dcs fanuc

OPERATOR’S MANUAL
B-63494EN/01
Ȧ No part of this manual may be reproduced in any form.
Ȧ 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”.
SAFETY PRECAUTIONS
B-63494EN/01
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.
s-1
TABLE OF CONTENTS
B-63494EN/01
TABLE OF CONTENTS
SAFETY PRECAUTIONS
PRECAUTIONS................................
................................................................
................................................................................................
.......................................................................................
....................................................... s-1
s-1
1
OVERVIEW
OVERVIEW................................
EW................................................................
................................................................................................
................................................................................................
.........................................................................
......................................... 1
1.1
DIRECTIVE AND STANDARDS ..................................................................................................... 3
1.1.1
Directives.................................................................................................................................... 3
1.1.2
Related Safety Standards.......................................................................................................... 3
1.1.3
Risk Analysis and Evaluation................................................................................................... 3
1.1.4
Certification Test ....................................................................................................................... 4
1.2
DEFINITION OF TERMS ................................................................................................................ 5
1.2.1
General Definition of Terms ..................................................................................................... 5
1.2.2
Definition of Terms Related to the Safety Function................................................................ 5
1.3
BASIC PRINCIPLE OF DUAL CHECK SAFETY .......................................................................... 6
1.3.1
Features of Dual Check Safety ................................................................................................. 6
1.3.2
Compliance with the Safety Standard (EN954-1, Category 3) ............................................... 7
1.4
1.3.2.1
Latent error detection and cross-check ...........................................................................................8
1.3.2.2
Safety monitoring cycle and cross-check cycle ................................................................................9
1.3.2.3
MCC off Test .....................................................................................................................................9
1.3.2.4
Error analysis .................................................................................................................................10
1.3.2.5
Remaining risks..............................................................................................................................10
GENERAL INFORMATION........................................................................................................... 12
2
SYSTEM CONFIGURATION
CONFIGURATION ................................................................
................................................................................................
...........................................................................
........................................... 14
3
SAFETY FUNCTIONS ................................................................
................................................................................................
.....................................................................................
..................................................... 16
3.1
APPLICATION RANGE ................................................................................................................. 17
3.2
BEFORE USING THE SAFETY FUNCTION............................................................................... 20
3.2.1
Important Items to Check Before Using the Safety Function .............................................. 20
3.2.2
MCC off Test of the Safe Stop Function ................................................................................. 20
3.3
STOP ................................................................................................................................................ 21
3.3.1
Stopping the Spindle Motor .................................................................................................... 21
3.3.2
Stopping the Servo Motor........................................................................................................ 22
3.3.3
Stop States ............................................................................................................................... 22
3.4
SAFE-RELATED I/O SIGNAL MONITORING ............................................................................ 24
3.5
EMERGENCY STOP ...................................................................................................................... 29
3.6
SAFE SPEED MONITORING........................................................................................................ 30
3.7
SAFE MACHINE POSITION MONITORING .............................................................................. 31
c-1
TABLE OF CONTENTS
3.8
4
6
7
MCC OFF TEST .............................................................................................................................. 32
INSTALLATION
INSTALLATION ................................................................
................................................................................................
...............................................................................................
............................................................... 33
4.1
5
B-63494EN/01
OVERALL CONNECTION DIAGRAM ......................................................................................... 35
4.1.1
For One-path............................................................................................................................ 35
4.1.2
For Two-path............................................................................................................................ 37
4.2
DI/DO CONNECTION (VIA THE PMC) ....................................................................................... 40
4.3
DI/DO CONNECTION (VIA THE FSSB) ...................................................................................... 41
4.3.1
FSSB I/O Connection............................................................................................................... 41
4.3.2
FSSB I/O Attachment.............................................................................................................. 43
4.3.3
FSSB I/O Specification List..................................................................................................... 47
I/O SIGNALS ................................................................
................................................................................................
................................................................................................
....................................................................
.................................... 48
5.1
OVERVIEW ..................................................................................................................................... 49
5.2
SIGNALS ......................................................................................................................................... 50
5.3
SIGNAL ADDRESSES.................................................................................................................... 55
5.4
SAFETY SIGNAL MODES............................................................................................................. 56
5.5
NOTES ON MULTI-PATH CONTROL ......................................................................................... 57
5.5.1
Two-CPU Two-Path Control (Without Axis Change between Paths)................................... 57
5.5.2
Two-CPU Two-Path Control (With Axis Change between Paths) ........................................ 58
5.5.3
One-CPU Two-Path Control.................................................................................................... 59
5.5.4
Two-CPU Three-Path Control................................................................................................. 60
5.5.5
Loader Control ......................................................................................................................... 61
PARAMETERS ................................................................
................................................................................................
................................................................................................
.................................................................
................................. 62
6.1
OVERVIEW ..................................................................................................................................... 63
6.2
PARAMETERS ................................................................................................................................ 64
6.3
PARAMETERS RELATED TO THE USE OF FSSB I/O UNIT ................................................... 72
6.4
FUNCTIONS THAT REQUIRE SPECIAL PARAMETER SETTINGS....................................... 74
6.4.1
Tandem Control ....................................................................................................................... 74
6.4.2
Simple Electronic Gear Box and Electronic Gear Box 2-pair ............................................... 74
6.4.3
Multi-path Control................................................................................................................... 74
START-UP ................................................................
................................................................................................
................................................................................................
........................................................................
........................................ 75
7.1
START-UP OPERATION................................................................................................................ 76
7.1.1
Acceptance Test and Report for Safety Functions................................................................. 76
7.1.2
Start-up of the Dual Check Safety Function.......................................................................... 78
7.1.2.1
Initial start-up ................................................................................................................................78
c-2
TABLE OF CONTENTS
B-63494EN/01
7.1.2.2
7.1.3
8
Series start-up ................................................................................................................................80
Troubleshooting ....................................................................................................................... 80
MAINTENANCE ................................................................
................................................................................................
..............................................................................................
.............................................................. 81
8.1
SAFETY PRECAUTIONS............................................................................................................... 82
8.2
ALARMS AND MESSAGES ........................................................................................................... 86
9
8.2.1
Overview................................................................................................................................... 86
8.2.2
Servo Alarms............................................................................................................................ 87
8.2.3
Serial Spindle Alarms.............................................................................................................. 91
8.2.4
Alarms Displayed on the Spindle Unit................................................................................... 92
8.2.5
System Alarms ......................................................................................................................... 93
8.2.6
Boot System Alarms ................................................................................................................ 93
DIAGNOSIS ................................................................
................................................................................................
................................................................................................
......................................................................
...................................... 94
9.1
OVERVIEW ..................................................................................................................................... 95
9.2
DIAGNOSIS..................................................................................................................................... 96
10
SAMPLE SYSTEM CONFI
CONFIGURATION
GURATION ................................................................
.......................................................................................
....................................................... 97
10.1
SAMPLE CONFIGURATION......................................................................................................... 98
10.1.1
For One-path............................................................................................................................ 98
10.1.2
For Two-path (When the main side and sub side use a common MCC)............................... 99
10.1.3
For Two-path (When the main side and sub side use independent MCCs and
protection doors) .................................................................................................................... 100
10.2
SAMPLE CONNECTIONS ........................................................................................................... 101
10.2.1
Emergency Stop Signal (*ESP1, *ESP2).............................................................................. 101
10.2.2
Guard Open Request Signal (ORQ)...................................................................................... 102
10.2.3
Test Mode Signal (OPT) ........................................................................................................ 102
10.2.4
Guard Unlock Signal (*LGD), Guard Lock State Signal (GDL),
Guard State Signal (SGD)..................................................................................................... 103
10.2.5
11
MCC On Enable Signal (MCF), MCC Contact State Signal (*SMC).................................. 105
COMPONENTS LIST ................................................................
................................................................................................
.................................................................................
................................................. 106
11.1
HARDWARE COMPONENTS ..................................................................................................... 107
11.1.1
Hardware Components for Series 16i/18i/21i/160i/180i/210i/160is/180is/210is-MODEL A107
11.1.2
Hardware Components for Series 16i/18i/21i/160i/180i/210i/160is/180is/210is-MODEL B107
11.1.3
Hardware Components for Other Units............................................................................... 108
11.2
SOFTWARE COMPONENTS....................................................................................................... 109
11.3
SERVO AMPLIFIER..................................................................................................................... 111
c-3
1.OVERVIEW
B-63494EN/01
1
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.
-1-
1.OVERVIEW
B-63494EN/01
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.
-2-
1.OVERVIEW
B-63494EN/01
1.1
DIRECTIVE AND STANDARDS
1.1.1
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
1.1.2
1998 Safety of machinery
1989 Electromagnetic compatibility
1973 Low Voltage Equipment
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)
1.1.3
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
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.
-3-
1.OVERVIEW
1.1.4
B-63494EN/01
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.
-4-
1.OVERVIEW
B-63494EN/01
1.2
DEFINITION OF TERMS
1.2.1
General Definition of Terms
Reliability and safety
Reliability and safety are defined by EN292-1 as follows:
Term
Reliability
Safety
1.2.2
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
Definition of Terms Related to the Safety Function
Safe-related I/O signal
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 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.
-5-
1.OVERVIEW
B-63494EN/01
1.3
BASIC PRINCIPLE OF DUAL CHECK SAFETY
1.3.1
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.
-6-
1.OVERVIEW
B-63494EN/01
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
Monitor
Monitor
CPU
CPU
Magnetic
contactor
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.
-7-
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
Detection of latent errors
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.
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 ?.).
-8-
1.OVERVIEW
B-63494EN/01
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.
-9-
1.OVERVIEW
1.3.2.4
B-63494EN/01
Error analysis
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
Cause
Amplifier or control unit
failure, operation error, etc.
Excessive feed
axis speed
Amplifier or control unit
failure, operation error, etc.
Feed axis
safety machine
position error
Amplifier or control unit
failure, operation error, etc.
Input/output
signal error
Wiring error, control unit
failure, 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 when the protection door is closed
Error
Input/output
signal error
1.3.2.5
Cause
Wiring error, control unit
failure, etc.
Action
Safety limitation speed
monitoring function
EN60204-1 Category 1/0
stop
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).
- 10 -
1.OVERVIEW
B-63494EN/01
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
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.
- 11 -
1.OVERVIEW
1.4
B-63494EN/01
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
- 12 -
1.OVERVIEW
B-63494EN/01
[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
- 13 -
2.SYSTEM CONFIGURATION
2
B-63494EN/01
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
- α series servo amplifier
- α series spindle amplifier
- α series power supply module
- αi series servo amplifier
- αi series spindle amplifier
- αi series power supply module
Motor
- α series servo motor
- α series spindle motor
- β series servo motor
- αi series servo motor
- αi series spindle motor
I/O
- I/O unit (I/O Link)
- I/O module (FSSB)
Software
- Dual check software
- 14 -
2.SYSTEM CONFIGURATION
B-63494EN/01
Detector system
The detectors below can be used.
- Feed axis detector
- Servo motor built into α1000, αA64, αA32
- Separate detector (A/B phase pulse)
- αA16000i , αA1000i, αI1000i, αA64i
- βA64B, βA32B
- βΙ64B, βΙ32B
- Spindle detector
- M sensor
- MZ sensor
- BZ sensor
- Mi sensor
- MZi sensor
- BZi sensor
- 15 -
3.SAFETY FUNCTIONS
3
B-63494EN/01
SAFETY FUNCTIONS
- 16 -
3.SAFETY FUNCTIONS
B-63494EN/01
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.
- 17 -
3.SAFETY FUNCTIONS
B-63494EN/01
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.
- 18 -
3.SAFETY FUNCTIONS
B-63494EN/01
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
Cross-check
CNC
CPU
Spindle
CPU
SPM
Protective
door
Spindle
motor
Safe speed monitoring
Protective door
lock signal
Servo motor
SVM
Door lock/
open/close
monitoring
Cross-check
PSM
Monitor
CPU
Safe speed monitoring
Safe machine position
monitoring
Dual monitoring of MCC
Powerdown
(MCC)
I/O, safe speed of the
servo motor, and
machine position are
checked by the CNC
CPU and monitor
CPU in redundant
mode.
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
- 19 -
3.SAFETY FUNCTIONS
B-63494EN/01
3.2
BEFORE USING THE SAFETY FUNCTION
3.2.1
Important Items to Check Before Using the Safety Function
3.2.2
•
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).
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.
- 20 -
3.SAFETY FUNCTIONS
B-63494EN/01
3.3
STOP
3.3.1
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.
- 21 -
3.SAFETY FUNCTIONS
3.3.2
B-63494EN/01
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
Name
MCC off timer 1
1948
MCC off timer 2
- 22 -
If the protective door
is closed
If the protective door
is opened
3.SAFETY FUNCTIONS
B-63494EN/01
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.
- 23 -
3.SAFETY FUNCTIONS
3.4
B-63494EN/01
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.
