal (*SMC) is 1 in the emergency stop state, the CNC sets the guard unlock enable signal (*LGD) to 1 (to enable guard unlocking). The MCC contact state signal (*SMC) is used to check if the MCC-on enable signal (MCF) operates normally in MCC off Test mode. Input this signal according to the MCC state.

Guard unlock enable signal

*LGD <F191#0>
[Classification] [Function] Output signal This signal notifies that guard unlocking is enabled with the dualcheck safety system. When guard unlock enable signal (*LGD) is 0, the guard is locked. When *LGD is 1, the guard is unlocked. Guard unlock enable signal (*LGD) is not output via the FSSB. In the following cases, this signal is set to 1 (to enable guard unlocking): When emergency stop state is set, and MCC contact state signal (*SMC) is 1 (MCC-off state) When guard open request signal (ORQ) is 1, the servo and spindle motors rotate within the safety speeds, the machine is positioned within the safety area, and MCC off Test execution request signal (RQT) is 0 In cases other than the above, this signal is set to 0 (to disable guard unlocking).

[Output condition]

MCC-on enable signal

MCF1 <F191#1>,MCF2 <DO+000#1>


[Classification] [Function] Output signal This signal posts notification that the MCC can be turned on with the dual-check safety system. When MCC-on enable signal (MCF) is 0, the MCC is turned off. When MCF is 1, the MCC is turned on. In the following cases, this signal is set to 0 (to prevent the MCC from being turned on): When a safety-related alarm is issued When the emergency stop state is issued In cases other than above, this signal is state to 1 (to enable the MCC to be turned on).

[Output condition]

MCC off Test execution request signal

RQT <F191#2>
[Classification] [Function] Output signal This signal requests that MCC off Test mode be set, and a check is made to determine whether the safety output signals (MCC-on enable signal (MCF)) operate normally. When MCC off Test execution
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5.I/O SIGNALS
request signal (RQT) is set to 1, set MCC off Test mode and conduct a safety output signal MCC off Test as soon as possible. When MCC off Test execution request signal (RQT) is 1, guard unlock enable signal (*LGD) is set to 0 to disable guard unlocking even if safety signal mode B (state in which a guard open request is input, and the guard is closed) is set and the conditions including speed are satisfied. When safety signal mode C (state where a guard open request is input, and the guard is open) is set, and MCC off Test execution request signal (RQT) is set to 1, guard unlock enable signal (*LGD) is 0 to disable guard unlocking until MCC off Test execution request signal (RQT) is set to 0 after the guard is closed once. When MCC off Test execution request signal (RQT) is 1, the warning "PLEASE EXECUTE SAFE TEST" is displayed on a screen such as a parameter screen. (On some screens, no warning is displayed.) MCC off Test execution request signal (RQT) is not output via the FSSB. In the following cases, this signal is set to 1: A MCC off Test is not completed after power-on (when bit 3 of parameter No. 1902 is 0). Twenty-four hours have elapsed since the completion of the last MCC off Test.

[Output condition]

CAUTION 1. If the current date and time lags behind the date and time of
the previously completed MCC off Test due to a clock change or the like, it is assumed that 24 hours have elapsed since the previous MCC off Test. 2. From February 28 to March 1, the elapse of 24 hours may be assumed even if 24 hours has not elapsed after the completion of the previous MCC off Test. 3. MCC must have forced guided contacts and must fulfil the Standard IEC60204 and the standard IEC 255.This is mandatory. In the following case, this signal is set to 0: A MCC off Test is completed.

5.2.1

Signal Addresses

Via the PMC


#7 X008 #6 #5 #4 *ESP1 #3 #2 #1 #0

#7 G008

#6

#5

#4 *ESPG

#3

#2

#1

#0

#7

#6

#5

#4

#3

#2

#1

#0

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5.I/O SIGNALS
G191 *SMC1 GDL1 SGD1 ORQ OPT

B-63494EN/01

#7 F191

#6

#5

#4

#3

#2 RQT

#1 MCF1

#0 *LGD

Via the FSSB


#7 DI+0000 #6 #5 #4 #3 #2 #1 #0 *ESP2

#7 DI+001

#6 *SMC2

#5 GDL2

#4 SGD2

#3

#2

#1

#0

#7 DO+000

#6

#5

#4

#3

#2

#1 MCF2

#0

CAUTION Emergency stop signals (*ESP) via the PMC <X008#4> and via the FSSB <DI+000#0> are checked each other (dual-check for safety input signals), but *ESP via the PMC <G008#4> is not checked.

5.2.2

Safety Signal Modes


Depending on the safety input signal state, the CNC, monitor, and spindle software internally have one of the six modes (safety signal modes) indicated in the table below.
Safety signal mode Safety signal state Machine state Emergency stop state State for conducting a MCC off Test Normal operation state State in which a guard open request is input, and the guard is closed State in which a guard open request is input, and the guard is open Abnormal state (state in which the guard is open although no guard open request is input.)

Emergency stop mode *ESP = 0 MCC off Test mode OPT = 1 Safety signal mode A ORQ = 0 and SGD = 1 Safety signal mode B ORQ = 1, and SGD = 1

Safety signal mode C ORQ = 1, and SGD = 0

Safety signal mode D ORQ = 0 and SGD = 0

In general, safety signal mode transitions are made as described below. Usually, safety signal mode A is set. In safety signal mode A, guard unlock enable signal (*LGD) is 0, and the guard is locked. When an emergency stop is required, emergency stop mode is set. In emergency stop mode, the MCC contact state signal (*SMC) is checked. When *SMC = 0 (MCC-on state), guard unlock enable
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5.I/O SIGNALS
signal (*LGD) is set to 0 (to disable guard unlocking). When *SMC = 1 (MCC-off state), guard unlock enable signal (*LGD) is set to 1 (to enable guard unlocking). When a MCC off Test is to be conducted, MCC off Test mode is set. In MCC off Test mode, safety output signal MCC off Test processing is performed. (MCC-on enable signal (MCF) are output in various patterns, and a test is conducted to determine whether appropriate MCC contact state signal (*SMC) patterns are input respectively.) When the guard is to be opened, safety signal mode B is set. In safety signal mode B, the CNC, monitor, and spindle software check the machine position and the speed on each axis. If safety is assured, guard unlock enable signal (*LGD) is set to 1 to enable the guard to be opened. When the guard is opended in safety signal mode B after guard unlock enable signal (*LGD) is set to 1, safety signal mode C is set. In safety signal mode C, the CNC, monitor, and spindle software check the machine position and the speed on each axis. If an abnormality is detected, an alarm is issued, MCC-on enable signal (MCF) is set to 0, and the MCC is turned off. Safety signal mode D represents an abnormal state in which the guard is open although no guard open request is made. In safety signal mode D, an alarm is issued, the MCC-on enable signal (MCF) is set to 0, and the MCC is turned off.

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PARAMETERS

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6.PARAMETERS

6.1

Overview
The parameters related to the dual-check safety function (safety parameters) are protected by a code (No. 3225) for the safety parameters. The value of a safety parameter cannot be modified unless the same value as the code for the safety parameters is set as the key (No. 3226) for the safety parameters. The safety parameters are stored in two locations on the CNC. The CNC, monitor, and spindle software check the matching of the parameters stored at the two locations. If a mismatch is found, an alarm is issued. If the setting of a safety parameter is modified, the power must be turned off then back on. The new setting of the parameter becomes effective after the power is turned back on. For information about emergency stop mode, MCC off Test mode, and safety signal modes A/B/C/D described in this section, see Section 6.

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6.2

Parameters
1023 Servo axis number for each axis

[Data type] [Valid data range]

Byte axis 1, 2, 3, ..., number of controlled axes Set which servo axis corresponds to each controlled axis. Usually, set the same value for a controlled axis number and servo axis number. A controlled axis number represents an array number for an axis type parameter or axis type machine signal. For details of the setting, refer to the description of FSSB setting in the connection manual (function part).
Positional deviation limit during a stop for each axis

1829

[Data type] [Unit of data] [Valid data range]

Word axis Detection unit 0 to 32767 Set a positional deviation limit for each axis at stop time. If a positional deviation limit during a stop is exceeded at stop time, a servo alarm is issued, and an immediate stop (same as an emergency stop) is performed. When the dual-check safety function is used, the CNC and monitor make a positional deviation check in safety signal mode C (state in which a guard open request is input, and the guard is opened); in the other modes, only the CNC performs a positional deviation check.
Positional deviation limit during movement for each axis in safety signal mode C

1838

[Data type] [Unit of data] [Valid data range]

2-word axis Detection unit 0 to 99999999 Set a positional deviation limit during movement for each axis in safety signal mode C (state in which a guard open request is input, and the guard is opened) when the dual-check safety function is used. If a positional deviation limit during movement is exceeded during movement, a servo alarm is issued, and an immediate stop (same as an emergency stop) is performed. When the dual-check safety function is used, the CNC and monitor make a positional deviation check in safety signal mode C (state in which a guard open request is input, and the guard is opened); in other modes, only the CNC makes a positional deviation check. When the guard is open, axis movement is performed at a speed not exceeding the safety speed. So, usually, set a value smaller than a positional deviation limit during movement (parameter No. 1828).
#7 #6 DCE #5 #4 #3 STP #2 #1 #0

1902

[Data type] STP

Bit When the power is turned on, a safety output signal MCC off Test in the MCC off Test mode is:
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6.PARAMETERS
0: 1: Conducted. (The warning "PLEASE EXECUTE MCC OFF TEST" is displayed at power-on, and MCC off Test execution request signal (RQT) is output.) Not conducted.

CAUTION 1. The STP parameter is used temporarily, for example, when a safety output signal MCC off Test is not to be made in the MCC off Test mode at power-on as in the case of machine adjustment. Usually, set STP = 0. 2. Even when STP = 1, a safety output signal MCC off Test is required if the power is turned 24 hours or more after the completion of the previous MCC off Test. WARNING Set STP = 0 after the STP parameter is used temporarily as in the case of machine adjustment.
DCE The dual-check safety function is: 0: Disabled. 1: Enabled.