- 24 -
3.SAFETY FUNCTIONS
B-63494EN/01
CNC
I/O
I/O
CNC
CPU
Machine
UNIT
DI
LINK
DO
Cross check
FSSB I/O
DI
FSSB
Monitor
CPU
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>
Dual input monitoring
Dual input monitoring
Dual input monitoring
Dual input monitoring
Duplicated output
Input
<G191#2>
<F191#0>
<F191#2>
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.
- 25 -
3.SAFETY FUNCTIONS
4. *SMC
B-63494EN/01
MCC contact state 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 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.
- 26 -
3.SAFETY FUNCTIONS
B-63494EN/01
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
CNC (PMC)
Door open request
24V
G
ORQ
X
Ladder
ORQ-I
LGD
Protective door
F
Y
Ladder
LGD-O
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
ORQ-I
0
ORQ
0
*LGD
0
*LGD-O
0
B
C
D
1
1
1
0
1
1
0
0
1
0
0
0
E
1
1
1
1
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 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
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
- 27 -
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 closed
Door opened
t
(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 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.
- 28 -
3.SAFETY FUNCTIONS
B-63494EN/01
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.
- 29 -
3.SAFETY FUNCTIONS
3.6
B-63494EN/01
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.
- 30 -
3.SAFETY FUNCTIONS
B-63494EN/01
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.
- 31 -
3.SAFETY FUNCTIONS
3.8
B-63494EN/01
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.
- 32 -
4.INSTALLATION
B-63494EN/01
4
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
Ambient
Temperature
of the unit
Humidity
Vibration
Meters above
sea level
Environment
Operating
Storage
Transport
Normal
LCD–mounted
type control
unit and display
unit (except
unit with data
server function)
0°C to 58°C
–20°C to 60°C
Stand–alone
type control
unit
LCD–mounted
type control
unit with PC
and data server
functions
0°C to 55°C
5°C to 53°C
75% RH or less, no condensation
10% to 75% RH,
no condensation
10% to 90% RH,
no condensation
Short period(less 95% RH or less, no condensation
than 1 month)
Operating
0.5 G or less
Non–operating
1.0 G or less
Operating
Up to 1000 m
Up to 1000 m
Non–operating
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.)
- 33 -
4.INSTALLATION
B-63494EN/01
Environmental conditions for servo amplifier
The servo amplifier α 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 55°C (at operation)
-20 to 60°C (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.
- 34 -
4.INSTALLATION
B-63494EN/01
4.1
OVERALL CONNECTION DIAGRAM
4.1.1
For One-path
LCD display unit
Mother board
24V-IN(CP1A)
24 VDC
supply
power
To I/O device
24V-OUT(CP1B)
Soft key cable
MDI(CA55)
MDI UNIT
CK2
CK1
R232(JD36A)
RS-232C I/O device
R232(JD36B)
RS-232C I/O device
Touch panel
HDI(JA40)
High-speed skip input
Distribution-type
I/O board
24VDC
CPD1
JA3
JD1
I/O-LINK(JD1A)
Manual
pulse generator
Operator's
panel
JD1
I/O unit, etc.
24VDC
CPD1
JD1
JD1
- 35 -
Power
magnetics
cabinet
4.INSTALLATION
B-63494EN/01
LCD display unit
Mother board
SPDL(JA41)
JA7B
JA7A
JY2
SPM
TB2
Spindle motor
Second spindle
FSSB(COP10A)
COP10B
COP10A
COP10B
COP10A
JF1
Axis 2
servo monitor
TB2
SVM
COP10B
COP10A
Axis 1
servo motor
TB2
SVM
JF1
Axis 3
servo motor
TB2
SVM
JF1
(This diagram assumes the use of a 1-axis amplifier.)
Separate detector interface unit
24VDC
CP11A
COP10B
COP10A
JF101
JF102
Linear scale axis 2
JF103
Linear scale axis 3
JF104
JA4A
Battery for absolute
position detector
FSSB I/O
DC24V
CP11A CB155A
COP10B CB156A
COP10A
SV-CHK(CA54)
Servo check board
- 36 -
Power
magnetics
cabinet
4.INSTALLATION
B-63494EN/01
4.1.2
For Two-path
Main board
I/O Link (JD44A)
SPDL (JA41)
FSSB (COP10A-1)
I/O module for
operator’s panel
JD1B
CE56
JD1A
CE57
Machine
operator’s
panel
I/O module for
connector panel
JD1B
CB150
JD1A
Power
magnetics
cabinet
Safe-related and other signals
To next I/O unit
200VAC 2φ
PSM
CX1A
CZ1 CX4
CX3
MCC
Emergency
stop
200VAC 3φ
TB1
CXA2A
CXA2B
TB1
SPM
JA7B
JA7A
JYA2
CZ2
Spindle motor
TB1
CXA2A
TB1
CXA2B
To next SPM (JA7B)
Axis control card
SVM1
COP10B
COP10A
JF1
CZ2
Servo motor
To next SVM (COP10B)
- 37 -
4.INSTALLATION
B-63494EN/01
From previous SVM (COP10A)
Separate detector
interface unit
COP10B
JF101
COP10A
JF102
JF103
JF104
JA4A
Separate
detector
Separate
detector
Separate
detector
Separate
detector
Battery
Safe-related signals
FSSB I/O module
COP10B
CB155
COP10A
CB156
- 38 -
Power
magnetics
cabinet
4.INSTALLATION
B-63494EN/01
Sub CPU board
TB1
CXA2B
SPM
SPDL (JA41)
JA7B
JYA2
JA7A
CZ2
Spindle motor
TB1
CXA2A
To next SPM (JA7B)
CXA2B
TB1
SVM1
Axis control card
FSSB (COP10A-1)
COP10B
JF1
COP10A
CZ2
Servo motor
to next SVM (COP10B)
From previous SVM (COP10A)
Separate detector
interface unit
COP10B
JF101
Separate detector
COP10A
JF102
Separate detector
JF103
JF104
JA4A
Separate detector
Separate detector
Battery
Safe-related signals
FSSB I/O module
COP10B
CB155
COP10A
CB156
- 39 -
Power
magnetics
cabinet
4.INSTALLATION
4.2
B-63494EN/01
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:
PMC→
→CNC
#7
#6
#5
G008
PMC→
→CNC
#3
#2
#1
#0
#1
#0
*ESPG
#7
G191
CNC→
→PMC
#4
#7
#6
#5
#4
#3
#2
*SMC1
GDL1
SGD1
ORQ
OPT
#6
#5
#4
#3
#2
#1
#0
RQT
MCF1
*LGD
F191
For the meaning of each of the above signals, see Chapter 6,
"OPERATION."
Hatted signals means dual monitoring.
- 40 -
4.INSTALLATION
B-63494EN/01
4.3
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.
4.3.1
FSSB I/O Connection
Power supply connection
External power supply
CP11A
1
2
3
+24V
0V
24 VDC stabilized
power supply
24 VDC±10%
Cable
CP11A
AMP Japan
1-178288-3 (Housing)
1-175218-5 (Contact)
+24V(1)
0V(2)
Recommended cable specification:
External power supply
Select a one that matches
the pins of the external
power supply.
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.
- 41 -
4.INSTALLATION
B-63494EN/01
DI/DO connection
Pin No.
Signal name
CB155A(A01)
CB155A(B01)
+24V
RV
CB155A(A02)
RV
CB155A(A07)
RV
CB155A(B07)
RV
CB155A(A08)
RV
CB155A(B08)
SGD2
RV
CB155A(A09)
GDL2
RV
CB155A(B09)
SMC2
RV
CB155A(A10)
*ESP2
Pin No.
DOCOM
CB155A(B06)
+24V
0V
+24V stabilized
power supply
Signal name
CB155A(A11)
Relay
DV
MCF2
CB155A(B11)
DV
Relay
CB155A(A17,B17)
For the meanings
"OPERATION."
- 42 -
of
the
above
signals,
see
Chapter
6,
4.INSTALLATION
B-63494EN/01
4.3.2
FSSB I/O Attachment
External dimensions
CP11A
CP11B
Upper:CB156A
Lower:CB155A
COP10A COP10B
- 43 -
4.INSTALLATION
B-63494EN/01
Screw attachment
Mounting hole
machining diagram
- 44 -
4.INSTALLATION
B-63494EN/01
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
- 45 -
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.
- 46 -
4.INSTALLATION
B-63494EN/01
4.3.3
FSSB I/O Specification List
Installation conditions
Ambient temperature Operating 0°C to 55°C
of the unit
Storage, transportation -20°C to 60°C
Temperature variation 1.1°C /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.
Power supply capacity
Supply voltage
24V±10% is fed from the CP11A
connector of the basic module.
±10% includes momentary
variations and ripples.
Power supply
capacity
Remarks
0.3A+7.3mAxDI
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 µA or less
OFF time
Driver delay time: 50 µs(MAX)
Delay time
In addition, the FSSB transfer period and
ladder scan period must be considered.
- 47 -
5.I/O SIGNALS
5
B-63494EN/01
I/O SIGNALS
- 48 -
5.I/O SIGNALS
B-63494EN/01
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.
- 49 -
5.I/O SIGNALS
5.2
B-63494EN/01
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.
- 50 -
5.I/O SIGNALS
B-63494EN/01
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.
1
2
3
4
5
MCF1 (PMC)
MCF2 (FSSB)
*SMC1 (PMC)
*SMC2 (FSSB)
Timer limit
Timer
Test start
Test completion
Example 1) Timing chart 1 of MCC off test (normal state)
Test No.
1
2
3
4
MCF1 (PMC)
MCF2 (FSSB)
*SMC1 (PMC)
*SMC2 (FSSB)
Timer limit
Alarm !!
Timer
Test start
Example 2) Timing chart 2 of MCC off test (abnormal state)
- 51 -
5.I/O SIGNALS
B-63494EN/01
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]
[Operation]
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.
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]
[Operation]
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.
- 52 -
5.I/O SIGNALS
B-63494EN/01
MCC contact state signal
*SMC1 <G191#6>, *SMC2 <DI+001#6>
[Classification]
[Function]
[Operation]
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.
Guard unlock signal
*LGD <F191#0>
[Classification]
[Function]
[Output condition]
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).
MCC-on enable signal
MCF1 <F191#1>,MCF2 <DO+000#1>
[Classification]
[Function]
[Output condition]
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).
- 53 -
5.I/O SIGNALS
B-63494EN/01
MCC off Test execution request signal
RQT <F191#2>
[Classification]
[Function]
[Output condition]
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.
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.
- 54 -
5.I/O SIGNALS
B-63494EN/01
5.3
SIGNAL ADDRESSES
Via the PMC
#7
#6
#5
(For loader control)
X1000
#4
#3
#2
#1
#0
#4
#3
#2
#1
#0
#4
#3
#2
#1
#0
#1
#0
*ESP1
X008
#7
#6
#5
#6
#5
*ESP1
#7
G008
*ESPG
#7
G191
#7
#6
#5
#4
#3
#2
*SMC1
GDL1
SGD1
ORQ
OPT
#6
#5
#4
#3
F191
#2
#1
#0
RQT
MCF1
*LGD
#2
#1
Via the FSSB
#7
#6
#5
#4
#3
#0
*ESP2
DI+0000
#7
DI+001
#7
#6
#5
#4
*SMC2
GDL2
SGD2
#6
#5
#4
DO+000
#3
#2
#3
#2
*BRK
#1
#0
#1
#0
MCF2
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.
- 55 -
5.I/O SIGNALS
5.4
B-63494EN/01
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
Machine state
*ESP = 0
OPT = 1
ORQ = 0, and SGD = 1
ORQ = 1, and SGD = 1
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.
- 56 -
5.I/O SIGNALS
B-63494EN/01
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
DO1C
DI1C
CNC
CPU
SUB BOARD
crosscheck
Path 2
Monitor
CPU
Safety
Safetyarea
area11
Guard
Guard
MCC
MCC
and
andsosoonon
- 57 -
DO1M
DO2C
DI1M
DI2C
CNC
CPU
crosscheck
Monitor
CPU
Safety
Safetyarea
area22
Guard
Guard
MCC
MCC
and
andsosoonon
DO2M
DI2M
5.I/O SIGNALS
5.5.2
B-63494EN/01
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
DO1C
DI1C
CNC
CPU
SUB BOARD
crosscheck
Path 2
Monitor
CPU
DO1M
DO2C
DI1M
DI2C
Safety
Safetyarea
area
Guard
Guard
MCC
MCC
and
andsosoonon
- 58 -
CNC
CPU
crosscheck
Monitor
CPU
DO2M
DI2M
5.I/O SIGNALS
B-63494EN/01
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
crosscheck
Monitor
CPU
Path 2
Safety
Safetyarea
area
Guard
Guard
MCC
MCC
and
andsosoonon
- 59 -
DOM
DIM
5.I/O SIGNALS
5.5.4
B-63494EN/01
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
DO1C
DI1C
CNC
CPU
SUB BOARD
crosscheck
Monitor
CPU
DO1M
DI1M
DO2C
DI2C
DO3C
DI3C
Safety
Safetyarea
area11
Guard
Guard
MCC
MCC
and
andsosoonon
- 60 -
Path 2
CNC
CPU
crosscheck
Monitor
CPU
Path 3
Safety
Safetyarea
area22
Guard
Guard
MCC
MCC
and
andsosoonon
DO2M
DI2M
5.I/O SIGNALS
B-63494EN/01
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
CNC
CPU
LOADER BOARD
crosscheck
Monitor
CPU
Safety
Safetyarea
area11
Guard
Guard
MCC
MCC
and
andsosoonon
- 61 -
DO1M
DOLC
DI1M
DILC
CNC
CPU
crosscheck
Monitor
CPU
Safety
Safetyarea
area22
Guard
Guard
MCC
MCC
and
andsosoonon
DOLM
DILM
6.PARAMETERS
6
B-63494EN/01
PARAMETERS
- 62 -
6.PARAMETERS
B-63494EN/01
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.
- 63 -
6.PARAMETERS
6.2
B-63494EN/01
PARAMETERS
1023
[Data type]
[Valid data range]
Servo axis number for each axis
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
[Data type]
[Unit of data]
[Valid data range]
Positional deviation limit during a stop for each axis
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).
- 64 -
6.PARAMETERS
B-63494EN/01
1838
[Data type]
[Unit of data]
[Valid data range]
1902
[Data type]
STP
Positional deviation limit during movement for each axis in safety signal mode C
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
#5
0
DCE
0
#4
#3
#2
#1
#0
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.
- 65 -
6.PARAMETERS
B-63494EN/01
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
[Data type]
DCN
#6
#5
#4
#3
#2
#1
#0
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
[Data type]
[Unit of data]
[Valid data range]
Safety speed for each axis
2-word axis
Increment
system
Unit of data
Millimeter machine 1 mm/min
Inch machine
0.1 inch/min
Rotation axis
1 deg/min
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
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).
- 66 -
6.PARAMETERS
B-63494EN/01
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
Safe machine position of each axis (+ direction)
1944
Safe machine position of each axis (- direction)
[Data type]
[Unit of data]
2-word axis
Increment system
IS-A
Millimeter machine 0.01
Inch machine
0.001
[Valid data range]
IS-B
0.001
0.0001
IS-C
0.0001
0.00001
Unit
mm
inch
-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.
- 67 -
6.PARAMETERS
B-63494EN/01
1945
[Data type]
[Unit of data]
[Valid data range]
Safety input signal check timer
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
[Data type]
[Unit of data]
[Valid data range]
MCC off Test timer
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.
1947
MCC-off timer 1
1948
MCC-off timer 2
[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
- 68 -
6.PARAMETERS
B-63494EN/01
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
Timer used
When a spindle alarm is issued
When the guard is closed
When the guard is open
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
[Data type]
[Unit of data]
[Valid data range]
Brake signal timer
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.
1959
[Data type]
#7
#6
#5
#4
#3
#2
#1
#0
0
0
0
0
0
0
0
0
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.
- 69 -
6.PARAMETERS
B-63494EN/01
2078
Monitor conversion factor (numerator) of each axis
2079
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
[Data type]
[Valid data range]
Code for safety parameters
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.
- 70 -
6.PARAMETERS
B-63494EN/01
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
[Data type]
[Valid data range]
Key for safety parameters
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
[Data type]
[Unit of data]
[Valid data range]
Safe speed of each spindle
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.
- 71 -
6.PARAMETERS
6.3
B-63494EN/01
PARAMETERS RELATED TO THE USE OF FSSB I/O UNIT
#7
#6
#5
#4
#3
#2
#1
1902
[Data type]
FMD
#0
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
#6
1905
[Data type]
IO1
IO2
#5
#4
IO2
IO1
#3
#2
#1
#0
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.
- 72 -
6.PARAMETERS
B-63494EN/01
1910
Address conversion table value for slave 1 of FSSB channel 1 (ATR)
:
1919
Address conversion table value for slave 10 of FSSB channel 1 (ATR)
1970
Address conversion table value for slave 1 of FSSB channel 2 (ATR)
:
1979
[Data type]
[Valid data range]
Address conversion table value for slave 10 of FSSB channel 2 (ATR)
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."
- 73 -
6.PARAMETERS
B-63494EN/01
6.4
FUNCTIONS THAT REQUIRE SPECIAL PARAMETER
SETTINGS
6.4.1
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.
- 74 -
7.START-UP
B-63494EN/01
7
START-UP
- 75 -
7.START-UP
7.1
B-63494EN/01
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 1MΩ. For further details, please refer to Chapter 19.3 of IEC
60204-1.
7.1.1
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.
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.
- 76 -
7.START-UP
B-63494EN/01
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.
- 77 -
7.START-UP
B-63494EN/01
7.1.2
Start-up of the Dual Check Safety Function
7.1.2.1
Initial start-up
Main flow
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
- 78 -
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
7.START-UP
B-63494EN/01
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.
- 79 -
7.START-UP
7.1.2.2
B-63494EN/01
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.
- 80 -
8.MAINTENANCE
B-63494EN/01
8
MAINTENANCE
- 81 -
8.MAINTENANCE
8.1
B-63494EN/01
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.
- 82 -
8.MAINTENANCE
B-63494EN/01
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.
- 83 -
8.MAINTENANCE
B-63494EN/01
2.
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.
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 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.
- 84 -
8.MAINTENANCE
B-63494EN/01
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 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.
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.
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.
- 85 -
8.MAINTENANCE
B-63494EN/01
8.2
ALARMS AND MESSAGES
8.2.1
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.
- 86 -
8.MAINTENANCE
B-63494EN/01
8.2.2
No.
364
402
403
410
411
453
470
471
473
474
475
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).
Replace the α 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 α 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 α 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.
- 87 -
8.MAINTENANCE
No.
476
477
478
479
480
481
482
483
B-63494EN/01
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.
- 88 -
8.MAINTENANCE
B-63494EN/01
No.
484
486
487
488
489
490
491
492
494
Meaning
n AXIS:SERVO SAFETY
FUNCTION ERR
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.
- 89 -
8.MAINTENANCE
No.
495
Meaning
n AXIS:ILLEGAL MACHINE
POS.(CNC)
496
n AXIS:ILLEGAL AXIS DATA
(CNC)
497
n AXIS:SAFETY PARAM
TRANS ERROR
n AXIS:AXIS NUMBER NOT
SET (CNC)
498
B-63494EN/01
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.
- 90 -
8.MAINTENANCE
B-63494EN/01
8.2.3
Serial Spindle Alarms
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)
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)
- 91 -
8.MAINTENANCE
8.2.4
B-63494EN/01
Alarms Displayed on the Spindle Unit
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
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.
- 92 -
8.MAINTENANCE
B-63494EN/01
8.2.5
System Alarms
No.
Meaning
900 ROM PARITY
920 SERVO ALARM (1-4
AXIS)
921 SERVO ALARM (5-8
AXIS)
973 NON MASK
INTERRUPT
8.2.6
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.
Boot System Alarms
Message
ROM PARITY ERROR:
NC BASIC. HIT SELECT.
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.
- 93 -
9.DIAGNOSIS
9
B-63494EN/01
DIAGNOSIS
- 94 -
9.DIAGNOSIS
B-63494EN/01
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.
- 95 -
9.DIAGNOSIS
9.2
B-63494EN/01
DIAGNOSIS
#7
Diagnosis No. 376
FGD
FGL
FMC
Diagnosis No. 377
Diagnosis No. 378
MDA
MDB
MDC
MDD
TST
ESP
#5
#4
FGL
FGD
#3
#2
#1
#0
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
PTS
PRQ
PGD
PGL
PMC
#6
FMC
#6
#5
#4
#3
#2
PMC
PGL
PGD
PRQ
PTS
#1
#0
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
ESP
TST
#5
#4
#3
#2
#1
#0
MDD
MDC
MDB
MDA
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
Diagnosis No. 379
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.
- 96 -
10.SAMPLE SYSTEM CONFIGURATION
B-63494EN/01
10
SAMPLE SYSTEM CONFIGURATION
- 97 -
10.SAMPLE SYSTEM CONFIGURATION
B-63494EN/01
10.1
SAMPLE CONFIGURATION
10.1.1
For One-path
- 98 -
10.SAMPLE SYSTEM CONFIGURATION
B-63494EN/01
10.1.2
For Two-path (When the main side and sub side use a
common MCC)
- 99 -
10.SAMPLE SYSTEM CONFIGURATION
10.1.3
B-63494EN/01
For Two-path (When the main side and sub side use
independent MCCs and protection doors)
- 100 -
10.SAMPLE SYSTEM CONFIGURATION
B-63494EN/01
10.2
SAMPLE CONNECTIONS
10.2.1
Emergency Stop Signal (*ESP1, *ESP2)
I/O-Link I/O UNIT
+24V
*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
- 101 -
X008#4
X00n#n
Ladder
program
*ESPG
(G008#4)
10.SAMPLE SYSTEM CONFIGURATION
10.2.2
B-63494EN/01
Guard Open Request Signal (ORQ)
Guard open
request button
+24V
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].
- 102 -
10.SAMPLE SYSTEM CONFIGURATION
B-63494EN/01
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
Safety relay
RY1
SW3
RY1
RY3
RY2
RY2
RY3
0V
RY3
RY1
RY2
0V
[Sample control components]
SW1/SW2:
I/O Link I/O UNIT
X00n#n
Guard state monitoring
dissociation mechanism
Y00n#n
Guard lock switch
RY1, RY2, RY3:
Safety relay
SGD
(G191#4)
*LGD
(F191#0)
switch with forced
SW3:
PMC
FSSB I/O UNIT
SGD
(DI+001#4)
- 103 -
Ladder
program
10.SAMPLE SYSTEM CONFIGURATION
B-63494EN/01
OPERATING PRINCIPLE
This section describes the operation of various guard monitoring limit
switches with lock mechanism and safety relays.
State transition of components
SW1
SW2
SW3
RY1
RY2
RY3
SGD
1
Guard closed
Guard locked
CLOSE
CLOSE
CLOSE
ON
ON
OFF
1
2
Guard closed
Guard unlocked
CLOSE
CLOSE
OPEN
OFF
ON
OFF
0
3
Guard opened
Guard unlocked
OPEN
OPEN
OPEN
OFF
OFF
ON
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.
- 104 -
10.SAMPLE SYSTEM CONFIGURATION
B-63494EN/01
10.2.5
MCC On Enable Signal (MCF), MCC Contact State Signal
(*SMC)
I/O Link I/O UNIT
+24V
X00n#n
Y00n#n
PMC
*SMC1
(G191#6)
MCF1
(F191#1)
0V
FSSB I/O UNIT
*SMC2
(DI+001#6)
MCF
(DO+000#1)
0V
PSM
200A
200B
CX3
MCC
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.
- 105 -
11.COMPONENTS LIST
11
B-63494EN/01
COMPONENTS LIST
- 106 -
11.COMPONENTS LIST
B-63494EN/01
11.1
HARDWARE COMPONENTS
11.1.1
Hardware Components for Series
16i/18i/21i/160i/180i/210i/160is/180is/210is-MODEL A
1
Main board
Specification number
Of primary component
A20B-8100-0130
2
CPU card
A20B-3300-0170
3
Servo card
A17B-3300-0200
4
DRAM MODULE
A20B-3900-0131
5
SRAM MODULE
A20B-3900-0060
6
FROM MODULE
A20B-3900-0011
No.
Description
11.1.2
No.
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
Hardware Components for Series
16i/18i/21i/160i/180i/210i/160is/180is/210is-MODEL B
Description
Specification number
Of primary component
A20B-8100-0660
1
Main board
2
3
CPU card
Servo card
4
FROM/SRAM MODULE
A20B-3300-0311
A20B-3300-0244
A17B-3300-0500
A20B-3900-0160
5
6
7
Power supply module
Sub CPU board
Loader control board
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
- 107 -
Remarks
11.COMPONENTS LIST
11.1.3
B-63494EN/01
Hardware Components for Other Units
Specification number
Of primary component
A20B-2100-0270
No.
Description
1
2
FSSB ADDITIONAL
DETECTOR INTERFACE
I/O module
3
I/O Unit base module
A20B-9001-0020
4
I/O Unit interface module
A20B-8000-0410
5
DC digital input module
A20B-9000-0901
A20B-9000-0902
6
DC digital output module
A20B-9000-0921
7
8
9
DC digital input/output
module
AC digital input module
AC digital output module
10
Relay output module
11
FSSB I/O module
Specification number
of secondary component
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-2100-0390
- 108 -
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
Remarks
11.COMPONENTS LIST
B-63494EN/01
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
Functions
B1F2
B1F4
CNC functions for lathe with up to 8 servo
axes and up to 2 spindle axes.