CAUTION Usually set the DCE = 1 in the dual-check safety system. The system cannot start-up because MCC-on enable signal (MCF) = 0 when the DCE = 0. WARNING All bits of parameter No.1902 except STP and DCE must be set 0. If one of these bits is set 1, the safety functions may be executed incorrectly.
1942 Safety speed for each axis

[Data type] [Unit of data] [Valid data range]

2-word axis

Increment system

Valid data range Unit of data IS-A, IS-B 0 ~ 240000 0 ~ 96000 0 ~ 240000 IS-C 0 ~ 100000 0 ~ 48000 0 ~ 100000

Millimeter machine 1 mm/min Inch machine 0.1 inch/min Rotation axis 1 deg/min

Set a safety speed for each axis. When safety signal mode B (state in which a guard open request is input, and the guard is closed) is set with the dual-check safety
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6.PARAMETERS

B-63494EN/01

function, the CNC and monitor check the speed command for each axis. If there is at least one axis for which a speed greater than the safety speed is specified, the guard unlock enable signal (*LGD) is set to 0 to disable guard unlocking. The state in which the speeds specified for all axes are within the safety speeds is one condition for setting the guard unlock enable signal (*LGD) to 1 (to enable guard unlocking). In safety signal mode C (state in which a guard open request is input, and the guard is open), the CNC and monitor check the speed command for each axis. If there is at least one axis for which a speed greater than the safety speed is specified, a servo alarm is issued.
1943 1944 Safety position of each axis (+ direction) Safety position of each axis (- direction)

[Data type] [Unit of data]

2-word
Increment system IS-A IS-B 0.001 0.0001 IS-C 0.0001 0.00001 Unit mm inch

Millimeter machine 0.01 Inch machine 0.001

[Valid data range]

-99999999 to 99999999 Set a safety position for each axis. When safety signal mode B (state in which a guard open request is input, and the guard is closed) is set with the dual-check safety function, the CNC and monitor check the machine position of each linear axis. If there is at least one linear axis whose machine position is not in the safety position (safety position (- direction) machine position safety position (+ direction)), the guard unlock enable signal (*LGD) is set to 0 to disable guard unlocking. The state in which the machine positions of all linear axes are within the safety positions is one condition for setting the guard unlock enable signal (*LGD) to 1 (to enable guard unlocking). In safety signal mode C (state in which a guard open request is input, and the guard is open), the CNC and monitor check the machine position of each linear axis. If there is at least one linear axis whose machine position is not in the safety position, a servo alarm is issued.

WARNING CNC and monitor check the machine position of each linear axis, and not check it of each rotation axis. WARNING CNC and monitor check the machine position of only each axis whose reference position is established, and not check it of each axis whose reference position is not established.
1945 Safety input signal check timer

[Data type] [Unit of data]

Word ms
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6.PARAMETERS
[Valid data range] 0 to 32767 For input signals related to the dual-check safety function (safety input signals), two paths are used: one path for input to the CNC via the PMC, and the other for input to the monitor via the FSSB. The CNC and monitor exchange the input signals with each other at all times to check each other. If a mismatch greater than the time set in this parameter is detected between an input signal via one path and the same signal via the other path, a servo alarm is issued. If a value of less than 16 is specified, a specification of 16 ms is assumed.
MCC off Test timer

1946

[Data type] [Unit of data] [Valid data range]

Word ms 0 to 32767 When MCC off Test mode is set with the dual-check safety function, the CNC conducts a safety output signal MCC off Test. If a MCC off Test is not completed within the time set in this parameter, a servo alarm is issued. If a value of less than 0 is specified, a specification of 10000 ms is assumed.
MCC-off timer 1 MCC-off timer 2

1947 1948

[Data type] [Unit of data] [Valid data range]

Word ms 0 to 32767 When the MCC-on enable signal (MCF) needs to be set to 0 (MCC off) with the dual-check safety function for a cause such as an alarm or emergency stop, the CNC and monitor set MCC-on enable signal (MCF) to 0 when an MCC-off timer value has elapsed after the alarm or emergency stop state. If a spindle alarm is issued, however, the timers are not used. Instead, MCC-on enable signal (MCF) is set to 0 immediately. If the MCC is cut off while the spindle motor is rotating, the spindle motor will continue to rotate (free-run) and stop after time. When the spindle motor should stop as quickly as possible, please use these parameters and control the spindle motor to stop, and after that cut MCC off.
State When a spindle alarm is issued When the guard is closed When the guard is open Timer used No timer is used. MCC-off timer 1 (No. 1947) MCC-off timer 2 (No. 1948)

3225

Code for safety parameters

[Data type] [Valid data range]

2-word 0 to 99999999 Set a code (password) for protecting against modifications to parameters related to the dual-check safety function (safety
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parameters). When a code for safety parameters is set, the parameters are locked. At this time, the setting (code) is not displayed but is blank, and safety parameter input is disabled. If an attempt is made to input data in a locked safety parameter, the result indicated in the table below is produced, depending on the method of input. No attempt is successful.
Input method Result

MDI input Warning "WRITE PROTECT" G10 (programmable parameter input) P/S231 FORMAT ERROR IN G10 L50 Input via the reader/punch interface No alarm is issued, but parameter input is disabled. Input through a window Completion code 7 (write protect)

A code for safety parameters can be set when the safety parameters are not locked, that is, when the code for safety parameters is 0, or when the code for safety parameters is the same as the key for safety parameters (No. 3226). The following safety parameters are protected by a code for safety parameters: No.1023, No.1829, No.1838, No.1902 #3, No.1902 #6, No.1942, No.1943, No.1944, No.1945, No.1946, No.1947, No.1948, No.3225, No.4372
3226 Key for safety parameters

[Data type] [Valid data range]

2-word 0 to 99999999 When the same value as the code for safety parameters is set in this parameter, the key is opened to enable modifications to the safety parameters. The value set in this parameter is not displayed. When the power is turned off, the value set in this parameter is cleared, resulting in the locked state.

CAUTION Once a key is set, the key must be cancelled or memory must be cleared before the safety parameters can be modified. Moreover, the code for the safety parameters cannot be modified. Be careful when setting a code for safety parameters.
4372 Safety speed of each spindle

[Data type] [Unit of data] [Valid data range]

Word min-1 0 to 32767 Set a safety speed for each spindle in terms of motor speed. When safety signal mode B (state in which a guard open request is input, and the guard is closed) is set with the dual-check safety function, the CNC and spindle software check the speed of each spindle motor. If there is at least one spindle whose speed is greater
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6.PARAMETERS
than the safety speed, guard unlock enable signal (*LGD) is set to 0 to disable guard unlocking. The state in which the speeds of all spindle motors are within the safety speeds is one condition for setting guard unlock enable signal (*LGD) to 1 (to enable guard unlocking). When safety signal mode C (state in which a guard open request is input, and the guard is open) is set, the CNC and spindle software check the speed of each spindle motor. If there is at least one spindle whose speed is greater than the safety speed, a spindle alarm is issued.

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MAINTENANCE

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7.MAINTENANCE

7.1

SAFETY PRECAUTIONS
This section describes the safety precautions related to the use of CNC units. It is essential that these precautions be observed by users to ensure the safe operation of machines equipped with a CNC unit (all descriptions in this section assume this configuration). CNC maintenance involves various dangers. CNC maintenance must be undertaken only by a qualified technician. Users must also observe the safety precautions related to the machine, as described in the relevant manual supplied by the machine tool builder. Before checking the operation of the machine, take time to become familiar with the manuals provided by the machine tool builder and FANUC. CAUTION Maintenance on a live system requires careful planning, adherence to operating and maintenance procedures, and the appropriate permits and permissions. These matters are the responsibility of the owner/operator of the system and are outside the scope of this document.

TRAINING
FANUC Training Center provides versatile training course for the person who is concerned with hardware and software installation, maintenance and operation. FANUC recommend studying and learning how efficiently operate FANUC products.

QUALIFIED PERSONNEL
Only qualified personnel should be allowed to specify, apply, install, commissioning, operate, maintain, or perform any other function related to the products described in the product manuals. Examples of such qualified persons are defined as follows: System application and design engineers who are familiar with the safety concepts of machine tool. Installation, startup, and service personnel who are trained to install and maintain such machine tool. Operating personnel trained to operate machine tool and trained on the specific safety issues and requirements of the particular equipment.

MAINTENANCE PARTS TO BE MAINTAINED PERIODICALLY

Memory backup battery replacement

WARNING When replacing the memory backup batteries, keep the power to the machine (CNC) turned on, and apply an emergency stop to the machine. Because this work is performed with the power on and the cabinet open, only those personnel who have received approved safety and maintenance training may perform this work.
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When replacing the batteries, be careful not to touch the highvoltage circuits (marked and fitted with an insulating cover). Touching the uncovered highvoltage circuits presents an extremely dangerous electric shock hazard. NOTE The CNC uses batteries to preserve the contents of its memory, because it must retain data such as programs, offsets, and parameters even while external power is not applied. If the battery voltage drops, a low battery voltage alarm is displayed on the machine operators panel or CRT screen. When a low battery voltage alarm is displayed, replace the batteries within a week. Otherwise, the contents of the CNCs memory will be lost. To replace the battery, see the procedure described in Section 2.10 of the maintenance manual B-63005EN/01.

WARNINGS RELATED TO CHECK OPERATION


WARNING 1. When checking the operation of the machine with the cover removed (1) The users clothing could become caught in the spindle or other components, thus presenting a danger of injury. When checking the operation, stand away from the machine to ensure that your clothing does not become tangled in the spindle or other components. (2) When checking the operation, perform idle operation without workpiece. When a workpiece is mounted in the machine, a malfunction could cause the workpiece to be dropped or destroy the tool tip, possibly scattering fragments throughout the area. This presents a serious danger of injury. Therefore, stand in a safe location when checking the operation. 2. When checking the machine operation with the power magnetics cabinet door opened. (1) The power magnetics cabinet has a highvoltage section (carrying a mark). Never touch the highvoltage section. The highvoltage section presents a severe risk of electric shock. Before starting any check of the operation, confirm that the cover is mounted on the high voltage section. When the highvoltage section itself must be checked, note that touching a terminal presents a severe danger of electric shock. (2) Within the power magnetics cabinet, internal units present potentially injurious corners and projections. Be careful when working inside the power magnetics cabinet. 3. Never attempt to machine a workpiece without first checking the operation of the machine. Before starting a production run, ensure that the machine is operating correctly by performing a trial run using, for example, the single
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block, feedrate override, or machine lock function or by operating the machine with neither a tool nor workpiece mounted. Failure to confirm the correct operation of the machine may result in the machine behaving unexpectedly, possibly causing damage to the workpiece and/or machine itself, or injury to the user. 4. Before operating the machine, thoroughly check the entered data. Operating the machine with incorrectly specified data may result in the machine behaving unexpectedly, possibly causing damage to the workpiece and/or machine itself, or injury to the user. 5. Ensure that the specified feedrate is appropriate for the intended operation. Generally, for each machine, there is a maximum allowable feedrate. The appropriate feedrate varies with the intended operation. Refer to the manual provided with the machine to determine the maximum allowable feedrate. If a machine is run at other than the correct speed, it may behave unexpectedly, possibly causing damage to the workpiece and/or machine itself, or injury to the user. 6. When using a tool compensation function, thoroughly check the direction and amount of compensation. Operating the machine with incorrectly specified data may result in the machine behaving unexpectedly, possibly causing damage to the workpiece and/or machine itself, or injury to the user.