BEF2
BEF4
CNC functions for lathe with up to 6 servo
axes and up to 2 spindle axes.
DEF2
DEF4
CNC functions for lathe with up to 4 servo
axes and up to 2 spindle axes.
D1F1
CNC functions for manual lathe with up to 2
servo axes and up to 1 spindle axis
B0F2
B0F4
CNC functions for machining center with up
to 8 servo axes and up to 2 spindle axes.
BDF2
BDF4
CNC functions for machining center with up
to 6 servo axes and up to 2 spindle axes.
DDF2
DDF4
CNC functions for machining center with up
to 4 servo axes and up to 2 spindle axes.
D0F1
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
Functions
B1H1
CNC functions for lathe with up to 8 servo
axes and up to 2 spindle axes.
BEH1
CNC functions for lathe with up to 6 servo
axes and up to 2 spindle axes.
DEH1
CNC functions for lathe with up to 4 servo
axes and up to 2 spindle axes.
B0H1
CNC functions for machining center with up
to 8 servo axes and up to 2 spindle axes.
BDH5
BDH1
DDH1
- 109 -
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.
11.COMPONENTS LIST
B-63494EN/01
[Monitor software]
Series / Version
Functions
90A9 / 03
90B9 / 01
Monitor functions
Monitor functions
Monitor
Monitor
[Servo control software]
Series / Version
Functions
90A5 / 01
90B0 / 09
90B7 / 04
Servo functions
Servo functions
Learning control
Series / Version
Functions
9D20 / 10
9D50 / 04
Spindle functions
Spindle functions
Servo
Servo
Servo
[Spindle software]
Spindle
Spindle
- 110 -
11.COMPONENTS LIST
B-63494EN/01
11.3
SERVO AMPLIFIER
No.
1
Description
Power Supply Module
(Standard)
2
Power Supply Module
(Resister Discharge type)
3
Servo Amplifier Module
(1 axis type)
4
Servo Amplifier Module
(2 axes type)
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
- 111 -
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
11.COMPONENTS LIST
No.
4
Description
Servo Amplifier Module
(2 axes type)
5
Servo Amplifier Module
(3 axes type)
6
Spindle Amplifier Module
(SPM HRV Type I )
7
Spindle Amplifier Module
(SPM HRV Type IV )
8
Spindle Amplifier Module
(SPM HRV Type A )
9
Spindle Amplifier Module
(SPM HRV Type B )
B-63494EN/01
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
- 112 -
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
Remarks
INDEX
B-63494EN/01
INDEX
For Two-path..................................................... 37
A
For Two-path (When the main side and sub side
ALARMS AND MESSAGES ............................ 86
use a common MCC) ..................................... 99
Alarms Displayed on the Spindle Unit ........... 92
For Two-path (When the main side and sub side
APPLICATION RANGE................................... 17
use independent MCCs and protection doors)
B
...................................................................... 100
FSSB I/O Attachment....................................... 43
BASIC PRINCIPLE OF DUAL CHECK
FSSB I/O Connection........................................ 41
SAFETY........................................................... 6
FSSB I/O Specification List.............................. 47
BEFORE USING THE SAFETY FUNCTION 20
FUNCTIONS THAT REQUIRE SPECIAL
Boot System Alarms ......................................... 93
PARAMETER SETTINGS............................ 74
C
G
Certification Test ................................................ 4
General Definition of Terms .............................. 5
Compliance with the Safety Standard (EN954-1,
GENERAL INFORMATION ............................ 12
Category 3) ...................................................... 7
Guard lock state signal..................................... 52
COMPONENTS LIST..................................... 106
Guard open request signal ............................... 52
D
Guard Open Request Signal (ORQ) ............... 102
DEFINITION OF TERMS ................................. 5
Guard state signal ............................................ 52
Definition of Terms Related to the Safety
Guard unlock signal.......................................... 53
Function .......................................................... 5
Guard Unlock Signal (*LGD), Guard Lock State
DI/DO CONNECTION (VIA THE FSSB) ....... 41
Signal (GDL), Guard State Signal (SGD).. 103
DI/DO CONNECTION (VIA THE PMC)......... 40
H
DIAGNOSIS................................................ 94, 96
HARDWARE COMPONENTS....................... 107
DIRECTIVE AND STANDARDS ...................... 3
Hardware Components for Other Units........ 108
Directives ............................................................ 3
Hardware Components for Series
E
16i/18i/21i/160i/180i/210i/160is/180is/210isMODEL A .................................................... 107
EMERGENCY STOP........................................ 29
Hardware Components for Series
Emergency stop signal ..................................... 50
Emergency Stop Signal (*ESP1, *ESP2)....... 101
16i/18i/21i/160i/180i/210i/160is/180is/210is-
Error analysis ................................................... 10
MODEL B .................................................... 107
ety monitoring cycle and cross-check cycle ....... 9
I
F
I/O SIGNALS .................................................... 48
Important Items to Check Before Using the
Features of Dual Check Safety .......................... 6
Safety Function ............................................. 20
For One-path............................................... 35, 98
i-1
11.COMPONENTS LIST
B-63494EN/01
Initial start-up .................................................. 78
SAFE SPEED MONITORING ......................... 30
INSTALLATION............................................... 33
SAFETY FUNCTIONS..................................... 16
SAFETY I/O MONITORING............................ 24
L
SAFETY PRECAUTIONS ............................ 1, 82
Latent error detection and cross-check ............. 8
Safety Signal Modes ......................................... 56
Loader Control .................................................. 61
SAMPLE CONFIGURATION .......................... 98
M
SAMPLE CONNECTIONS ............................ 101
SAMPLE SYSTEM CONFIGURATION ......... 97
MAINTENANCE .............................................. 81
Serial Spindle Alarms....................................... 91
MCC contact state signal ................................. 53
Series start-up................................................... 80
MCC off Test ....................................................... 9
Servo Alarms..................................................... 87
MCC OFF TEST ............................................... 32
SERVO AMPLIFIER ...................................... 111
MCC off Test execution request signal............ 54
Signal Addresses............................................... 55
MCC off Test of the Safe Stop Function.......... 20
SIGNALS........................................................... 50
MCC On Enable Signal (MCF), MCC Contact
Simple Electronic Gearbox and Two Groups of
State Signal (*SMC) ................................... 105
Electronic Gearboxes .................................... 74
MCC-on enable signal ...................................... 53
SOFTWARE COMPONENTS ........................ 109
Multi-path Control............................................ 74
START-UP......................................................... 75
N
Start-up of the Safety Function ....................... 78
START-UP OPERATION ................................. 76
NOTES ON MULTI-PATH CONTROL........... 57
STOP.................................................................. 21
O
Stop States ........................................................ 22
One-CPU Two-Path Control ............................ 59
Stopping the Servo Motor................................. 22
OVERALL CONNECTION DIAGRAM........... 35
Stopping the Spindle Motor ............................. 21
Overview ........................................................... 86
System Alarms .................................................. 93
P
SYSTEM CONFIGURATION .......................... 14
PARAMETERS ........................................... 62, 64
T
PARAMETERS RELATED TO THE USE OF
Tandem Control ................................................ 74
FSSB I/O UNIT............................................. 72
Test mode signal ............................................... 50
R
Test Mode Signal (OPT) ................................. 102
Troubleshooting ................................................ 80
Related Safety Standards .................................. 3
Two-CPU Three-Path Control.......................... 60
Remaining risks................................................ 10
Two-CPU Two-Path Control (With Axis Change
Risk Analysis and Evaluation............................ 3
between Paths) .............................................. 58
S
Two-CPU Two-Path Control (Without Axis
Change between Paths) ................................ 57
SAFE MACHINE POSITION MONITORING 31
-2-
Feb., 2002
Date
01
Edition
Contents
Edition
Date
Dual Check Safety OPERATOR’S MANUAL (B-63494EN)
Revision Record
Contents
TECHNICAL REPORT (MANUAL)
NO.TMN 00 / 117E
Date: ． ．2000.
General Manager of
Hardware Laboratory
Dual Check Safety USER’S 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.
IDE
B-63494EN/01-05
General
Manager
Original section of issue
Vice General Department
Section
Manager
Manager
Manager
FANUC
Person in
Charge
USER’S 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
1.1.1
Directives .................................................................................................................................... 3
1.1.2
Related Safety Standards.......................................................................................................... 3
1.1.3
Risk Analysis and Evaluation................................................................................................... 3
1.1.4
Certification Test.................................................................................................................... 5
1.2
DEFINITION OF TERMS ......................................................................................................................... 6
1.2.1
General Definition of Terms ................................................................................................... 6
1.2.2
Definition of Terms Related to the Safety Function ......................................................... 6
1.3
BASIC PRINCIPLE OF DUAL CHECK SAFETY .......................................................................................... 8
1.3.1
Features of Dual Check Safety................................................................................................ 8
1.3.2
Compliance with the Safety Standard (EN954-1, Category 3)................................................ 8
1.4
GENERAL INFORMATION........................................................................................................... 16
2
SYSTEM CONFIGURATION ............................................................................................................. 18
3
SAFETY FUNCTIONS ......................................................................................................................... 20
3.1
APPLICATION RANGE ................................................................................................................. 21
3.2
BEFORE USING THE SAFETY FUNCTION............................................................................... 25
3.2.1
Important Items to Check Before Using the Safety Function ................................................ 25
3.2.2
MCC off Test of the Safe Stop Function.................................................................................. 25
3.3
4
STOP ................................................................................................................................................ 26
3.3.1
Stopping the Spindle Motor .................................................................................................... 26
3.3.2
Stopping the Servo Motor ........................................................................................................ 27
3.3.3
Stop States................................................................................................................................ 27
3.4
SAFETY I/O MONITORING .......................................................................................................... 30
3.5
EMERGENCY STOP ...................................................................................................................... 37
3.6
SAFE SPEED MONITORING........................................................................................................ 39
3.7
SAFE MACHINE POSITION MONITORING .............................................................................. 41
3.8
MCC OFF TEST .............................................................................................................................. 42
INSTALLATION ................................................................................................................................... 43
4.1
OVERALL CONNECTION DIAGRAM ......................................................................................... 43
4.2
DI/DO CONNECTION (VIA THE PMC) ....................................................................................... 47
4.3
DI/DO CONNECTION (VIA THE FSSB) ...................................................................................... 48
4.3.1
FSSB I/O Connection.............................................................................................................. 48
c-2
Table of Contents
B-63494EN/01
5
6
7
8
4.3.2
FSSB I/O Attachment ............................................................................................................. 49
4.3.3
FSSB I/O Specification List ................................................................................................... 55
I/O SIGNALS ......................................................................................................................................... 56
5.1
OVERVIEW ......................................................................................................................................... 57
5.2
SIGNALS ............................................................................................................................................ 58
5.2.1
Signal Addresses...................................................................................................................... 61
5.2.2
Safety Signal Modes ................................................................................................................ 62
PARAMETERS...................................................................................................................................... 64
6.1
OVERVIEW ......................................................................................................................................... 65
6.2
PARAMETERS ..................................................................................................................................... 66
MAINTENANCE ................................................................................................................................... 72
7.1
SAFETY PRECAUTIONS............................................................................................................... 73
7.2
ALARMS ............................................................................................................................................. 77
7.2.1
Servo Alarms ............................................................................................................................ 77
7.2.2
Serial Spindle Alarms ............................................................................................................. 81
7.2.3
Alarms Displayed on the Spindle Unit................................................................................... 82
7.2.4
System Alarms ......................................................................................................................... 84
7.2.5
Boot System Alarms................................................................................................................. 84
START-UP ............................................................................................................................................. 85
8.1
9
START-UP OPERATION ......................................................................................................................... 86
8.1.1
Acceptance test and report for safety functions ............................................................. 86
8.1.2
Start-up of the Safety Function .......................................................................................... 88
8.1.3
Troubleshooting ....................................................................................................................... 91
SAMPLE SYSTEM CONFIGURATION............................................................................................ 92
9.1
SAMPLE CONFIGURATION......................................................................................................... 93
9.2
SAMPLE CONNECTIONS ............................................................................................................. 94
9.2.1
Emergency Stop Signal (*ESP1, *ESP2)................................................................................ 94
9.2.2
Guard Open Request Signal (ORQ) ........................................................................................... 95
9.2.3
Test Mode Signal (OPT) ............................................................................................................. 95
9.2.4
Guard Unlock Enable Signal (*LGD),
Guard Lock State
Signal (GDL), Guard State Signal (SGD) ............................................................................................. 97
9.2.5
MCC On Enable Signal (MCF),
MCC Contact State
Signal (*SMC) ......................................................................................................................................... 99
c-3
Table of Contents
10
B-63494EN/01
COMPONENTS LIST..................................................................................................................... 100
c-4
1.OVERVIEW
B-63494EN/01
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.
-1-
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.
-2-
1.OVERVIEW
B-63494EN/01
1.1
DIRECTIVE AND STANDARDS
1.1.1
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
1.1.2
1998 Safety of machinery
1989 Electromagnetic compatibility
1973 Low Voltage Equipment
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
Safety of machinery - Basic concepts, general principles
for design – Part 1: Basic terminology, methodology
EN292-2
1991
Safety of machinery - Basic concepts, general principles
for
design
–
Part
2:
Technical
principles
and
specifications
EN954-1
1996
Safety of machinery - Safety-related parts of control
systems –
Part 1: General principles for design
EN1050
1996
Safety of machinery - Principles for risk assessment
EN60204-1
Safety of machinery - Electrical equipment of machines
1997
Part 1: General requirements
DIN
V
VDE0801
(1990) Principles for computers in safety- related systems
including amendment A1(1994)
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.
Risk
evaluation must reveal all remaining risks and must be
documented.
-4-
1.OVERVIEW
B-63494EN/01
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.
-5-
1.OVERVIEW
1.2
1.2.1
B-63494EN/01
DEFINITION OF TERMS
General Definition of Terms
Reliability and safety
Reliability and safety are defined by EN292-1 as follows:
Term
Definition
Reli-
Capability of a machine, machine component, or
ability
equipment
to
perform
its
required
function
under a specified condition for a specified
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
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
nor dangerous operation.
The following are measures for
incorporating the safety stop feature:
Contactor
between
-6-
the
line
and
drive
system
(line
1.OVERVIEW
B-63494EN/01
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
limitation
speed
from
being
changed
by
an
unauthorized person.
Safety machine position
When the drive system has reached a specified positional
limit, a transition is made to the safety 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.
-7-
1.OVERVIEW
B-63494EN/01
1.3
BASIC PRINCIPLE OF DUAL CHECK SAFETY
1.3.1
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
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.
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.
-8-
1.OVERVIEW
B-63494EN/01
To satisfy these requirements, the dual check safety
function is implemented using the two-channel configuration
shown below.
CNC
CNC
CPU
CPU
Shut off pow er
Cross-check
of data and
results
Motor detector signal
Door switch signal
Monitor
Monitor
CPU
CPU
Magnetic
contactor
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.
-9-
1.OVERVIEW
1.3.2.1
B-63494EN/01
Latent error detection and cross-check
Detection of latent errors
This detection function can detect latent software and
hardware
errors
in
a
system
that
has
a
two-channel
configuration.
So, the safety-related portions of the two
channels
to
need
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.
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-
1.OVERVIEW
B-63494EN/01
The cross-check cycle represents a cycle at which all data
subject to cross-checking is compared.
1.3.2.3
MCC off Test
Cross-check cycle: 16 ms
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.
essential to dual check safety.
conducted
at
specified
times
This test is
A MCC off Test must be
(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.
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
-12-
1.OVERVIEW
B-63494EN/01
Error analysis when the protection door is open
Error
Cause
Action
Spindle safety Amplifier
or
excessive
failure,
operation
speed
etc.
failure,
or
control
operation
limitation
speed
error, monitoring function
unit Safety
limitation
speed
error, monitoring function
EN60204-1 Category 1/0 stop
etc.
axis Amplifier
Feed
unit Safety
EN60204-1 Category 1/0 stop
Excessive feed Amplifier
axis speed
control
safety machine failure,
or
control
operation
unit Safety
limitation
speed
error, monitoring function
EN60204-1 Category 1/0 stop
position error etc.
Input/output
Wiring
error,
signal error
failure, etc.
control
unit Safety
limitation
speed
monitoring function
EN60204-1 Category 1/0 stop
Error analysis when the protection door is closed
Error
Cause
Input/output
Wiring
error,
signal error
failure, etc.
Action
control
unit 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 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
B-63494EN/01
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-
1.OVERVIEW
B-63494EN/01
correctly and confirm test is completely.
-15-
1.OVERVIEW
1.4
B-63494EN/01
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
−
-16-
1.OVERVIEW
B-63494EN/01
[ 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
-17-
2.SYSTEM CONFIGURATION
B-63494EN/01
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
:
:
:
4 maximum
6 maximum
6 maximum
Number of spindle controlled axes
- Series 21i/210is/210i
- Series 18i/180is/180i
- Series 16i/160is/160i
:
:
:
2 maximum
3 maximum
4 maximum
Amplifier
- α series servo amplifier
- α series spindle amplifier
- α series power supply module
Motor
- α series servo motor
- α 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 α1000
- Separate detector (A/B phase pulse)
Spindle detector
- M sensor
- MZ sensor
- BZ sensor
-18-
2.SYSTEM CONFIGURATION
B-63494EN/01
CAUTION
The dual check safety system can not be used below
functions
- I/O Linkβ
- 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
-19-
3.SAFETY FUNCTIONS
B-63494EN/01
SAFETY FUNCTIONS
-20-
3.SAFETY FUNCTIONS
B-63494EN/01
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-
3.SAFETY FUNCTIONS
B-63494EN/01
(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.
-22-
3.SAFETY FUNCTIONS
B-63494EN/01
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
Spindle
CPU
Emergency
stop
Dual monitoring of protective door state
Spindle
motor
Cross-
CNC
CPU
Protective
door
SPM
Safe speed monitoring
Protective door
lock signal
Servo motor
SVM
Door lock/
open/close
monitoring
Cross-check
PSM
Monitor
Safe speed monitoring
Safe machine position
monitoring
Dual monitoring of MCC
CPU
Powerdown
(MCC)
I/O, safe speed of
the servo motor, and
machine
position
are checked by the
CNC
CPU
and
monitor CPU in
redundant mode.
Power-down
Dual monitoring of MCC
Dual power-down
Detection of potential cause of error by
self test
-23-
3.SAFETY FUNCTIONS
B-63494EN/01
Safety functions
- 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
-24-
3.SAFETY FUNCTIONS
B-63494EN/01
3.2
BEFORE USING THE SAFETY FUNCTION
3.2.1
Important Items to Check Before Using the Safety Function
3.2.2
−
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).
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.
-25-
3.SAFETY FUNCTIONS
B-63494EN/01
3.3
STOP
3.3.1
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-
3.SAFETY FUNCTIONS
B-63494EN/01
which the spindle motor cannot be controlled
encountered, immediate power-down is carried out.
3.3.2
is
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-
3.SAFETY FUNCTIONS
B-63494EN/01
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
Name
number
1947
MCC off timer 1
If the protective
door is closed
1948
MCC off timer 2
If the protective
door is opened
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.
-28-
3.SAFETY FUNCTIONS
B-63494EN/01
-29-
3.SAFETY FUNCTIONS
3.4
B-63494EN/01
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.
Name
1945
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-
3.SAFETY FUNCTIONS
B-63494EN/01
- 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
Machine
I/O
CNC
CPU
DI
I/O
DO
Cross check
FSSB
DI
Monitor
CPU
FSSB
DO
Duplicated I/O
Symbol
Signal name
I/O address
Emergency stop
<X008#4> <DI+000#0>
SGD
Guard state signal
<G191#4> <DI+001#4>
GDL
Guard lock state signal
<G191#5> <DI+001#5>
*SMC
MCC state contact signal
<G191#6> <DI+001#6>
MCF
MCC off signal
<F191#1> <DO+000#1>
ORQ
OPT
*LGD
RQT
Guard open request signal
Test mode signal
Guard unlock signal
MCC
off
Test
execution
request signal
<G191#3>
<G191#2>
<F191#0>
<F191#2>
*ESP
-31-
Dual input
monitoring
Dual input
monitoring
Dual input
monitoring
Dual input
monitoring
Duplicated
output
Input
Input
Output
Output
3.SAFETY FUNCTIONS
B-63494EN/01
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.
-32-
3.SAFETY FUNCTIONS
B-63494EN/01
IMPORTANT
!
6.
ORQ
The Ladder program cannot be checked for an error.
Check the safety function (see Chapter n).
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
B-63494EN/01
through the PMC.
9.
RQT
MCC off Test execution request signal
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
CNC (PMC)
Door open request
24V
G
ORQ
X
Ladder
ORQ-I
LGD
Protective door
F
Y
Ladder
LGD-O
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.
-34-
3.SAFETY FUNCTIONS
B-63494EN/01
State transition
ORQ-I
ORQ
*LGD
*LGD-O
A
0
0
0
0
B
C
D
1
1
1
0
1
1
0
0
1
0
0
0
E
1
1
1
1
D
F
1
0
1
1
1
1
0
0
G
A
0
0
0
0
1
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
-35-
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 closed
Door opened
ｔ
(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-
3.SAFETY FUNCTIONS
B-63494EN/01
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.
-37-
3.SAFETY FUNCTIONS
B-63494EN/01
This is mandatory.
-38-
3.SAFETY FUNCTIONS
B-63494EN/01
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.
!
IMPORTANT
-39-
3.SAFETY FUNCTIONS
B-63494EN/01
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.
-40-
3.SAFETY FUNCTIONS
B-63494EN/01
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.
-41-
3.SAFETY FUNCTIONS
3.8
B-63494EN/01
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.
-42-
4.INSTALLATION
B-63494EN/01
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
Ambient
Temperature
of the unit
Humidity
Vibration
Meters above
sea level
Environment
Operating
Storage
Transport
Normal
LCD–mounted
type
control
unit
and
display
unit
(except
unit
with
data
server function)
0°C to 58°C
–20°C to 60°C
75%
RH
condensation
95%
RH
condensation
or
Stand–alone
type control
unit
LCD–mounted
type
control
unit with PC
and data server
functions
0°C to 55°C
5°C to 53°C
less,
no
10% to 75% RH,
no condensation
10% to 90% RH,
no condensation
or
less,
no
Short
period(less than
1 month)
Operating
0.5 G or less
Non–operating
1.0 G or less
Operating
Up to 1000 m
Up to 1000 m
Non–operating
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.)
-43-
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 55°C (at operation)
–20 to 60°C
(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.
-44-
4.INSTALLATION
B-63494EN/01
4.1
OVERALL CONNECTION DIAGRAM
LCD display unit
Mother board
24V-IN(CP1A)
24 VDC
supply
power
To I/O device
24V-OUT(CP1B)
MDI UNIT
Soft key cable
MDI(CA55)
CK2
CK1
R232(JD36A)
RS-232C I/O device
R232(JD36B)
RS-232C I/O device
Touch panel
HDI(JA40)
High-speed skip input
Distribution-type
I/O board
DC24V
CPD1
JA3
JD1
I/O-LINK(JD1A)
Manual
pulse generator
Operator's
panel
JD1
I/O unit, etc.
DC24V
CPD1
JD1
JD1
-45-
Power
magnetics
cabinet
4.INSTALLATION
B-63494EN/01
LCD display unit
Mother board
SPDL(JA41)
JA7B
JA7A
JY2
SPM
TB2
Spindle motor
Second spindle
FSSB(COP10A)
COP10A
SVM
COP10B
COP10A
JF1
Axis 2
servo monitor
TB2
SVM
COP10B
COP10A
Axis 1
servo motor
TB2
COP10B
JF1
Axis 3
servo motor
TB2
SVM
JF1
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
JF101
Linear scale axis 1
JF102
Linear scale axis 2
JF103
Linear scale axis 3
JF104
Linear scale axis 4
JA4A
Battery for absolute
position detector
COP10A
FSSB I/O
DC24V
CP11A CB155A
COP10B CB156A
COP10A
SV-CHK(CA54)
Servo check board
-46-
Power
magnetics
cabinet
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:
PMC→CNC
G008
PMC→CNC#7
*ESPG
#6
G191
CNC→PMC#7
#5
*SMC1
#6
#4
GDL1
#5
#4
F191
#3
SGD1
#3
#2
#1
ORQ
OPT
#2
#1
RQT
#0
#0
MCF1
*LGD
For the meaning of each of the above signals, see Chapter 6,
"OPERATION."
Hatted signals means dual monitoring.
-47-
4.INSTALLATION
4.3
B-63494EN/01
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.
4.3.1
FSSB I/O Connection
Power supply connection
External power
supply
ＣＰ１１Ａ
１ ＋２４Ｖ
２
０Ｖ
３
24 VDC regulated power
supply
24 VDC±10%
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.
-48-
4.INSTALLATION
B-63494EN/01
DI/DO connection
Pin No.
Signal name
+24V
CB155A(A01)
CB155A(B01)
ＲＶ
CB155A(A02)
ＲＶ
CB155A(A07)
ＲＶ
CB155A(B07)
ＲＶ
CB155A(A08)
ＲＶ
CB155A(B08)
SGD2
ＲＶ
CB155A(A09)
GDL2
ＲＶ
CB155A(B09)
SMC2
ＲＶ
CB155A(A10)
*ESP2
Pin No.