WARNINGS RELATED TO REPLACEMENT


WARNING 1. Always turn off the power to the CNC and the main power to the power magnetics cabinet. If only the power to the CNC is turned off, power may continue to be supplied to the serve section. In such a case, replacing a unit may damage the unit, while also presenting a danger of electric shock. 2. When a heavy unit is to be replaced, the task must be undertaken by two persons or more. If the replacement is attempted by only one person, the replacement unit could slip and fall, possibly causing injury. 3. After the power is turned off, the servo amplifier and spindle amplifier may retain voltages fora while, such that there is a danger of electric shock even while the amplifier is turned off. Allow at least twenty minutes after turning off the power for these residual voltages to dissipate. 4. When replacing a unit, ensure that the new unit has the same parameter and other settings as the old unit. (For details, refer to the manual provided with the machine.) Otherwise, unpredictable machine movement could damage the workpiece or the machine itself, and present a danger of injury.

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5. After replacing a safety related unit such as encoder and I/O module, conduct a check test on the safety related and record the test results in a check report.

WARNINGS RELATED TO PARAMETERS


WARNING 1. When machining a workpiece for the first time after modifying a parameter, close the machine cover. Never use the automatic operation function immediately after such a modification. Instead, confirm normal machine operation by using functions such as the single block function, feedrate override function, and machine lock function, or by operating the machine without mounting a tool and workpiece. If the machine is used before confirming that it operates normally, the machine may move unpredictably, possibly damaging the machine or workpiece, and presenting a risk of injury. 2. The CNC and PMC parameters are set to their optimal values, so that those parameters usually need not be modified. When a parameter must be modified for some reason, ensure that you fully understand the function of that parameter before attempting to modify it. If a parameter is set incorrectly, the machine may move unpredictably, possibly damaging the machine or workpiece, and presenting a risk of injury.

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7.2

Alarms
Alarms related to the dual-check safety function cannot be cancelled by a reset. To cancel the alarms, turn off the power. For information about emergency stop mode, MCC off Test mode, and safety signal modes A/B/C/D, see Section 6.

7.2.1
No. 364

Servo Alarms
Meaning n AXIS: SOFT PHASE ALARM(INT) Description The servo control software detected an abnormal data skip in a velocity feedback signal on axis n (axis 1 to axis 8). For the axis control card, the correct servo software is not installed in flash memory. When the dual-check safety function is used: An incorrect axis control card is mounted. Incorrect servo software is installed in flash memory. Monitor software is not installed in flash memory. The CNC detected that the positional deviation during a stop on axis n (axis 1 to axis 8) exceeded the setting (parameter No. 1829). The CNC detected that the positional deviation during movement on axis n (axis 1 to axis 8) exceeded the setting in parameter No. 1828 (parameter No. 1838 when the safety signal mode C (state wherer a guard open request is input, and the guard is open) is set with the dual-check safety function). The servo control software detected an alpha pulse coder signal error on axis n (axis 1 to axis 8). An error occurred in a monitor RAM check. The monitor detected an alpha pulse coder signal error on axis n (axis 1 to axis 8). The monitor detected an abnormal data skip in a velocity feedback signal on axis n (axis 1 to axis 8). Remedy Replace the alpha pulse coder, or take measures to correct noise on the feedback cable. Mount the correct axis control card, and install the correct servo software and monitor software in flash memory.

403

SERVO ALARM : CARD/SOFT MISMATCH

410

SERVO ALARM : n AXIS EXCESS ERR

Confirm a proper valule is set to parameter No. 1829.

411

SERVO ALARM : n AXIS EXCESS ERR

Confirm a proper value is set to parameter No. 1828 or No. 1838.

453

n AXIS:SPC SOFT DISCONNECT ALARM

Replace the alpha pulse coder.

470 471

n AXIS:ILLEGAL RAM (MNT) n AXIS:SPC SOFT DISCONNECT (MNT) n AXIS:SOFT PHASE ALARM(INT/MNT)

Replace the axis control card. Replace the alpha pulse coder.

473

Replace the alpha pulse coder, or take measures to correct noise on the feedback cable.

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No. 474 Meaning n AXIS:EXCESS ERROR (STOP:MNT) Description The monitor detected that the positional deviation during a stop on axis n (axis 1 to axis 8) exceeded the setting (parameter No. 1829) in safety signal mode C (state in which a guard open request is input, and the guard is open). n AXIS:EXCESS ERROR The monitor detected that the (MOVE:MNT) positional deviation during movement on axis n (axis 1 to axis 8) exceeded the setting (parameter No. 1838) in safety signal mode C (state in which a guard open request is input, and the guard is open). n AXIS:ILLEGAL SPEED CMD. The monitor detected that the (MNT) specified speed on axis n (axis 1 to axis 8) exceeded the safety speed (parameter No. 1942) in safety signal mode C (state in which a guard open request is input, and the guard is open). n AXIS:ILLEGAL MACHINE The monitor detected that the POS.(MNT) machine position on axis n (axis 1 to axis 8) is not in the safety area (parameter No. 1943 and No. 1944) in safety signal mode C (state in which a guard open request is input, and the guard is open). n AXIS:ILLEGAL AXIS DATA The monitor detected that an (MNT) error occurred on axis n (axis 1 to axis 8) during axis data transfer.

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Remedy Confirm a proper value is set to parameter No. 1828.

475

Confirm a proper value is set to parameter No. 1838.

476

When the guard is open, confirm a proper value is set to parameter No. 1942, and the operation is done within the safety speed.

477

When the guard is open, confirm proper values is set to parameter No. 1943 and No. 1944, and operation is done in the safety area.

478

479

ILLEGAL SAFETY DI (MNT)

480

n AXIS:ILLEGAL SAFETY MODE (MNT)

The monitor detected a mismatch exceeding the set time (parameter No. 1945) between a safety input signal via the PMC and the same signal via the FSSB. The monitor detected that safety Check if the guard state signal(SGD) is correctly signal mode D (state in which the guard is open although no connected. guard open request is input) was set, or the guard is open when guard unlock enable signal (*LGD) is not output.

If the alarm occurs after performing axis number setting for the servo amplifier, set parameter No.2212#4 to 1, and reset the bit to 0, and then turn off the power to the entire system. In the other case, replace the servo amplifier the alarm occurred. Check the safety input signals via the PMC and via the FSSB are equal.

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Description The monitor detected that a safety parameter error occurred with axis n (axis 1 to axis 8). n AXIS:AXIS NUMBER NOT The monitor detected that the SET (MNT) axis number of axis n (axis 1 to axis 8) is not set with the servo amplifier. MONITOR SAFETY FUNCTION An error occurred in safety ERROR functions of monitor: 1. Monitor or CNC detected the inexecution of monitor safety functions. 2. A mismatch between the monitor results of the safety functions and the servo software or CNC results of them occurred. 3. An error occurred in a monitor CPU test. n AXIS:SERVO SAFETY An error occurred in safety FUNCTION ERR functions of servo software: 1. Servo software or CNC detected the inexecution of servo software safety functions. 2. A mismatch between the servo software results of the safety functions and the monitor results of them occurred. 3. An error occurred in a servo RAM test. 4. An error occurred in a servo CPU test. ILLEGAL SAFETY DI (CNC) The CNC detected a mismatch exceeding the set time (parameter No. 1945) between a safety input signal input via the PMC and the same signal input via the FSSB. ILLEGAL SAFETY MODE The CNC detected that safety (CNC) signal mode D (state in which the guard is open although no guard open request is input) was set, or the guard is open when guard unlock enable signal (*LGD) is not output. SAFE TEST OVER TIME A safety output signal MCC off Test in MCC off Test mode was not completed within the set time (parameter No. 1946). SAFETY PARAM ERROR The CNC detected a safety (CNC) parameter error. Meaning n AXIS:SAFETY PARAM ERROR (MNT) Remedy Set the safety parameters again. Turn off the power to the entire system. Then an axis number is automatically set. Replace the axis control card.

No. 481

482

483

484

Replace the axis control card.

486

Check the safety input signals via the PMC and via the FSSB are equal.

487

Check if the guard state signal(SGD) is correctly connected.

488

Check the MCC contact.

489

Set the safety parameters again.

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No. 490 Description An error occurred in safety functions of CNC: 1. CNC or monitor detected the inexecution of CNC safety functions. 2. A mismatch between the CNC results of the safety functions and the monitor or spindle results of them occurred. 3. An error occurred in a servo RAM test. 4. An error occurred in a servo CPU test. 5. CNC MCC off Test at powerup was not executed. LOCAL BUS TEST ERROR An error occurred in a local bus test. The mother board may be faulty. F-BUS TEST ERROR An error occurred in an F-BUS test. The mother board or option board may be faulty. n AXIS:ILLEGAL SPEED CMD. The CNC detected that the (CNC) specified speed on axis n (axis 1 to axis 8) exceeded the setting (parameter No. 1942) in safety signal mode C (state in which a guard open request is input, and the guard is open). n AXIS:ILLEGAL MACHINE The CNC detected that the POS.(CNC) machine position on axis n (axis 1 to axis 8) is not in the safety area (parameter No. 1943 and No. 1944) in safety signal mode C (state in which a guard open request is input, and the guard is open). n AXIS:ILLEGAL AXIS DATA The CNC detected that an error (CNC) occurred on axis n (axis 1 to axis 8) during axis data transfer. Meaning CNC SAFETY FUNCTION ERROR Remedy Replace the CPU card.

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491

Replace the mother board.

492

Replace the mother board or the option board. When the guard is open, confirm a proper value is set to parameter No. 1942, and the operation is done within the safety speed.

494

495

When the guard is open, confirm proper values is set to parameter No. 1943 and No. 1944, and operation is done in the safety area.

496

497

n AXIS:SAFETY PARAM TRANS ERROR n AXIS:AXIS NUMBER NOT SET (CNC)

498

If the alarm occurs after performing axis number setting for the servo amplifier, set parameter No.2212#4 to 1, and reset the bit to 0, and then turn off the power to the entire system. In the other case, replace the servo amplifier the alarm occurred. Replace the CPU card or the A safety parameter transfer error occurred on axis n (axis 1 axis control card. to axis 8). The CNC detected that the axis Turn off the power to the entire number of axis n (axis 1 to axis system. Then an axis number is automatically set. 8) is not set with the servo amplifier.