DOCOM
Signal name
CB155A(B06)
0V
+24V
+24V regulated
power supply
CB155A(A11)
Relay
ＤＶ
MCF2
CB155A(B11)
ＤＶ
Relay
CB155A(A17,B17)
4.3.2
For the meanings
"OPERATION."
FSSB I/O Attachment
External dimensions
-49-
of
the
above
signals,
see
Chapter
6,
4.INSTALLATION
B-63494EN/01
CP11A
CP11B
Upper:CB156A
Lower:CB155A
COP10A COP10B
-50-
4.INSTALLATION
B-63494EN/01
Screw attachment
Mounting hole
machining diagram
付穴加
-51-
4.INSTALLATION
B-63494EN/01
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.
-52-
4.INSTALLATION
B-63494EN/01
Working space around the I/O unit
Attachment to a DIN rail
-53-
4.INSTALLATION
B-63494EN/01
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.
-54-
4.INSTALLATION
B-63494EN/01
4.3.3
FSSB I/O Specification List
Installation conditions
Ambient temperature
of the unit
Temperature variation
Humidity
Vibration
Atmosphere
Other conditions
Operating
0℃～55℃
Storage, transportation －20℃～60℃
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.
Power supply capacity
Supply voltage
24V±10% 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 μA or less
Driver delay time: 50 μs(MAX)
In addition, the FSSB transfer period and ladder scan period must be
considered.
-55-
5.I/O SIGNALS
B-63494EN/01
I/O SIGNALS
-56-
5.I/O SIGNALS
B-63494EN/01
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.
-57-
5.I/O SIGNALS
5.2
B-63494EN/01
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
-58-
5.I/O SIGNALS
B-63494EN/01
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]
[Operation]
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.
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]
[Operation]
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.
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
-59-
5.I/O SIGNALS
B-63494EN/01
[Operation]
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 condition]
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).
MCC-on enable signal
MCF1 <F191#1>,MCF2 <DO+000#1>
[Classification]
[Function]
[Output condition]
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).
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
-60-
5.I/O SIGNALS
B-63494EN/01
[Output condition]
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.
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
#6
#5
X008
#4
#3
#2
#1
#0
#3
#2
#1
#0
#3
#2
#1
#0
*ESP1
#7
#6
#5
G008
#4
*ESPG
#7
#6
#5
-61-
#4
5.I/O SIGNALS
B-63494EN/01
G191
*SMC1
#7
GDL1
#6
#5
SGD1
#4
ORQ
OPT
#3
#2
F191
RQT
#1
MCF1
#0
*LGD
Via the FSSB
#7
#6
#5
#4
#3
#2
#1
DI+0000
#0
*ESP2
#7
DI+001
#6
*SMC2
#7
#5
GDL2
#6
#5
#4
#3
#2
#1
#0
#3
#2
#1
#0
SGD2
#4
DO+000
MCF2
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
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
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.)
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
-62-
5.I/O SIGNALS
B-63494EN/01
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.
-63-
6.PARAMETERS
B-63494EN/01
PARAMETERS
-64-
6.PARAMETERS
B-63494EN/01
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.
-65-
6.PARAMETERS
6.2
B-63494EN/01
Parameters
1023
[Data type]
[Valid data range]
Servo axis number for each axis
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).
1829
[Data type]
[Unit of data]
[Valid data range]
1838
Positional deviation limit during a stop for each axis
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
[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
1902
[Data type]
STP
#6
#5
DCE
#4
#3
#2
#1
#0
STP
Bit
When the power is turned on, a safety output signal MCC off Test in
the MCC off Test mode is:
-66-
6.PARAMETERS
B-63494EN/01
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
[Data type]
[Unit of data]
[Valid data range]
Safety speed for each axis
2-word axis
Valid data range
Increment
system
Unit of data
Millimeter machine 1 mm/min
Inch machine
0.1 inch/min
Rotation axis
1 deg/min
IS-A, IS-B
0 ~ 240000
0 ~ 96000
0 ~ 240000
IS-C
0 ~ 100000
0 ~ 48000
0 ~ 100000
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
-67-
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
Safety position of each axis (+ direction)
1944
Safety position of each axis (- direction)
[Data type]
[Unit of data]
2-word
Increment system
IS-A
Millimeter machine 0.01
Inch machine
0.001
[Valid data range]
IS-B
0.001
0.0001
IS-C
0.0001
0.00001
Unit
mm
inch
-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
[Data type]
[Unit of data]
Safety input signal check timer
Word
ms
-68-
6.PARAMETERS
B-63494EN/01
[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.
1946
[Data type]
[Unit of data]
[Valid data range]
MCC off Test timer
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.
1947
MCC-off timer 1
1948
[Data type]
[Unit of data]
[Valid data range]
MCC-off timer 2
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
Timer used
When a spindle alarm is issued
When the guard is closed
When the guard is open
3225
[Data type]
[Valid data range]
No timer is used.
MCC-off timer 1 (No. 1947)
MCC-off timer 2 (No. 1948)
Code for safety parameters
2-word
0 to 99999999
Set a code (password) for protecting against modifications to
parameters related to the dual-check safety function (safety
-69-
6.PARAMETERS
B-63494EN/01
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
[Data type]
[Valid data range]
Key for safety parameters
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
[Data type]
[Unit of data]
[Valid data range]
Safety speed of each spindle
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
-70-
6.PARAMETERS
B-63494EN/01
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.
-71-
7.MAINTENANCE
B-63494EN/01
MAINTENANCE
-72-
7.MAINTENANCE
B-63494EN/01
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.
-73-
7.MAINTENANCE
B-63494EN/01
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 B-63005EN/01.
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.
2. 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.
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
-74-
7.MAINTENANCE
B-63494EN/01
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.
-75-
7.MAINTENANCE
B-63494EN/01
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.
-76-
7.MAINTENANCE
B-63494EN/01
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
Servo Alarms
No.
364
Meaning
n AXIS: SOFT PHASE
ALARM(INT)
403
SERVO ALARM : CARD/SOFT
MISMATCH
410
SERVO ALARM : n AXIS
EXCESS ERR
411
SERVO ALARM : n AXIS
EXCESS ERR
453
n AXIS:SPC SOFT
DISCONNECT ALARM
470
n AXIS:ILLEGAL RAM (MNT)
471
n AXIS:SPC SOFT
DISCONNECT (MNT)
473
n AXIS:SOFT PHASE
ALARM(INT/MNT)
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).
-77-
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.
Confirm a proper valule is set to
parameter No. 1829.
Confirm a proper value is set to
parameter No. 1828 or No.
1838.
Replace the alpha pulse coder.
Replace the axis control card.
Replace the alpha pulse coder.
Replace the alpha pulse coder,
or take measures to correct
noise on the feedback cable.
7.MAINTENANCE
No.
474
475
476
477
478
B-63494EN/01
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.
479
ILLEGAL SAFETY DI (MNT)
480
n AXIS:ILLEGAL SAFETY
MODE (MNT)
Remedy
Confirm a proper value is set to
parameter No. 1828.
Confirm a proper value is set to
parameter No. 1838.
When the guard is open,
confirm a proper value is set to
parameter No. 1942, and the
operation is done within the
safety speed.
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.
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.
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.
-78-
7.MAINTENANCE
B-63494EN/01
No.
481
482
483
484
486
487
488
489
Meaning
n AXIS:SAFETY PARAM
ERROR (MNT)
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.
-79-
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.
Replace the axis control card.
Check the safety input signals
via the PMC and via the FSSB
are equal.
Check if the guard state
signal(SGD) is correctly
connected.
Check the MCC contact.
Set the safety parameters
again.
7.MAINTENANCE
No.
490
491
492
494
495
496
B-63494EN/01
Meaning
CNC SAFETY FUNCTION
ERROR
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.
497
n AXIS:SAFETY PARAM
TRANS ERROR
498
n AXIS:AXIS NUMBER NOT
SET (CNC)
Remedy
Replace the CPU card.
Replace the mother board.
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.
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.
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.
-80-
7.MAINTENANCE
B-63494EN/01
7.2.2
Serial Spindle Alarms
No.
749
Meaning
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
SPINDLE-2 ILLEGAL AXIS
DATA
766
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)
-81-
7.MAINTENANCE
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)
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)
7.2.3
B-63494EN/01
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)
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)
Alarms Displayed on the Spindle Unit
No.
Meaning
AL-16 RAM Alarm
Description
An error occurred in a spindle
RAM test.
-82-
Remedy
Replace spindle amplifier
module.
7.MAINTENANCE
B-63494EN/01
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
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.
-83-
7.MAINTENANCE
7.2.4
7.2.5
B-63494EN/01
System Alarms
No.
900
Meaning
ROM PARITY
920
SERVO ALARM (1-4 AXIS)
921
SERVO ALARM (5-8 AXIS)
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.
Replace the axis control card.
Replace the axis control card.
Boot System Alarms
Message
ROM PARITY ERROR:
NC BASIC. HIT SELECT.
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
-84-
Remedy
Reinstall the CNC basic ROM in
flash memory.
8.START-UP
B-63494EN/01
START-UP
-85-
8.START-UP
8.1
B-63494EN/01
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 Ω. 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-
8.START-UP
B-63494EN/01
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.
-87-
8.START-UP
B-63494EN/01
Safety 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.
8.1.2
Start-up of the Safety Function
8.1.2.1
Initial start-up
Main flow
Disable dual check
safety
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.
-88-
8.START-UP
B-63494EN/01
Prepa-
Disable the dual check Bit 6 of PRM No. 1902 = 0
ration
safety function.
1
Prepa-
Disable output (MCF), Connect the relay for driving based
ration
from I/O, that indicates on I/O output
2
MCC is turned off.
Note)
When the dual check safety function is disabled, the
MCC on enable signal (MCF) is not output.
connection to temporarily disable MCF.
So, make a
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 is set as slave 2
Make the settings indicated in the table below.
Parameter setting
Meaning
Bit 0 of No. 1902 = 1
Manually sets the FSSB setting mode.
Bit 4 of No. 1905 = 1
Uses the first FSSB I/O unit.
No. 1910 = 0
Sets the value of parameter No. 1023 less 1 when
the slave is an amplifier
No. 1911 = 1
Sets the value of parameter No. 1023 less 1 when
the slave is an amplifier
No. 1912 = 16
16 when the slave is a pulse module
Nos. 1913 to 1919 = 40 when there is no slave
40
Step 3
Safety parameter input
Enable the dual check safety function, and enter the safety
parameters.
-89-
8.START-UP
B-63494EN/01
Prepara-
Enable the dual check safety Bit 6 of PRM No. 1902 = 1
tion 1
function.
Prepara-
Enables output (MCF), from Enable I/O output.
tion 2
I/O, that indicates MCC is
turned off.
Set the safety parameters indicated in the table below.
Parameter setting
Meaning
1942
Safety speed on each axis
1943
Safety position (+ direction) on each axis
1944
Safety position (- direction) on each axis
1945
Timer for safety input signal check
1946
Timer for MCC off Test
1947
Timer 1 for MCC off
1948
Timer 2 for MCC off
1838
Positional deviation limit value in mode C
2078
Dual position feedback conversion coefficient
(numerator)
2079
Dual position feedback conversion coefficient
(denominator)
4372
Safety speed on each spindle
Step 4
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.
-90-
The
8.START-UP
B-63494EN/01
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.
Perform a safety
function check test in addition to the normal start-up
procedure.
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.
-91-
9.SAMPLE SYSTEM CONFIGURATION
B-63494EN/01
SAMPLE SYSTEM CONFIGURATION
-92-
9.SAMPLE SYSTEM CONFIGURATION
B-63494EN/01
9.1
SAMPLE CONFIGURATION
-93-
9.SAMPLE SYSTEM CONFIGURATION
B-63494EN/01
9.2
SAMPLE CONNECTIONS
9.2.1
Emergency Stop Signal (*ESP1, *ESP2)
I/O-Link I/O UNIT
+24V
*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
X00n#n
-94-
Ladder
program
*ESPG
(G008#4)
9.SAMPLE SYSTEM CONFIGURATION
B-63494EN/01
9.2.2
Guard Open Request Signal (ORQ)
+24V
Guard
open
request button
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)
-95-
9.SAMPLE SYSTEM CONFIGURATION
B-63494EN/01
NOTES
Create a Ladder program for performing a MCC off Test, then
input the program to the PMC side [G191#2].