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7.2.2
No. 749

Serial Spindle Alarms


Meaning S-SPINDLE LSI ERROR Description It is serial communication error while system is executing after power supply on. Remedy Check optical cable connection between main CPU board and spindle amplifier printed board. Replace optical cable, main CPU board, option 2 board or spindle amplifier printed board. If this alarm occurs when CNC power supply is turned on or when this alarm can not be cleared even if CNC is reset, turn off the power supply also turn off the power supply in spindle side. An error occurred in any spindle Replace the CPU card or spindle amplifier module. safety functions on the first spindle. 1. CNC detected that some spindle safety functions were not executed. 2. A safety parameter transfer error occurred. Check the spindlle amplifier For the first spindle, the CNC detected a mismatch between connectoin state and spindle the spindle amplifier connection amplifier hardware setting. Replace the CPU card or state and spindle amplifier spindle amplifier module. hardware setting. If this alarm is issued because the spindle amplifier configuration is changed, correct the setting on the spindle amplifier side. When the guard is open, For the first spindle, the CNC detected that the speed of the perform operation at a speed not exceeding the safety speed. spindle motor exceeded the Check the safety speed safety speed (parameter No. 4372) in safety signal mode C parameter(parameter No.4372). Replace the CPU card or (state in which a guard open request is input, and the guard spindle amplifier module. is open). Alternatively, for the first spindle, the CNC detected a mismatch between the CNC and spindle software, as to which of the speed of the spindle motor and the safety speed (parameter No. 4372) is greater. Same as alarm No. 755. (For Same as alarm No. 755. (For the second spindle) the second spindle) Same as alarm No. 756. (For Same as alarm No. 756. (For the second spindle) the second spindle)

755

SPINDLE-1 SAFETY FUNCTION ERROR

756

SPINDLE-1 ILLEGAL AXIS DATA

757

SPINDLE-1 SAFETY SPEED OVER

765 766

SPINDLE-2 SAFETY FUNCTION ERROR SPINDLE-2 ILLEGAL AXIS DATA

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No. 767 775 776 777 785 786 787 7n16 Meaning SPINDLE-2 SAFETY SPEED OVER SPINDLE-3 SAFETY FUNCTION ERROR SPINDLE-3 ILLEGAL AXIS DATA SPINDLE-3 SAFETY SPEED OVER SPINDLE-4 SAFETY FUNCTION ERROR SPINDLE-4 ILLEGAL AXIS DATA SPINDLE-4 SAFETY SPEED OVER SPN n :S-SPINDLE ERROR (AL-16) SPN n :S-SPINDLE ERROR (AL-69) SPN n :S-SPINDLE ERROR (AL-69) SPN n :S-SPINDLE ERROR (AL-71) SPN n :S-SPINDLE ERROR (AL-72) SPN n :S-SPINDLE ERROR (AL-74) SPN n :S-SPINDLE ERROR (AL-76) SPN n :S-SPINDLE ERROR (AL-77) SPN n :S-SPINDLE ERROR (AL-78) Description Same as alarm No. 757. (For the second spindle) Same as alarm No. 755. (For the third spindle) Same as alarm No. 756. (For the third spindle) Same as alarm No. 757. (For the third spindle) Same as alarm No. 755. (For the fourth spindle) Same as alarm No. 756. (For the fourth spindle) Same as alarm No. 757. (For the fourth spindle) See the description of AL-16 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-69 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-70 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-71 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-72 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-74 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-76 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-77 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-78 in Subsection 7.2.3. (For the n-th spindle)

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7n69

7n70

7n71

7n72

7n74

7n76

7n77

7n78

Remedy Same as alarm No. 757. (For the second spindle) Same as alarm No. 755. (For the third spindle) Same as alarm No. 756. (For the third spindle) Same as alarm No. 757. (For the third spindle) Same as alarm No. 755. (For the fourth spindle) Same as alarm No. 756. (For the fourth spindle) Same as alarm No. 757. (For the fourth spindle) See the description of AL-16 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-69 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-70 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-71 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-72 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-74 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-76 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-77 in Subsection 7.2.3. (For the n-th spindle) See the description of AL-78 in Subsection 7.2.3. (For the n-th spindle)

7.2.3

Alarms Displayed on the Spindle Unit


Description An error occurred in a spindle RAM test. Remedy Replace spindle amplifier module.

No. Meaning AL-16 RAM Alarm

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Description The spindle software detected that the speed of the spindle motor exceeded the safety speed (parameter No. 4372) in safety signal mode C (state in which a guard open request is input, and the guard is open). The spindle software detected a mismatch between between the spindle amplifier connection state and spindle amplifier hardware setting. If this alarm is issued because the spindle amplifier configuration is changed, correct the setting on the spindle amplifier side. The spindle software detected a safety parameter error. Remedy When the guard is open, perform operation at a speed not exceeding the safety speed. Check the safety speed parameter(parameter No.4372). Replace spindle amplifier module. Check the spindlle amplifier connectoin state and spindle amplifier hardware setting. Replace the CPU card or spindle amplifier module. If this alarm is issued because the spindle amplifier configuration is changed, correct the setting on the spindle amplifier side. Set the safety parameter again. Replace the CPU card or spindle amplifier module. The spindle software detected a Replace the CPU card or spindle amplifier module. mismatch between the CNC result of the motor speed check and the spindle result of it. An error occurred in a spindle Replace spindle amplifier amplifier CPU test. module. An error occurred in a spindle Replace spindle amplifier ROM CRC test. module. Any safety function was not Replace spindle amplifier executed. module. The spindle software detected a Replace the CPU card or spindle amplifier module. mismatch between the CNC result of the axis number check and the spindle result of it. The spindle software detected a Replace the CPU card or spindle amplifier module. mismatch between the CNC result of the safety parameters check and the spindle result of it. The safety functions at power- Replace spindle amplifier module. up for spindle were not executed. Replace the spindle amplifier.

No. Meaning AL-69 Safety speed over

AL-70 Illegal axis data

AL-71 Safety parameter error

AL-72 Mismatch the results of motor speed check

AL-74 CPU test alarm AL-75 CRC alarm AL-76 Inexecution of safety functions AL-77 Mismatch the results of axis number check

AL-78 Mismatch the results of safety parameters check

AL-79 Inexecution of safety functions at power-up

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7.2.4
No. 900

System Alarms
Meaning ROM PARITY Description Parity error of the CNC, macro, or servo ROM. When the dual-check safety function is used: 1. Parity error of the CNC, macro, or servo ROM 2. CRC error of the CNC, servo system, or monitor ROM Servo alarm (first to fourth axis). A watchdog alarm condition occurred, or a RAM parity error occurred in the axis control card. In the dual-check safety system with 4-axes control card, servo alarm (first/second axis, or monitor). Servo alarm (fifth to eighth axis). A watchdog alarm condition occurred, or a RAM parity error occurred in the axis control card. In the dual-check safety system with 6-axes control card, servo alarm (monitor). In the dual-check safety system with 8-axes control card, servo alarm (fifth/sixth axis, or monitor). Remedy Reinstall the indicated ROM in flash memory.

920

SERVO ALARM (1-4 AXIS)

Replace the axis control card.

921

SERVO ALARM (5-8 AXIS)

Replace the axis control card.

7.2.5

Boot System Alarms


Message Description Parity error of the CNC basic ROM. When the dual-check safety function is used: 1. Parity error of the CNC basic ROM 2. CRC error of the CNC basic ROM Remedy Reinstall the CNC basic ROM in flash memory.

ROM PARITY ERROR: NC BASIC. HIT SELECT.

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START-UP

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8.1

START-UP OPERATION
The machine tool builder has to do tests for insulation and protective bonding. Testing must be performed according to Chapter 19.2 and 19.3 of the standard IEC 60204-1 by an appropriately authorized person and recorded. Continuity of the protective bonding circuit When the machine is installed and the electrical connections are complete, including those to the power supply, the continuity of the protective bonding circuit can be verified by a loop impedance test in accordance with 612.6.3 of IEC 60364-6-61. For further details, please refer to Chapter 19.2 of IEC 60204-1. Insulation resistance tests The insulation resistance measured at 500 V d.c. between the power circuit conductors and the protective bonding circuit is to be not less than 1 M . For further details, please refer to Chapter 19.3 of IEC 60204-1.

8.1.1

Acceptance test and report for safety functions


Acceptance test for Safety function The machine tool builder is to conduct a dual check safety function check test during machine start-up operation. In this test, limits need to be exceeded to check that the dual check safety function operates normally. Acceptance report A qualified person is to check each dual check safety function and record the test results in a check report. Note: When modifying dual check safety function data, conduct an additional check test on the modified dual check safety function and record the test results in a check report. Safety-related I/O monitoring test Data cross-check operation is tested with the I/O device connector detached. MCC off Test check -86-

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8.START-UP
The test mode signal is used to check that a MCC off Test is conducted. Negative test: Conduct a MCC off Test by disconnecting the MCC contact signal (input). Check that an alarm is issued and the MCC remains to be shut off. Safety limitation speed monitoring test This test checks that when the actual speed exceeds a speed limit, safety stop state is set by a stop response.

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8.START-UP
Safety machine position monitoring test A positional limit test is conducted by

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making

many

different movements. A positional limit is placed at the center of an axis, and the position is moved at many different speeds in a rapid traverse mode. Thus, the distance traveled on the axis until stop state is set by a stop response is measured. The machine tool builder is to determine a safety limit stop position including a safety margin. Data modification The user needs to enter the correct password before setting safety parameters with the system. After a safety parameter is modified, a check test needs to be conducted on the related safety function, and the test results need to be recorded in a report.

8.1.2
8.1.2.1

Start-up of the Safety Function Initial start-up


Main flow

Disable dual check safety Machine start-up Step 1


Initial state

FSSB I/O setting

Safety parameter input

First, check that the machine starts up normally when the dual check safety function is disabled.

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B-63494EN/01

8.START-UP

Preparation 1 Preparation 2

Disable the dual check Bit 6 of PRM No. 1902 = 0 safety function. Disable output (MCF), Connect the relay for driving based from I/O, that indicates on I/O output MCC is turned off. Note) When the dual check safety function is disabled, the So, make a To enable the dual

MCC on enable signal (MCF) is not output. connection to temporarily disable MCF.

check safety function, reset the temporary connection. Step 2 FSSB I/O setting Make the same settings as for the pulse module. Example: When a two-axis amplifier is set as slave 1, and FSSB I/O is set as slave 2 Make the settings indicated in the table below. Parameter setting Bit 0 of No. 1902 = 1 Bit 4 of No. 1905 = 1 No. 1910 = 0 No. 1911 = 1 No. 1912 = 16 40 Step 3 Safety parameter input Enable the dual check safety function, and enter the safety parameters. Meaning Manually sets the FSSB setting mode. Uses the first FSSB I/O unit. Sets the value of parameter No. 1023 less 1 when the slave is an amplifier Sets the value of parameter No. 1023 less 1 when the slave is an amplifier 16 when the slave is a pulse module Nos. 1913 to 1919 = 40 when there is no slave

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8.START-UP

B-63494EN/01

Preparation 1 Preparation 2

Enable the dual check safety Bit 6 of PRM No. 1902 = 1 function. Enables output (MCF), from Enable I/O output. I/O, that indicates MCC is turned off. Set the safety parameters indicated in the table below.

Parameter setting 1942 1943 1944 1945 1946 1947 1948 1838 2078 2079 4372 Step 4

Meaning Safety speed on each axis Safety position (+ direction) on each axis Safety position (- direction) on each axis Timer for safety input signal check Timer for MCC off Test Timer 1 for MCC off Timer 2 for MCC off Positional deviation limit value in mode C Dual position feedback conversion coefficient (numerator) Dual position feedback conversion coefficient (denominator) Safety speed on each spindle

Execution of general machine tests Axis and spindle optimization Dual check safety function adjustment (safety limitation speed, safety machine position) Step 5 Test for checking the safety function Check test execution and report creation Step 6 Parameter preservation Save all parameters including the safety parameters. parameters are used to start up the series. -90The

B-63494EN/01

8.START-UP

Step 7 Set a password. A password is used to disable unauthorized persons from modifying safety parameters. Before safety parameters of the equipment for which a password (No. 3225) is set can be modified, the password value must be set as the keyword (No. 3226). Only those persons authorized to conduct a check test should know the password value.

8.1.2.2

Series start-up start-up


The parameters for the safety monitoring function are transferred together with other parameters to the CNC as in the case of normal series start-up. procedure. Perform a safety function check test in addition to the normal start-up

8.1.3

Troubleshooting
Alarms related to the safety function are output on the ALARM screen. Correct the cause of trouble according to the chapter describing alarms and messages in this manual. When a component related to the safety function is to be replaced, an authorized person must conduct a safety function check test.

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9.SAMPLE SYSTEM CONFIGURATION

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SAMPLE SYSTEM CONFIGURATION

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9.SAMPLE SYSTEM CONFIGURATION

9.1

SAMPLE CONFIGURATION

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9.SAMPLE SYSTEM CONFIGURATION

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9.2
9.2.1

SAMPLE CONNECTIONS
Emergency Stop Signal (*ESP1, *ESP2)

+24V

I/O-Link I/O UNIT *ESP1 (X008#4)

FSSB I/O UNIT *ESP2 (DI+000#0)

0V

PSM CX4 ESP

NOTES Use a two-contact emergency stop button with a forced dissociation mechanism. Connect the emergency stop button to the PSM, as illustrated in the figure. When the signal is input, the spindle slows down and stops. Input a power-down factor to [G008#4] other than the signal from the emergency stop button. Create a Ladder program so that [X008#4] becomes a factor of [G008#4]. Machine side I/O-Link I/O UNIT PMC Emergency stop factor
Emergency stop button
Emergency stop factor other than emergency stop button

X008#4 Ladder program

X00n#n -94-

*ESPG (G008#4)

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9.SAMPLE SYSTEM CONFIGURATION

9.2.2

Guard Open Request Signal (ORQ)


Guard open request button

+24V

I/O-Link I/O UNIT PMC X00n#n


Ladder program

ORQ (G191#3)

NOTES Create a Ladder program of conditions for making a guard open request and then input the program to the PMC side [G191#3]. When the guard open request signal (ORQ) is input and when CNC safety has been confirmed, the guard unlock enable signal (*LGD) is output. If the CNC is not safe, ORQ input will not result in output of *LGD. If the input of ORQ is canceled while the guard is open, the CNC enters a safely stopped status (state in which the guard is open although the guard open request signal is not input). Close the guard (SGD is set to 1), then cancel this signal.

9.2.3

Test Mode Signal (OPT)


Test start button

+24V

I/O-Link I/O UNIT PMC

X00n#n

Ladder program

OPT (G191#2)

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9.SAMPLE SYSTEM CONFIGURATION


NOTES

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Create a Ladder program for performing a MCC off Test, then input the program to the PMC side [G191#2].

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9.SAMPLE SYSTEM CONFIGURATION

9.2.4

Guard Unlock Enable Signal (*LGD), Guard Lock State Signal (GDL), Guard State Signal (SGD)

+24V SW1 SW2

Guard closed

Guard-monitoring limit switch SW3

Safety relay RY1 RY1 RY3 RY2 RY2 0V RY3 RY3 RY1 RY2 0V

[Sample control components] SW1/SW2: Guard state monitoring switch with forced dissociation mechanism SW3: Guard lock switch RY1, RY2, RY3: Safety relay

I/O Link I/O UNIT X00n#n

PMC SGD (G191#4) *LGD (F191#0)

Y00n#n

Ladder program

FSSB I/O UNIT SGD (DI+001#4) -97-

9.SAMPLE SYSTEM CONFIGURATION


OPERATING PRINCIPLE This section describes the operation of

B-63494EN/01

various

guard

monitoring limit switches with lock mechanism and safety relays. State transition of components SW1 1 Guard closed Guard locked 2 Guard closed Guard unlocked 3 Guard opened Guard unlocked In a normal operation, the transition of 1, 2, 3, 1, 2, and so on is repeated. RY3 detects whether RY1 and RY2 contacts are made. If an unusual event is detected, SGD input is turned off. NOTES This example does not use the guard lock state signal (GDL). If GDL is not used, as in this example, tie [G191#5] and [DI+001#5] to 1. The guard state is monitored, and the guard state signal (SGD) affects the dual check safety function. The guard lock state signal (GDL) only indicates whether an input mismatch is found. The state of the GDL signal does not affect the dual check safety function. The illustrated sample system determines that the guard is open (sets SGD to 0) when the guard is unlocked. When the guard open request signal (ORQ) is accepted and when it has been confirmed that the CNC is in a safe state, the guard unlock enable signal (*LGD) is output. Based on this signal, use a Ladder program to create a guard unlock signal. OPEN OPEN OPEN OFF OFF ON 0 CLOSE CLOSE OPEN OFF ON OFF 0 SW2 SW3 RY1 RY2 ON RY3 OFF SGD 1

CLOSE CLOSE CLOSE ON

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9.SAMPLE SYSTEM CONFIGURATION

9.2.5

MCC On Enable Signal (MCF), Contact State Signal (*SMC)

MCC

+24V

I/O Link I/O UNIT PMC X00n#n *SMC1 (G191#6)

Y00n#n 0V FSSB I/O UNIT *SMC2 (DI+001#6) MCF (DO+000#1) 0V PSM 200A 200B CX3 MCC

MCF1 (F191#1)

U V W Electromagnetic contactor (MAIN MCC)

NOTES With the MCF signal of the PMC side, allocate [F191#1] to general-purpose output. On the FSSB side, directly connect [DO+000#1]. Also connect MCF to PSM, as illustrated in the figure. If an error occurs in the PSM, the PSM turns off the MCC.

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10.COMPONENTS LIST

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COMPONENTS LIST
Table 10.1. HARDWARE COMPONENTS
No. 1 Description Main board Specification number Of primary component A20B-8100-0130 Specification number of secondary component A20B-8100-0135 A20B-8100-0140 A20B-8100-0145 A20B-8100-0142 A20B-8100-0144 A20B-8100-0136 A20B-8100-0137 A20B-8100-0138 A20B-8100-0139 A20B-8100-0460 A20B-8100-0461 A20B-8100-0462 A20B-8100-0463 A20B-8100-0540 A20B-8100-0541 A20B-8100-0542 A20B-8100-0543 A16B-3200-0320 A16B-3300-0070 A16B-3300-0170 2 3 CPU card Servo card A20B-3300-0170 A17B-3300-0200 A20B-3300-0050 A20B-3300-0070 A20B-3300-0031 A20B-3300-0033 A20B-3300-0121 A20B-3300-0030 A20B-3300-0032 A20B-3300-0120 A17B-3300-0101 A17B-3300-0103 A17B-3300-0201 A17B-3300-0300 A17B-3300-0100 A17B-3300-0102 4 Graphic card A20B-3300-0150 A20B-3300-0020 A20B-3300-0021 A20B-3300-0151 A20B-3300-0023 A20B-3300-0153 A20B-3300-0024 A20B-3300-0154 A20B-3300-0025 A20B-3300-0091 A20B-3300-0090 A20B-3300-0161 A20B-3300-0162 A20B-3300-0190 5 DRAM MODULE A20B-3900-0131 A20B-3900-0030 A20B-3900-0042 A20B-3900-0041 A20B-3900-0040 A20B-3900-0132 A20B-3900-0130 6 SRAM MODULE A20B-3900-0060 A20B-3900-0053 A20B-3900-0052 A20B-3900-0061 A20B-3900-0020 -100Remarks

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10.COMPONENTS LIST
A20B-3900-0011 A20B-3900-0014 A20B-3900-0074 A20B-3900-0013 A20B-3900-0073 A20B-3900-0012 A20B-3900-0072 A20B-3900-0071 A20B-3900-0010 A20B-3900-0070

FROM MODULE

FSSB ADDITIONAL DETECTOR INTERFACE

A20B-2100-0270

I/O module

A20B-2100-0150 A20B-2002-0400 A20B-2100-0410 A20B-2002-0401 A20B-2100-0411 A20B-2100-0320 A20B-2002-0470 A20B-2002-0520 A20B-2002-0521

10 11 12

I/O

Unit

base A20B-9001-0020

A20B-9001-0040 A20B-2000-0550 A20B-2000-0510 A20B-8000-0420 A20B-8000-0710 A20B-8000-0820 A20B-9000-0970 A20B-9000-0971 A20B-9001-0011 A20B-9001-0010 A20B-9001-0281 A20B-8000-0341 A20B-9000-0972 A20B-9001-0280 A20B-9001-0490 A20B-8000-0510

module I/O Unit interface A20B-8000-0410 module DC digital input A20B-9000-0901 A20B-9000-0902 module

13

DC digital output A20B-9000-0921 module

A20B-9001-0220 A20B-8002-0070 A20B-8000-0440 A20B-8000-0510 A20B-9001-0490 A20B-8000-0740 A20B-8000-0741 A20B-9001-0680 A20B-9001-0681 A20B-8000-0760 A20B-8000-0780

14

DC input/output module

digital

A20B-8000-0750 A20B-8000-0751 A20B-8000-0730 A20B-8000-0731

15 16

AC

digital

input

A20B-8000-0341 A20B-9001-0940 A20B-8000-0470 A20B-8000-0480 A20B-8000-0321 A20B-8000-0880 -101-

module AC digital output module

10.COMPONENTS LIST
17 18 Relay module FSSB I/O module A20B-2100-0390 output

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A20B-9001-0200 A20B-8000-0101 A20B-8000-0500

Table 10.2. SOFTWARE


Series / Version FS16i-TA FS160i-TA FS160is-TA FS18i-TA FS180i-TA FS180is-TA FS21i-TA FS210i-TA FS210is-TA FS20i-TA FS16i-MA FS160i-MA FS160is-MA FS18i-MA FS180i-MA FS180is-MA FS21i-MA FS210i-MA FS210is-MA FS20i-FA B1F2 / ZZ BEF2 / ZZ DEF2 / ZZ D1F1 / ZZ B0F2 / ZZ BDF2 / ZZ DDF2 / ZZ Functions CNC for lathe with up to 8 servo axes and up to 4 spindle axes. CNC for lathe with up to 6 servo axes and up to 3 spindle axes. CNC for lathe with up to 4 servo axes and up to 2 spindle axes. CNC for manual lathe with up to 2 servo axes and up to 1 spindle axis CNC for machining center with up to 8 servo axes and up to 4 spindle axes. CNC for machining center with up to 6 servo axes and up to 3 spindle axes. CNC for machining center with up to 4 servo axes and up to 2 spindle axes. CNC for manual milling machine with up to 4 servo axes and up to 1 spindle axis.