-96-
9.SAMPLE SYSTEM CONFIGURATION
B-63494EN/01
9.2.4
Guard Unlock Enable Signal (*LGD),
Guard Lock State Signal (GDL), Guard State Signal (SGD)
+24V
Guard closed
SW1
SW2
Safety relay
Guard-monitoring
limit switch
RY1
SW3
RY1
RY3
RY2
RY2
RY3
RY3
0V
RY1
RY2
0V
I/O Link I/O UNIT
X00n#n
[Sample control components]
SW1/SW2:
Guard state monitoring
PMC
SGD
(G191#4)
*LGD
(F191#0)
switch with forced
dissociation mechanism
Y00n#n
SW3:
Guard lock switch
RY1, RY2, RY3:
FSSB I/O UNIT
Safety relay
SGD
(DI+001#4)
-97-
Ladder
program
9.SAMPLE SYSTEM CONFIGURATION
B-63494EN/01
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 Guard closed
SW2
SW3
RY1
RY2
RY3
SGD
CLOSE CLOSE CLOSE ON
ON
OFF
1
CLOSE CLOSE OPEN
OFF
ON
OFF
0
OPEN
OFF
OFF
ON
0
Guard locked
2 Guard closed
Guard unlocked
3 Guard opened
OPEN
OPEN
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.
-98-
9.SAMPLE SYSTEM CONFIGURATION
B-63494EN/01
9.2.5
MCC On Enable Signal (MCF),
Contact State Signal (*SMC)
+24V
MCC
I/O Link I/O UNIT PMC
X00n#n
*SMC1
(G191#6)
Y00n#n
MCF1
(F191#1)
0V
FSSB I/O UNIT
*SMC2
(DI+001#6)
MCF
(DO+000#1)
0V
PSM
200A
200B
CX3
MCC
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.
-99-
10.COMPONENTS LIST
B-63494EN/01
COMPONENTS LIST
Table 10.1. HARDWARE COMPONENTS
No.
1
Description
Main board
Specification number
Specification number
Of primary component
of secondary component
A20B-8100-0135 A20B-8100-0140
A20B-8100-0130
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
CPU card
A20B-3300-0170
A20B-3300-0050 A20B-3300-0070
3
Servo card
A17B-3300-0200
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-3300-0020 A20B-3300-0021
A20B-3300-0150
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-3900-0030 A20B-3900-0042
A20B-3900-0131
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
-100-
Remarks
10.COMPONENTS LIST
B-63494EN/01
7
FROM MODULE
A20B-3900-0014 A20B-3900-0074
A20B-3900-0011
A20B-3900-0013 A20B-3900-0073
A20B-3900-0012 A20B-3900-0072
A20B-3900-0071 A20B-3900-0010
A20B-3900-0070
8
A20B-2100-0270
FSSB
ADDITIONAL
DETECTOR
INTERFACE
9
A20B-2100-0150 A20B-2002-0400
I/O module
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
module
A20B-2000-0510
I/O Unit interface A20B-8000-0410
A20B-8000-0420 A20B-8000-0710
module
A20B-8000-0820
DC
digital
input A20B-9000-0901
A20B-9000-0970 A20B-9000-0971
A20B-9000-0902
A20B-9001-0011 A20B-9001-0010
module
A20B-9001-0281 A20B-8000-0341
A20B-9000-0972 A20B-9001-0280
A20B-9001-0490 A20B-8000-0510
13
DC digital output A20B-9000-0921
A20B-9001-0220 A20B-8002-0070
module
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
A20B-8000-0750 A20B-8000-0751
digital
A20B-8000-0730 A20B-8000-0731
input/output
module
15
AC
digital
input
A20B-8000-0341 A20B-9001-0940
AC digital output
A20B-8000-0470 A20B-8000-0480
module
A20B-8000-0321 A20B-8000-0880
module
16
-101-
10.COMPONENTS LIST
17
Relay
B-63494EN/01
output
A20B-9001-0200 A20B-8000-0101
module
18
FSSB I/O module
A20B-8000-0500
A20B-2100-0390
Table 10.2. SOFTWARE
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
Series / Version
Functions
B1F2 / ZZ
CNC for lathe with up to 8 servo
axes and up to 4 spindle axes.
BEF2 / ZZ
CNC for lathe with up to 6 servo
axes and up to 3 spindle axes.
DEF2 / ZZ
CNC for lathe with up to 4 servo
axes and up to 2 spindle axes.
D1F1 / ZZ
B0F2 / ZZ
BDF2 / ZZ
DDF2 / ZZ
D0F1 / ZZ
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.
[Monitor software]
Series / Version
Monitor
90A9 / 03
Functions
Monitor functions
[Servo control software]
Series / Version
Servo
90A5 / 01
Functions
Servo functions
[Spindle software]
Series / Version
Spindle
9D20 / ZZ
Functions
Spindle functions
-102-
TITLE
DRAW. NO.
CUST
SHEET
1
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.
EAO
B-63494EN/01-06
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
Dual Check Safety OPERATOR'S MANUAL
Spec.No./Version
B-63494EN/01
2. Summary of change
Group
Name / Outline
New, Add,
Correct,
Delete
Applicable
Date
Basic
Function
Optional
Function
Unit
Maintenance
parts
Notice
Correction
Another
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.
TITLE
01
EDIT.
DRAW. NO.
02.06.26 Arimoto First issue
DATE
DESIG.
DESCRIPTION
Dual Check Safety
OPERATOR'S MANUAL
Addition and correction of
sample system configuration
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
１/9
Change a title of 10.1.1 as follows
10.1.1
For One-path(When one PSM is used)
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
２/9
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)
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
３/9
Add 10.1.2 as follows
10.1.2
For One-path(When two PSMs are used)
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
４/9
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.
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
５/9
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
Guard2 closed
SW11 SW12
SW21 SW22
Guard lock 1
Guard lock 2
Guard-monitoring
limit switch 1
Guard-monitoring
limit switch 2
SW13
SW23
0V
0V
Safety relay
RY1
RY1
RY3
RY2
RY2
RY3
RY3
RY1
RY2
0V
PMC
SGD
(G191#4)
I/O Link I/O UNIT
X00n#n
*LGD
(F191#0)
Y00n#n
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,RY3：Safety relay
FSSB I/O UNIT
SGD
(DI+001#4)
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
６/9
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
Guard lock
SW1
SW2
SW3
RY1
RY2
RY3
SGD
１ CLOSE
LOCK
CLOSE
CLOSE
CLOSE
ON
ON
OFF
1
２ CLOSE
UNLOCK
CLOSE
CLOSE
OPEN
OFF
ON
OFF
0
OPEN
UNLOCK
OPEN
OPEN
OPEN
OFF
OFF
ON
0
３
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
Guard１ Guard lock1 Guard2 Guard lock
SW1
SW12
SW13
SW21
SW22
SW23
RY1
RY2
RY3 SGD
２
１
CLOSE
LOCK
CLOSE
LOCK
CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
ON
ON
OFF
1
２
CLOSE
UNLOCK
CLOSE
LOCK
CLOSE CLOSE
ＯＦ
ON
OFF
０
ＯＦ
ＯＦ
ON
０
Ｆ
Ｆ
ＯＰＥ
ＯＦ
ON
OFF
０
Ｎ
Ｆ
ＯＰＥ
ＯＦ
ON
OFF
０
Ｎ
Ｆ
ＯＰＥ
ＯＦ
ＯＦ
ON
０
Ｎ
Ｆ
Ｆ
ＯＰＥ
CLOSE CLOSE CLOSE
Ｎ
３
ＯＰＥ
UNLOCK
CLOSE
LOCK
Ｎ
４
５
CLOSE
CLOSE
LOCK
UNLOCK
CLOSE
CLOSE
UNLOCK
UNLOCK
ＯＰＥ
ＯＰＥ
ＯＰＥ
Ｎ
Ｎ
Ｎ
Ｆ
CLOSE CLOSE CLOSE
CLOSE CLOSE CLOSE CLOSE CLOSE
CLOSE CLOSE
ＯＰＥ
CLOSE CLOSE
Ｎ
６
ＯＰＥ
UNLOCK
Ｎ
CLOSE
UNLOCK
ＯＰＥ
ＯＰＥ
ＯＰＥ
Ｎ
Ｎ
Ｎ
CLOSE CLOSE
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
７/9
７
CLOSE
LOCK
ＯＰＥ
UNLOCK
CLOSE CLOSE CLOSE
ＯＰＥ
ＯＰＥ
ＯＰＥ
ＯＦ
ＯＦ
Ｎ
Ｎ
Ｎ
Ｆ
Ｆ
ＯＰＥ
ＯＰＥ
ＯＰＥ
ＯＰＥ
ＯＦ
ＯＦ
Ｎ
Ｎ
Ｎ
Ｎ
Ｆ
Ｆ
Ｎ
８
CLOSE
UNLOCK
ＯＰＥ
UNLOCK
CLOSE CLOSE
Ｎ
９
ＯＰＥ
UNLOCK
Ｎ
ＯＰＥ
Ｎ
UNLOCK
ＯＰＥ
ＯＰＥ
ＯＰＥ
ＯＰＥ
ＯＰＥ
ＯＰＥ
ＯＦ
ＯＦ
Ｎ
Ｎ
Ｎ
Ｎ
Ｎ
Ｎ
Ｆ
Ｆ
ON
０
ON
０
ON
０
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
８/9
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.
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
９/9
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
MCF1
(F191#1)
0V
FSSB I/O UNIT
*SMC2
(DI+001#6)
MCF2
(DO+000#1)
0V
PSM
200A
200B
CX3
MCC
U
V
W
Electromagnetic contactor (MAIN MCC)
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
１０/9
FANUC Series 16i/18i/21i–TB/MB
FANUC Series 18i-MB5
Dual Check Safety
Programmable Safe-related I/O signals
Specifications
Contents
1.1
OUTLINE ...................................................................................................................................................... 2
1.2
SPECIFICATIONS........................................................................................................................................ 4
1.3
SIGNALS ...................................................................................................................................................... 6
1.4
PARAMETERS............................................................................................................................................. 8
1.5
C-LANGUAGE EXECUTOR ........................................................................................................................ 9
1.6
ALARMS AND MESSAGES ...................................................................................................................... 14
A-78882E
FS16i/18i/21i-TB/MB, FS18i-MB5
Page
Contents
No.
02 Nov. 7, 2002 O.Abe corrected at [1]
Ed.
Date
Draw up
Jul.19, 2002
Name
04 Nov. 20, 2003 T.Inagaki corrected at [3]
03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1
Programmable Safe-related I/O signals
1/14
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
B1H1-22 or later
FS18i-TB
BEH1-22 or later
FS21i-TB
DEH1-22 or later
FS16i-MB
B0H1-22 or later
[1]
FS18i-MB
BDH1-22 or later
[3]
FS18i-MB5
BDH5-12 or later
FS21i-MB
DDH1-22 or later
Monitor
90B9-03
Servo
90B0-20 or later
90B3-04 or later
90B7-04 or later
C-language executor library
BY01-2.9F or later
A-78882E
FS16i/18i/21i-TB/MB, FS18i-MB5
Page
Contents
Programmable Safe-related I/O signals
No.
02 Nov. 7, 2002 O.Abe corrected at [1]
Ed.
Date
Draw up
Jul.19, 2002
Name
04 Nov. 20, 2003 T.Inagaki corrected at [3]
03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1
[3]
2/14
NOTE
[1]
This function will be under investigation at TUV soon.
So these required software versions are subject to change without notice.
A-78882E
FS16i/18i/21i-TB/MB, FS18i-MB5
Page
Contents
No.
02 Nov. 7, 2002 O.Abe corrected at [1]
Ed.
Date
Draw up
Jul.19, 2002
Name
04 Nov. 20, 2003 T.Inagaki corrected at [3]
03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1
Programmable Safe-related I/O signals
3/14
1.2
Specifications
CNC
C-language executor
User
Logic
[k]
[l]
Speed/
Position
Monitoring
and so on
[g]
PMC
Y signals
G191
G334
G335
G331
[e]
[e]
[m]
Free 8
DO
Crosscheck
MCF,LGD
F191
[f]
[b]
Monitor
DI
Crosscheck
[d]
Speed/
Position
Monitoring
and so on
User
Logic
Free 8 points
DI+000
~DI+003
X signals
[a]
I/O Link #1
MCF
[c]
[i]
[h]
[j]
DO+000
DO+001
FSSB I/O #2
*ESP, *SMC, GDL,
SGD, Free 16 points
ORQ, OPT
MCF, Free 8 points
Note) The mark [a]~[m] are for reference to
“Sequence
of
Programmable
Safe-related I/O signals Function”
mentioned in the following page.
LGD
Fig 1. Concept of function
A-78882E
FS16i/18i/21i-TB/MB, FS18i-MB5
Page
Contents
No.
02 Nov. 7, 2002 O.Abe corrected at [1]
Ed.
Date
Draw up
Jul.19, 2002
Name
04 Nov. 20, 2003 T.Inagaki corrected at [3]
03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1
Programmable Safe-related I/O signals
4/14
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]
Monitor CPU monitors the speed/position and so on and creates the signals
MCF.
[j]
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).
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.
A-78882E
FS16i/18i/21i-TB/MB, FS18i-MB5
Page
Contents
No.
02 Nov. 7, 2002 O.Abe corrected at [1]
Ed.