D0F1 / ZZ

[Monitor software] Series / Version Monitor 90A9 / 03 [Servo control software] Series / Version Servo 90A5 / 01 [Spindle software] Series / Version Spindle 9D20 / ZZ

Functions Monitor functions

Functions Servo functions

Functions Spindle functions

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TITLE

DRAW. NO. SHEET

CUST

TECHNICAL REPORT

(MANUAL)

NO.TMN 02/071E
Date July. .2002 General Manager of Hardware Laboratory

Dual Check Safety OPERATOR'S MANUAL Addition and correction of sample system configuration

1. Communicate this report to : Your information only GE Fanuc-N, GE Fanuc-E FANUC Robotics MILACRON Machine tool builder Sales agency End user 2. Summary for Sales Documents Two sample system configurations are added to dual check safety operator's manual. 3. Notice

4. Attached Document Drawing No. B-63494EN/01-06

EAO

Original section of issue

Senior Vice Department General Manager Manager

Section Manager

Person in Charge

Dual Check Safety OPERATOR'S MANUAL Addition and correction of sample system configuration
1. Type of applied technical documents Name Spec.No./Version 2. Summary of change Group Name / Outline New, Add, Correct, Delete Applicable Date Dual Check Safety OPERATOR'S MANUAL B-63494EN/01

Basic Function Optional Function Unit Maintenance parts Notice Correction


There are three corrections. Correction of figure at 10.1.2. Delete part of 10.2.1. Correction of symbol of part of contact of electromagnetic contactor in figure at 10.2.5. Two sample system configurations are added. For One-path(When two PSMs are used) When two protection doors are used in a machine.

Another

TITLE

Dual Check Safety OPERATOR'S MANUAL Addition and correction of sample system configuration

01
EDIT.

02.06.26 Arimoto First issue


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Change a title of 10.1.1 as follows 10.1.1 For One-path(When one PSM is used)

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Cange 10.1.2 to 10.1.3 and change figure as follows 10.1.3 For Two-path(When the main side and sub side use a common MCC)

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Add 10.1.2 as follows 10.1.2 For One-path(When two PSMs are used)

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Change 10.1.3 to 10.1.4 Delete statement shown below and figure of 10.2.1. Input a power-down factor to [G008#4] other than the signal from the emergency stop button. Create a Ladder program so that [X008#4] becomes a factor of [G008#4]. Add statement shown below between a title of 10.2.4 and figure. When one protection door is used Example combined a guard-monitoring limit switch with lock mechanism and a safety relay in case of one protection door is shown below.

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Add statement and figure shown below between figure and OPERATING PRINCIPLE at 10.2.4.. When two protection doors are used in a safety zone. Example combined two guard-monitoring limit switches with lock mechanism and a safety relay in case of two protection doors in a safety zone is shown below.
+24V

Guard1 closed
SW11 SW12 SW21 SW22

Guard2 closed

Guard lock 1
Guard-monitoring limit switch 1
SW13

Guard lock 2
Guard-monitoring limit switch 2
SW23

0V

0V

Safety relay
RY1 RY3 RY2 RY3 RY3 RY2 RY1 RY2 0V I/O Link I/O UNIT X00n#n PMC SGD (G191#4) *LGD (F191#0) Y00n#n RY1

Ladder program

Y00m#m

Sample control components SW11/SW12,SW21/SW22 Guard state monitoring switch with forced dissociation mechanism SW13,SW23 Guard lock switch RY1,RY2,RY3Safety relay
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FSSB I/O UNIT SGD (DI+001#4)

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Change OPERATING PRINCIPLE at 10.2.4 as follows OPERATING PRINCIPLE When one protection door is used State of components is shown below. State of components
Guard CLOSE CLOSE OPEN Guard lock LOCK UNLOCK UNLOCK SW1 CLOSE CLOSE OPEN SW2 CLOSE CLOSE OPEN SW3 CLOSE OPEN OPEN RY1 ON OFF OFF RY2 ON ON OFF RY3 OFF OFF ON SGD 1 0 0

In case of no welding of contact in safety relay when state of protection door is changed to open from close and close, transition of 1,2,3,2,1 is occured. RY3 detects whether RY1 and RY2 contacts are made. If an unusual event is detected, SGD input is turned off. When two protection doors are used in a safety zone This example has construction added a guard-monitoring limit switch to example of "When one protection door is used". Two guard state monitoring switches of two guard-monitoring limit switches are connected series. When at least one guard is open SGD is turned off and the system determines that the guard is open. Two signals are outputed from I/O Link I/O UNIT to open each guard lock switch individually. When at least one guard lock is released by these signals SGD input is turned off and the system determines that the guard is open. State of components is shown below. State of components
Guard Guard lock1 Guard2 Guard lock
CLOSE CLOSE LOCK UNLOCK CLOSE CLOSE LOCK LOCK CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE LOCK CLOSE UNLOCK UNLOCK CLOSE LOCK CLOSE UNLOCK CLOSE UNLOCK CLOSE CLOSE UNLOCK CLOSE UNLOCK CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE ON ON ON OFF ON OFF ON ON ON OFF OFF 1 SW1 SW12 SW13 SW21 SW22 SW23 RY1 RY2 RY3 SGD

CLOSE CLOSE CLOSE CLOSE CLOSE

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CLOSE

LOCK

UNLOCK

CLOSE CLOSE CLOSE

ON

CLOSE

UNLOCK

UNLOCK

CLOSE CLOSE

ON

UNLOCK

UNLOCK

ON

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In case of no welding of contact in safety relay when guard2 is open and close with keeping guard1 close transition of 1,4,7,4,1 is occured. RY3 detects whether RY1 and RY2 contacts are made like "When one protection door is used". If an unusual event is detected, SGD input is turned off.

Change NOTES at 10.2.4 as follows NOTE This example does not use the guard lock state signal (GDL). If GDL is not used, as in this example, tie [G191#5] and [DI+001#5] to 1. The guard state is monitored, and the guard state signal (SGD) affects the dual check safety function. The guard lock state signal (GDL) only indicates whether an input mismatch is found. The state of the GDL signal does not affect the dual check safety function. In case of that one protection door is used the illustrated sample system determines that the guard is open (sets SGD to 0) when the guard is unlocked. In case of that two protection doors are used in a safety zone the illustrated sample system determines that the guard is open (sets SGD to 0) when at least one guard is unlocked. When the guard open request signal (ORQ) is accepted and when it has been confirmed that the CNC is in a safe state, the guard unlock signal (*LGD) is output. Based on this signal, use a Ladder program to create a guard unlock signal.

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Change figure at 10.2.5 as follows(A symbol of a part of contact of electromagnetic contactor is changed.)

+24V

I/O Link I/O UNIT

PMC

X00n#n

*SMC1 (G191#6)

Y00n#n 0V
FSSB I/O UNIT
*SMC2 (DI+001#6) MCF2 (DO+000#1)

MCF1 (F191#1)

0V PSM 200A 200B U V W


Electromagnetic contactor (MAIN MCC)

CX3 MCC

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FANUC Series 16i/18i/21iTB/MB FANUC Series 18i-MB5


Dual Check Safety

Programmable Safe-related I/O signals Specifications

Contents

1.1 1.2 1.3 1.4 1.5 1.6

OUTLINE ...................................................................................................................................................... 2 SPECIFICATIONS........................................................................................................................................ 4 SIGNALS ...................................................................................................................................................... 6 PARAMETERS............................................................................................................................................. 8 C-LANGUAGE EXECUTOR ........................................................................................................................ 9 ALARMS AND MESSAGES ...................................................................................................................... 14

Name No.

FS16i/18i/21i-TB/MB, FS18i-MB5
Programmable Safe-related I/O signals

04 Nov. 20, 2003 T.Inagaki corrected at [3] 03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1 02 Nov. 7, 2002 O.Abe corrected at [1] Ed. Date Draw up Jul.19, 2002 Contents

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1.1

Outline
In the Dual Check Safety function, Safe-related I/O signal monitoring function has been developed for the machine having only one safety guard. This time, FANUC has added the new specifications to Safe-related I/O signal monitoring function as Programmable Safe-related I/O signals. These features are as follows. (1) Each path can have 16 points of DI signals which are cross-checked by both CNC CPU and Monitor CPU as Programmable Safe-related I/O signals. (2) Logic that handles those signals can be developed by machine tool builder using C-language executor and PMC ladder function. (3) As output of above mentioned logic, each path can have 8 points of DO signals which are cross-checked by both CNC CPU and Monitor CPU as Programmable Safe related I/O signals. note) The 2nd path of 1 CPU 2 path control and the 3rd path of 2 CPU 3 path control have no free DI/DO signals because they have no FSSB I/O module. This function will be helpful to apply to the machine having 2 safety guards and flexible machine inputs logic. The C-language executor is required to use this function. This function is inapplicable to loader control. Safe-related I/O signal monitoring function executed by the former method is applied to loader control. The following software are required for this improvement: FS16i-TB FS18i-TB FS21i-TB FS16i-MB FS18i-MB FS18i-MB5 FS21i-MB Monitor Servo B1H1-22 or later BEH1-22 or later DEH1-22 or later B0H1-22 or later BDH1-22 or later BDH5-12 or later DDH1-22 or later 90B9-03 90B0-20 or later 90B3-04 or later 90B7-04 or later C-language executor library BY01-2.9F or later [3] [1] [3]

Name No.

FS16i/18i/21i-TB/MB, FS18i-MB5
Programmable Safe-related I/O signals

04 Nov. 20, 2003 T.Inagaki corrected at [3] 03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1 02 Nov. 7, 2002 O.Abe corrected at [1] Ed. Date Draw up Jul.19, 2002 Contents

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NOTE This function will be under investigation at TUV soon. So these required software versions are subject to change without notice.

[1]

Name No.

FS16i/18i/21i-TB/MB, FS18i-MB5
Programmable Safe-related I/O signals

04 Nov. 20, 2003 T.Inagaki corrected at [3] 03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1 02 Nov. 7, 2002 O.Abe corrected at [1] Ed. Date Draw up Jul.19, 2002 Contents

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1.2

Specifications

CNC

C-language executor User Logic

[f]

[k]

[l]

Speed/ Position Monitoring and so on


MCF,LGD

[g]

DO Crosscheck G191 G334 G335


[b]

Free 8

Monitor
DI Crosscheck
[d]

F191

G331

PMC
[e]

User Logic

Speed/ Position Monitoring and so on

[i]

Y signals

[e] [m]

Free 8 points [a]

X signals

DI+000 ~DI+003

MCF [c]

[h] [j]

DO+000 DO+001

I/O Link #1

FSSB I/O #2

*ESP, *SMC, GDL, SGD, Free 16 points ORQ, OPT MCF, Free 8 points LGD
Note) The mark [a]~[m] are for reference to Sequence of Programmable Safe-related I/O signals Function mentioned in the following page.

Fig 1. Concept of function

Name No.

FS16i/18i/21i-TB/MB, FS18i-MB5
Programmable Safe-related I/O signals

04 Nov. 20, 2003 T.Inagaki corrected at [3] 03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1 02 Nov. 7, 2002 O.Abe corrected at [1] Ed. Date Draw up Jul.19, 2002 Contents

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Improving points for Safe-related I/O signal monitoring function


(1) Free 16 points input signals are added to I/O interface. (2) User can make 8 points free output from Free 16 points input signals.

Sequence of Programmable Safe-related I/O signals function


Programmable Safe-related I/O signals function works as following sequence. Please refer to Fig1. (Conceptual figure). [a] Safe-related DI signals (*ESP, *SMC, GDL, SGD, ORQ, OPT and free 16 points) are input to PMC via I/O Link #1 (X). [b] The user program (ladder) on PMC creates the signals (G191, G334, G335) by copying each signal (*SMC, GDL, SGD, ORQ, OPT and free 16 points) directly. [c] Safe-related DI signals (*ESP, *SMC, GDL, SGD and free 16 points) are input to Monitor via FSSB I/O #2 (DI+000 ~ DI+003). [d] CNC CPU and Monitor CPU execute cross-check for input signals. [e] The user program (ladder) on PMC creates the signals (free 8 points) based on the user logic, and output the signals to CNC CPU (G331) and to machine via I/O Link #1 (Y). [f] The user program on C-language executor creates the signals (free 8 points) based on the user logic (same logic used by the user program (ladder) on PMC), and transfers the signals to Monitor. [g] CNC CPU and Monitor CPU executes cross-check for output signals. [h] Monitor CPU outputs the signals (free 8 points) to machine via FSSB I/O #2 (DO+001). [i] [j] Monitor CPU monitors the speed/position and so on and creates the signals MCF. Monitor CPU outputs the signals (MCF) to machine via FSSB I/O #2 (DO+000). [k] CNC CPU monitors the speed/position and so on and creates the signals MCF and LGD. [l] CNC CPU outputs the signals (LGD, MCF) to PMC (F191). [m] PMC CPU outputs the signals (LGD, MCF) to machine via I/O Link #1 (Y).

[2]

Illegal state watching


When the states of the signal via PMC and of the signal via FSSB are different during a certain time, CNC CPU and Monitor CPU judge that an illegality related to safety occurs. And both CPUs stop the power to motor drive circuit immediately.

Name No.

FS16i/18i/21i-TB/MB, FS18i-MB5
Programmable Safe-related I/O signals

04 Nov. 20, 2003 T.Inagaki corrected at [3] 03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1 02 Nov. 7, 2002 O.Abe corrected at [1] Ed. Date Draw up Jul.19, 2002 Contents

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1.3
1.3.1

Signals
Signals

Programable safe-related DI signal [2] SDI00~SDI15 <G334, G335> <DI+002, DI+003>


[Classification] [Function] [Operation] Input signal CNC and Monitor use these signals only for cross-check for input signals in Dual Check Safety. These signals are able to be used freely by user. WARNING The 2nd path of 1 CPU 2 path control and the 3rd path of 2 CPU 3 path control have no Programmable safe-related DI signals because they have no FSSB I/O module.

Programmable safe-related DO signal [2] SDO00~SDO07 <G331> <DO+001>


[Classification] [Function] [Operation] Input signal CNC and Monitor use these signals only for cross-check for output signals in Dual Check Safety. These signals are able to be used freely by user. WARNING DO used in these signals name means output signals from the user program, but not from CNC. So these signals is addressed in G signals. The 2nd path of 1 CPU 2 path control and the 3rd path of 2 CPU 3 path control have no Programmable safe-related DO signals because they have no FSSB I/O module.

Name No.

FS16i/18i/21i-TB/MB, FS18i-MB5
Programmable Safe-related I/O signals

04 Nov. 20, 2003 T.Inagaki corrected at [3] 03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1 02 Nov. 7, 2002 O.Abe corrected at [1] Ed. Date Draw up Jul.19, 2002 Contents

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1.3.2
via PMC

Signal addresses

#7 X008 G008 G191 G331 G334 G335 SDO07 SDI07 SDI15

#6

#5

#4 *ESP1 *ESPG

#3

#2

#1

#0

*SMC1 SDO06 SDI06 SDI14

GDL1 SDO05 SDI05 SDI13

SGD1 SDO04 SDI04 SDI12

ORQ SDO03 SDI03 SDI11

OPT SDO02 SDI02 SDI10 SDO01 SDI01 SDI09 SDO00 SDI00 SDI08

#7 F191

#6

#5

#4

#3

#2 RQT

#1 MCF1

#0 LGD

via FSSB
#7 DI+000 DI+001 DI+002 DI+003 SDI07 SDI15 *SMC2 SDI06 SDI14 GDL2 SDI05 SDI13 SGD2 SDI04 SDI12 SDI03 SDI11 SDI02 SDI10 SDI01 SDI09 SDI00 SDI08 #6 #5 #4 #3 #2 #1 #0 *ESP2

#7 DO+000 DO+001 SDO07

#6

#5

#4

#3

#2

#1 MCF2

#0

SDO06

SDO05

SDO04

SDO03

SDO02

SDO01

SDO00

WARNING The 2nd path of 1 CPU 2 path control and the 3rd path of 2 CPU 3 path control have no Safe programmable DI/DO signals because they have no FSSB I/O module.

Name No.

FS16i/18i/21i-TB/MB, FS18i-MB5
Programmable Safe-related I/O signals

04 Nov. 20, 2003 T.Inagaki corrected at [3] 03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1 02 Nov. 7, 2002 O.Abe corrected at [1] Ed. Date Draw up Jul.19, 2002 Contents

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1.4

Parameters
#7 13800 [Data type] CIO Bit Programmable safe-related I/O signals are 0: Disabled. 1: Enabled. CAUTION When this parameter is set, power must be turned off before operation is continued. This parameter is protected by key and password of Dual Check Safety. If those parameters should be changed, please set the password for safe parameters to the key for safe parameters (parameter No.3226). In the multi-path system, this parameter is specified for each path. This parameter is disabled on the 2nd path of 1 CPU 2 path control, the 3rd path of 2 CPU 3 path control and the loader control. #6 #5 #4 #3 #2 #1 #0 CIO

Name No.

FS16i/18i/21i-TB/MB, FS18i-MB5
Programmable Safe-related I/O signals

04 Nov. 20, 2003 T.Inagaki corrected at [3] 03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1 02 Nov. 7, 2002 O.Abe corrected at [1] Ed. Date Draw up Jul.19, 2002 Contents

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1.5

C-language executor
These C-language executor libraries are added to handle the signals from/to Monitor.

Call CNC window <HILEV>


[Name] [Syntax] [Arguments] [Return] [Description] cnc_window int cnc_window( unsigned int *iodata ) iodata : Input/output data memory. Returns return-code of CNC window. This is same as the content of iodata[1]. Calls CNC window function. "iodata" is input/output data memory for CNC window function.The pointer to this memory area is store DS:SI and passed to CNC window process. The application program sets the required information into this memory and calls this function. The return information of CNC window is stored in "iodata". Work RAM area that CNC window requires (pointed by ES:DI) is provided by this function itself. Data structure of input/output memory is generally as follows. iodata[0] iodata[1] iodata[2] iodata[3] iodata[4] iodata[5] and after For example, you call this function as below to call "Read alarm status" function. unsigned int iodata[11] ; iodata[0] = 23 ; cnc_window( iodata ) ; The CNC alarm information will be stored in "iodata[5]". Function code Return code Data length Data number Data attribute General data buffer

Name No.

FS16i/18i/21i-TB/MB, FS18i-MB5
Programmable Safe-related I/O signals

04 Nov. 20, 2003 T.Inagaki corrected at [3] 03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1 02 Nov. 7, 2002 O.Abe corrected at [1] Ed. Date Draw up Jul.19, 2002 Contents

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High-Level application program can not call all CNC window functions. Only following functions are available. (1)Read program number in executing. (2) Read sequence number in executing. (3) Read actual feed rate of controlled axes. (4) Read actual spindle speed. (5) Read absolute position. (6) Read machine position. (7) Read relative position. (8) Read distance to go. (9) Read skipped position. (10) Read servo delay amount. (11) Read acceleration/deceleration delay amount. (12) Read alarm status. (13) Read abnormal load torque data. (14) Read load information of serial spindle. (15) Read A/D conversion data. (Read load data of servo axis) (16) Read Programable Safe-related DI Signal. (17) Write Programable Safe-related DO Signal.

[2] [2]

The detail descriptions of each functions will be offered later. This function takes approx. 0.03 msec at least for calling CNC window (in case of FS16i/18i). The execution time may exceed the max. execution time (1 msec) by calling this function so many times because of increasing processing time. Therefore, you should use this function up to 10 times at maximum for each 8 msec processing.

Name No.

FS16i/18i/21i-TB/MB, FS18i-MB5
Programmable Safe-related I/O signals

04 Nov. 20, 2003 T.Inagaki corrected at [3] 03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1 02 Nov. 7, 2002 O.Abe corrected at [1] Ed. Date Draw up Jul.19, 2002 Contents

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(16) Read Programable Safe-related DI Signal [2] Equivalence to "pmc_rdsafeprgio()" function. [Input] Function code Data length Data number Data attribute [Output] Return code iodate[0] = 136 iodata[2] = 0 iodata[3] = 0 iodata[4] = 0 iodata[1] = 0 Successful. 3 Invalid data number. programable safe-related DI signal iodata[5] upper byte:safe-related DI signal 1 (DI+000) [2] lower byte:safe-related DI signal 2 (DI+001) (17) Write Programable Safe-related DO Signal [2] Equivalence to "pmc_wrsafeprgio()" function. [Input] Function code Data length Data number Data attribute iodate[0] = 137 iodata[2] = 1 iodata[3] = 0 iodata[4] = 0 ( char )iodata[5] [Output] Return code iodata[1] = 0 Successful. 6 Option for dual check safty isn't added. [2] [3] 6 Option for dual check safty isn't added.

[3]

programable safe-related DO signal (DO+001) [2][3]

Name No.