Date
Draw up
Jul.19, 2002
Name
04 Nov. 20, 2003 T.Inagaki corrected at [3]
03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1
Programmable Safe-related I/O signals
5/14
[2]
1.3
Signals
1.3.1
Signals
Programable safe-related DI signal [2]
SDI00~SDI15 <G334, G335> <DI+002, DI+003>
[Classification]
[Function]
Input signal
CNC and Monitor use these signals only for cross-check for input signals in Dual
Check Safety.
[Operation]
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]
Input signal
CNC and Monitor use these signals only for cross-check for output signals in Dual
Check Safety.
[Operation]
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.
A-78882E
FS16i/18i/21i-TB/MB, FS18i-MB5
Page
Contents
No.
02 Nov. 7, 2002 O.Abe corrected at [1]
Ed.
Date
Draw up
Jul.19, 2002
Name
04 Nov. 20, 2003 T.Inagaki corrected at [3]
03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1
Programmable Safe-related I/O signals
6/14
1.3.2
Signal addresses
via PMC
#7
#6
#5
#4
X008
*ESP1
G008
*ESPG
G191
#3
#2
*SMC1
GDL1
SGD1
ORQ
OPT
#1
#0
G331
SDO07
SDO06
SDO05
SDO04
SDO03
SDO02
SDO01
SDO00
G334
SDI07
SDI06
SDI05
SDI04
SDI03
SDI02
SDI01
SDI00
G335
SDI15
SDI14
SDI13
SDI12
SDI11
SDI10
SDI09
SDI08
#7
#6
#5
#4
#3
#2
#1
#0
RQT
MCF1
LGD
#2
#1
#0
F191
via FSSB
#7
#6
#5
#4
#3
DI+000
*ESP2
DI+001
*SMC2
GDL2
SGD2
DI+002
SDI07
SDI06
SDI05
SDI04
SDI03
SDI02
SDI01
SDI00
DI+003
SDI15
SDI14
SDI13
SDI12
SDI11
SDI10
SDI09
SDI08
#7
#6
#5
#4
#3
#2
#1
#0
DO+000
DO+001
MCF2
SDO07
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.
A-78882E
FS16i/18i/21i-TB/MB, FS18i-MB5
Page
Contents
No.
02 Nov. 7, 2002 O.Abe corrected at [1]
Ed.
Date
Draw up
Jul.19, 2002
Name
04 Nov. 20, 2003 T.Inagaki corrected at [3]
03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1
Programmable Safe-related I/O signals
7/14
1.4
Parameters
#7
#6
#5
#4
#3
#2
13800
[Data type]
CIO
#1
#0
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.
A-78882E
FS16i/18i/21i-TB/MB, FS18i-MB5
Page
Contents
No.
02 Nov. 7, 2002 O.Abe corrected at [1]
Ed.
Date
Draw up
Jul.19, 2002
Name
04 Nov. 20, 2003 T.Inagaki corrected at [3]
03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1
Programmable Safe-related I/O signals
8/14
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]
Function code
iodata[1]
Return code
iodata[2]
Data length
iodata[3]
Data number
iodata[4]
Data attribute
iodata[5]
General data buffer
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]".
A-78882E
FS16i/18i/21i-TB/MB, FS18i-MB5
Page
Contents
No.
02 Nov. 7, 2002 O.Abe corrected at [1]
Ed.
Date
Draw up
Jul.19, 2002
Name
04 Nov. 20, 2003 T.Inagaki corrected at [3]
03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1
Programmable Safe-related I/O signals
9/14
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.
A-78882E
FS16i/18i/21i-TB/MB, FS18i-MB5
Page
Contents
No.
02 Nov. 7, 2002 O.Abe corrected at [1]
Ed.
Date
Draw up
Jul.19, 2002
Name
04 Nov. 20, 2003 T.Inagaki corrected at [3]
03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1
Programmable Safe-related I/O signals
10/14
(16) Read Programable Safe-related DI Signal [2]
Equivalence to "pmc_rdsafeprgio()" function.
[Input]
Function code
iodate[0] = 136
Data length
iodata[2] = 0
Data number
iodata[3] = 0
Data attribute
iodata[4] = 0
[Output] Return code
iodata[1] = 0 Successful.
[3]
3 Invalid data number.
6 Option for dual check safty isn't added.
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]
[3]
Equivalence to "pmc_wrsafeprgio()" function.
[Input]
Function code
iodate[0] = 137
Data length
iodata[2] = 1
Data number
iodata[3] = 0
Data attribute
iodata[4] = 0
programable safe-related DO signal (DO+001) [2][3]
( char )iodata[5]
[Output] Return code
iodata[1] = 0 Successful.
6 Option for dual check safty isn't added. [2]
A-78882E
FS16i/18i/21i-TB/MB, FS18i-MB5
Page
Contents
No.
02 Nov. 7, 2002 O.Abe corrected at [1]
Ed.
Date
Draw up
Jul.19, 2002
Name
04 Nov. 20, 2003 T.Inagaki corrected at [3]
03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1
Programmable Safe-related I/O signals
11/14
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
datano ;
/* Data No. */
int
dummy ; /* Not use
char
cdata[2] ; /* I/O signal */
*/
};
[Arguments]
[Return]
[Description]
[Examples]
datano
: data number( = 0 ).
Buf
: buffer in which the signal datas for programable safe-related DI stored. [2]
EW_OK( 0)
: Successful.
EW_NOOPT( 6)
: Option for dual check safty isn't added.
Read programable safe-related DI signals via FSSB I/O for dual check safety.
cdata[0]
safe-related input signal 1 (DI+002)
cdata[1]
safe-related input signal 2 (DI+003)
The following program reads signal datas for programable safe-related DI and
display them. [2]
void print_safetyprgio( void )
{
int
ret;
struct iodbsaftyprg
buf;
ret =
pmc_rdsafeprgio( 0 , &buf );
if( ret == 0 )
{
printf( "G334 : %02xh ¥n" , buf.cdata[0] ) ;
printf( "G335 : %02xh ¥n" , buf.cdata[1] ) ;
}
[3]
}
A-78882E
FS16i/18i/21i-TB/MB, FS18i-MB5
Page
Contents
No.
02 Nov. 7, 2002 O.Abe corrected at [1]
Ed.
Date
Draw up
Jul.19, 2002
Name
04 Nov. 20, 2003 T.Inagaki corrected at [3]
03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1
Programmable Safe-related I/O signals
12/14
Write Programable Safe-related DO Signal [2]
[Name]
[Syntax]
pmc_wrsafeprgio
#include
<fwindow.h>
int pmc_wrsafeprgio( char data ) ;
[Arguments]
[Return]
[Description]
data
[3]
: data of Programable Safe-related DO Signals.
EW_OK( 0)
: Successful.
EW_NOOPT( 6)
: Option for dual check safty isn't added. [2]
Write programable safe-related DO signals via FSSB I/O (DO+001) for dual check
safety. [2][3]
[Examples]
The following program initializes signal datas for programable safe-related DO. [2]
int init_prgio_di( void )
{
int ret;
ret = pmc_wrsafeprgio( 0x00 ) ;
[1]
[3]
if( ret == 0 )
return( 0 );
else
return( -1 );
}
A-78882E
FS16i/18i/21i-TB/MB, FS18i-MB5
Page
Contents
No.
02 Nov. 7, 2002 O.Abe corrected at [1]
Ed.
Date
Draw up
Jul.19, 2002
Name
04 Nov. 20, 2003 T.Inagaki corrected at [3]
03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1
Programmable Safe-related I/O signals
13/14
1.6
Alarms and messages
No.
479
Message
Description
ILLEGAL SAFETY DI (MNT)
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
[3]
(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.
A-78882E
FS16i/18i/21i-TB/MB, FS18i-MB5
Page
Contents
No.
02 Nov. 7, 2002 O.Abe corrected at [1]
Ed.
Date
Draw up
Jul.19, 2002
Name
04 Nov. 20, 2003 T.Inagaki corrected at [3]
03 Nov. 11, 2002 O.Abe corrected at [2] and corrected Fig. 1
Programmable Safe-related I/O signals
14/14
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.
EAO
B-63494EN/01-06
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
Dual Check Safety OPERATOR'S MANUAL
Spec.No./Version
B-63494EN/01
2. Summary of change
Group
Name / Outline
New, Add,
Correct,
Delete
Applicable
Date
Basic
Function
Optional
Function
Unit
Maintenance
parts
Notice
Correction
Another
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.
TITLE
01
EDIT.
DRAW. NO.
02.06.26 Arimoto First issue
DATE
DESIG.
DESCRIPTION
Dual Check Safety
OPERATOR'S MANUAL
Addition and correction of
sample system configuration
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
１/9
Change a title of 10.1.1 as follows
10.1.1
For One-path(When one PSM is used)
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
２/9
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)
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
３/9
Add 10.1.2 as follows
10.1.2
For One-path(When two PSMs are used)
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
４/9
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.
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
５/9
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
Guard2 closed
SW11 SW12
SW21 SW22
Guard lock 1
Guard lock 2
Guard-monitoring
limit switch 1
Guard-monitoring
limit switch 2
SW13
SW23
0V
0V
Safety relay
RY1
RY1
RY3
RY2
RY2
RY3
RY3
RY1
RY2
0V
PMC
SGD
(G191#4)
I/O Link I/O UNIT
X00n#n
*LGD
(F191#0)
Y00n#n
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,RY3：Safety relay
FSSB I/O UNIT
SGD
(DI+001#4)
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
６/9
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
Guard lock
SW1
SW2
SW3
RY1
RY2
RY3
SGD
１ CLOSE
LOCK
CLOSE
CLOSE
CLOSE
ON
ON
OFF
1
２ CLOSE
UNLOCK
CLOSE
CLOSE
OPEN
OFF
ON
OFF
0
OPEN
UNLOCK
OPEN
OPEN
OPEN
OFF
OFF
ON
0
３
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
Guard１ Guard lock1 Guard2 Guard lock
SW1
SW12
SW13
SW21
SW22
SW23
RY1
RY2
RY3 SGD
２
１
CLOSE
LOCK
CLOSE
LOCK
CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE
ON
ON
OFF
1
２
CLOSE
UNLOCK
CLOSE
LOCK
CLOSE CLOSE
ＯＦ
ON
OFF
０
ＯＦ
ＯＦ
ON
０
Ｆ
Ｆ
ＯＰＥ
ＯＦ
ON
OFF
０
Ｎ
Ｆ
ＯＰＥ
ＯＦ
ON
OFF
０
Ｎ
Ｆ
ＯＰＥ
ＯＦ
ＯＦ
ON
０
Ｎ
Ｆ
Ｆ
ＯＰＥ
CLOSE CLOSE CLOSE
Ｎ
３
ＯＰＥ
UNLOCK
CLOSE
LOCK
Ｎ
４
５
CLOSE
CLOSE
LOCK
UNLOCK
CLOSE
CLOSE
UNLOCK
UNLOCK
ＯＰＥ
ＯＰＥ
ＯＰＥ
Ｎ
Ｎ
Ｎ
Ｆ
CLOSE CLOSE CLOSE
CLOSE CLOSE CLOSE CLOSE CLOSE
CLOSE CLOSE
ＯＰＥ
CLOSE CLOSE
Ｎ
６
ＯＰＥ
UNLOCK
Ｎ
CLOSE
UNLOCK
ＯＰＥ
ＯＰＥ
ＯＰＥ
Ｎ
Ｎ
Ｎ
CLOSE CLOSE
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
７/9
７
CLOSE
LOCK
ＯＰＥ
UNLOCK
CLOSE CLOSE CLOSE
ＯＰＥ
ＯＰＥ
ＯＰＥ
ＯＦ
ＯＦ
Ｎ
Ｎ
Ｎ
Ｆ
Ｆ
ＯＰＥ
ＯＰＥ
ＯＰＥ
ＯＰＥ
ＯＦ
ＯＦ
Ｎ
Ｎ
Ｎ
Ｎ
Ｆ
Ｆ
Ｎ
８
CLOSE
UNLOCK
ＯＰＥ
UNLOCK
CLOSE CLOSE
Ｎ
９
ＯＰＥ
UNLOCK
Ｎ
ＯＰＥ
Ｎ
UNLOCK
ＯＰＥ
ＯＰＥ
ＯＰＥ
ＯＰＥ
ＯＰＥ
ＯＰＥ
ＯＦ
ＯＦ
Ｎ
Ｎ
Ｎ
Ｎ
Ｎ
Ｎ
Ｆ
Ｆ
ON
０
ON
０
ON
０
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
８/9
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.
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
９/9
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
MCF1
(F191#1)
0V
FSSB I/O UNIT
*SMC2
(DI+001#6)
MCF2
(DO+000#1)
0V
PSM
200A
200B
CX3
MCC
U
V
W
Electromagnetic contactor (MAIN MCC)
TITLE
DRAW. NO.
EDIT.
DATE
DESIG.
DESCRIPTION
CUST.
B-63494EN/01-06
FANUC
LTD
SHEET
１０/9