FS16i/18i/21i-TB/MB, FS18i-MB5
Programmable Safe-related I/O signals

04 Nov. 20, 2003 T.Inagaki corrected at [3] 03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1 02 Nov. 7, 2002 O.Abe corrected at [1] Ed. Date Draw up Jul.19, 2002 Contents

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Read Programable Safe-related DI Signal [2]


[Name] [Syntax] pmc_rdsafeprgio #include <fwindow.h> int pmc_rdsafeprgio( int datano , struct iodbsaftyprg *buf ) ; struct iodbsaftyprg { int int char }; [Arguments] [Return] [Description] datano Buf : data number( = 0 ). : buffer in which the signal datas for programable safe-related DI stored. [2] : Successful. : Option for dual check safty isn't added. safe-related input signal 1 (DI+002) safe-related input signal 2 (DI+003) datano ; /* Data No. */ */ dummy ; /* Not use

cdata[2] ; /* I/O signal */

EW_OK( 0) EW_NOOPT( 6) cdata[0] cdata[1]

Read programable safe-related DI signals via FSSB I/O for dual check safety.

[Examples]

The following program reads signal datas for programable safe-related DI and display them. [2] void print_safetyprgio( void ) { int struct iodbsaftyprg ret = ret; buf;

pmc_rdsafeprgio( 0 , &buf ); {

if( ret == 0 )

printf( "G334 : %02xh n" , buf.cdata[0] ) ; printf( "G335 : %02xh n" , buf.cdata[1] ) ; } } [3]

Name No.

FS16i/18i/21i-TB/MB, FS18i-MB5
Programmable Safe-related I/O signals

04 Nov. 20, 2003 T.Inagaki corrected at [3] 03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1 02 Nov. 7, 2002 O.Abe corrected at [1] Ed. Date Draw up Jul.19, 2002 Contents

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Write Programable Safe-related DO Signal [2]


[Name] [Syntax] [Arguments] [Return] [Description] [Examples] pmc_wrsafeprgio #include data <fwindow.h> : data of Programable Safe-related DO Signals. : Successful. : Option for dual check safty isn't added. [2] int pmc_wrsafeprgio( char data ) ;

[3]

EW_OK( 0) EW_NOOPT( 6) safety. [2][3]

Write programable safe-related DO signals via FSSB I/O (DO+001) for dual check The following program initializes signal datas for programable safe-related DO. [2] int init_prgio_di( void ) { int ret; ret = pmc_wrsafeprgio( 0x00 ) ; if( ret == 0 ) return( 0 ); else return( -1 ); }

[1] [3]

Name No.

FS16i/18i/21i-TB/MB, FS18i-MB5
Programmable Safe-related I/O signals

04 Nov. 20, 2003 T.Inagaki corrected at [3] 03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1 02 Nov. 7, 2002 O.Abe corrected at [1] Ed. Date Draw up Jul.19, 2002 Contents

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1.6
No. 479

Alarms and messages


Message ILLEGAL SAFETY DI (MNT) Description The Monitor detected a mismatch exceeding the set time (parameter No.1945) between a safe-related input signal via the PMC and the same signal via the FSSB. Check the safe-related input signals via the PMC and via the FSSB are equal. 485 ILLEGAL SAFETY DO (MNT) The Monitor detected a mismatch exceeding the set time (parameter No.1945) between a safe-related output signal via the PMC and the same signal via the FSSB. Check the safe-related output signals via the PMC and via the FSSB are equal. 486 ILLEGAL SAFETY DI (CNC) The CNC detected a mismatch exceeding the set time (parameter No.1945) between a safe-related input signal via the PMC and the same signal via the FSSB. Check the safe-related input signals via the PMC and via the FSSB are equal. 493 ILLEGAL SAFETY DO (CNC) The CNC detected a mismatch exceeding the set time (parameter No.1945) between a safe-related output signal via the PMC and the same signal via the FSSB. Check the safe-related output signals via the PMC and via the FSSB are equal. [3]

Name No.

FS16i/18i/21i-TB/MB, FS18i-MB5
Programmable Safe-related I/O signals

04 Nov. 20, 2003 T.Inagaki corrected at [3] 03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1 02 Nov. 7, 2002 O.Abe corrected at [1] Ed. Date Draw up Jul.19, 2002 Contents

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TECHNICAL REPORT

(MANUAL)

NO.TMN 02/071E
Date July. .2002 General Manager of Hardware Laboratory

Dual Check Safety OPERATOR'S MANUAL Addition and correction of sample system configuration

1. Communicate this report to : Your information only GE Fanuc-N, GE Fanuc-E FANUC Robotics MILACRON Machine tool builder Sales agency End user 2. Summary for Sales Documents Two sample system configurations are added to dual check safety operator's manual. 3. Notice

4. Attached Document Drawing No. B-63494EN/01-06

EAO

Original section of issue

Senior Vice Department General Manager Manager

Section Manager

Person in Charge

Dual Check Safety OPERATOR'S MANUAL Addition and correction of sample system configuration
1. Type of applied technical documents Name Spec.No./Version 2. Summary of change Group Name / Outline New, Add, Correct, Delete Applicable Date Dual Check Safety OPERATOR'S MANUAL B-63494EN/01

Basic Function Optional Function Unit Maintenance parts Notice Correction


There are three corrections. Correction of figure at 10.1.2. Delete part of 10.2.1. Correction of symbol of part of contact of electromagnetic contactor in figure at 10.2.5. Two sample system configurations are added. For One-path(When two PSMs are used) When two protection doors are used in a machine.

Another

TITLE

Dual Check Safety OPERATOR'S MANUAL Addition and correction of sample system configuration

01
EDIT.

02.06.26 Arimoto First issue


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Change a title of 10.1.1 as follows 10.1.1 For One-path(When one PSM is used)

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Cange 10.1.2 to 10.1.3 and change figure as follows 10.1.3 For Two-path(When the main side and sub side use a common MCC)

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Add 10.1.2 as follows 10.1.2 For One-path(When two PSMs are used)

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Change 10.1.3 to 10.1.4 Delete statement shown below and figure of 10.2.1. Input a power-down factor to [G008#4] other than the signal from the emergency stop button. Create a Ladder program so that [X008#4] becomes a factor of [G008#4]. Add statement shown below between a title of 10.2.4 and figure. When one protection door is used Example combined a guard-monitoring limit switch with lock mechanism and a safety relay in case of one protection door is shown below.

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Add statement and figure shown below between figure and OPERATING PRINCIPLE at 10.2.4.. When two protection doors are used in a safety zone. Example combined two guard-monitoring limit switches with lock mechanism and a safety relay in case of two protection doors in a safety zone is shown below.
+24V

Guard1 closed
SW11 SW12 SW21 SW22

Guard2 closed

Guard lock 1
Guard-monitoring limit switch 1
SW13

Guard lock 2
Guard-monitoring limit switch 2
SW23

0V

0V

Safety relay
RY1 RY3 RY2 RY3 RY3 RY2 RY1 RY2 0V I/O Link I/O UNIT X00n#n PMC SGD (G191#4) *LGD (F191#0) Y00n#n RY1

Ladder program

Y00m#m

Sample control components SW11/SW12,SW21/SW22 Guard state monitoring switch with forced dissociation mechanism SW13,SW23 Guard lock switch RY1,RY2,RY3Safety relay
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FSSB I/O UNIT SGD (DI+001#4)

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Change OPERATING PRINCIPLE at 10.2.4 as follows OPERATING PRINCIPLE When one protection door is used State of components is shown below. State of components
Guard CLOSE CLOSE OPEN Guard lock LOCK UNLOCK UNLOCK SW1 CLOSE CLOSE OPEN SW2 CLOSE CLOSE OPEN SW3 CLOSE OPEN OPEN RY1 ON OFF OFF RY2 ON ON OFF RY3 OFF OFF ON SGD 1 0 0

In case of no welding of contact in safety relay when state of protection door is changed to open from close and close, transition of 1,2,3,2,1 is occured. RY3 detects whether RY1 and RY2 contacts are made. If an unusual event is detected, SGD input is turned off. When two protection doors are used in a safety zone This example has construction added a guard-monitoring limit switch to example of "When one protection door is used". Two guard state monitoring switches of two guard-monitoring limit switches are connected series. When at least one guard is open SGD is turned off and the system determines that the guard is open. Two signals are outputed from I/O Link I/O UNIT to open each guard lock switch individually. When at least one guard lock is released by these signals SGD input is turned off and the system determines that the guard is open. State of components is shown below. State of components
Guard Guard lock1 Guard2 Guard lock
CLOSE CLOSE LOCK UNLOCK CLOSE CLOSE LOCK LOCK CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE LOCK CLOSE UNLOCK UNLOCK CLOSE LOCK CLOSE UNLOCK CLOSE UNLOCK CLOSE CLOSE UNLOCK CLOSE UNLOCK CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE ON ON ON OFF ON OFF ON ON ON OFF OFF 1 SW1 SW12 SW13 SW21 SW22 SW23 RY1 RY2 RY3 SGD

CLOSE CLOSE CLOSE CLOSE CLOSE

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CLOSE

LOCK

UNLOCK

CLOSE CLOSE CLOSE

ON

CLOSE

UNLOCK

UNLOCK

CLOSE CLOSE

ON

UNLOCK

UNLOCK

ON

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In case of no welding of contact in safety relay when guard2 is open and close with keeping guard1 close transition of 1,4,7,4,1 is occured. RY3 detects whether RY1 and RY2 contacts are made like "When one protection door is used". If an unusual event is detected, SGD input is turned off.

Change NOTES at 10.2.4 as follows NOTE This example does not use the guard lock state signal (GDL). If GDL is not used, as in this example, tie [G191#5] and [DI+001#5] to 1. The guard state is monitored, and the guard state signal (SGD) affects the dual check safety function. The guard lock state signal (GDL) only indicates whether an input mismatch is found. The state of the GDL signal does not affect the dual check safety function. In case of that one protection door is used the illustrated sample system determines that the guard is open (sets SGD to 0) when the guard is unlocked. In case of that two protection doors are used in a safety zone the illustrated sample system determines that the guard is open (sets SGD to 0) when at least one guard is unlocked. When the guard open request signal (ORQ) is accepted and when it has been confirmed that the CNC is in a safe state, the guard unlock signal (*LGD) is output. Based on this signal, use a Ladder program to create a guard unlock signal.

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Change figure at 10.2.5 as follows(A symbol of a part of contact of electromagnetic contactor is changed.)

+24V

I/O Link I/O UNIT

PMC

X00n#n

*SMC1 (G191#6)

Y00n#n 0V
FSSB I/O UNIT
*SMC2 (DI+001#6) MCF2 (DO+000#1)

MCF1 (F191#1)

0V PSM 200A 200B U V W


Electromagnetic contactor (MAIN MCC)

CX3 MCC

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