B-63494EN 01 Dual Check Safety Operator's Manualftp.ruigongye.com/200807/fanuccncdualcheck01.pdf ·...

OPERATOR’S MANUAL

B-63494EN/01

No part of this manual may be reproduced in any form.

All specifications and designs are subject to change without notice.

In this manual we have tried as much as possible to describe all thevarious 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 inthis manual should be regarded as ”impossible”.

B-63494EN/01 SAFETY PRECAUTIONS

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SAFETY PRECAUTIONSThis manual includes safety precautions for protecting the user andpreventing damage to the machine. Precautions are classified intoWarning 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.

WARNINGApplied when there is a danger of the user beinginjured or when there is a damage of both the userbeing injured and the equipment being damaged ifthe approved procedure is not observed.

CAUTIONApplied when there is a danger of the equipmentbeing damaged, if the approved procedure is notobserved.

NOTEThe Note is used to indicate supplementaryinformation other than Warning and Caution.

- Read this manual carefully, and store it in a safe place.

B-63494EN/01 TABLE OF CONTENTS

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TABLE OF CONTENTS

SAFETY PRECAUTIONSSAFETY PRECAUTIONSSAFETY PRECAUTIONSSAFETY PRECAUTIONS............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ s-s-s-s-1111

1111 OVERVIOVERVIOVERVIOVERVIEWEWEWEW.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1111

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

1.3.2.1 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

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

2222 SYSTEM CONFIGURATIOSYSTEM CONFIGURATIOSYSTEM CONFIGURATIOSYSTEM CONFIGURATIONNNN............................................................................................................................................................................................................................................................................................................................................................................................................................................ 14141414

3333 SAFETY FUNCTIONSSAFETY FUNCTIONSSAFETY FUNCTIONSSAFETY FUNCTIONS .................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 16161616

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

TABLE OF CONTENTS B-63494EN/01

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

4444 INSTALLATIOINSTALLATIOINSTALLATIOINSTALLATIONNNN............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 33333333

4.1 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

5555 I/OI/OI/OI/O SIGNALS SIGNALS SIGNALS SIGNALS ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 48484848

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

6666 PARAMETERSPARAMETERSPARAMETERSPARAMETERS .................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 62626262

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

7777 START-UPSTART-UPSTART-UPSTART-UP ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 75757575

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

B-63494EN/01 TABLE OF CONTENTS

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

7.1.3 Troubleshooting ....................................................................................................................... 80

8888 MAINTENANCEMAINTENANCEMAINTENANCEMAINTENANCE ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 81818181

8.1 SAFETY PRECAUTIONS............................................................................................................... 82

8.2 ALARMS AND MESSAGES........................................................................................................... 86

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

9999 DIAGNOSISDIAGNOSISDIAGNOSISDIAGNOSIS........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 94949494

9.1 OVERVIEW ..................................................................................................................................... 95

9.2 DIAGNOSIS..................................................................................................................................... 96

10101010 SAMPLE SYSTEM CONFISAMPLE SYSTEM CONFISAMPLE SYSTEM CONFISAMPLE SYSTEM CONFIGURATIONGURATIONGURATIONGURATION............................................................................................................................................................................................................................................................................................................................................................ 97979797

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 MCC On Enable Signal (MCF), MCC Contact State Signal (*SMC).................................. 105

11111111 COMPONENTS LISTCOMPONENTS LISTCOMPONENTS LISTCOMPONENTS LIST .................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 106106106106

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

B-63494EN/01 1.OVERVIEW

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1 OVERVIEWSetup for machining, which includes attaching and detaching aworkpiece to be machined, and moving it to the machining start pointwhile viewing it, is performed with the protection door opened. Thedual check safety function provides a means for ensuring a high levelof safety with the protection door opened.

The simplest method of ensuring safety when the protection door isopen is to shut off power to the motor drive circuit by configuring asafety circuit with a safety relay module. In this case, however, nomovements can be made on a move axis (rotation axis). Moreover,since the power is shut off, some time is required before machiningcan be restarted. This drawback can be corrected by adding a motorspeed detector to ensure safety. However, the addition of an externaldetector may pose a response problem, and the use of many safetyrelay modules results in a large and complicated power magneticscabinet circuit.

With the dual check safety function, two independent CPUs built intothe CNC monitor the speed and position of motors in dual mode. Anerror in speed and position is detected at high speed, and power to themotor is shut off via two independent paths. Processing and datarelated to safety is cross-checked by two CPUs. To prevent failuresfrom being built up, a safety-related hardware and software test mustbe conducted at certain intervals time.

The dual check safety function need not have an external detectoradded. Instead, only a detector built into a servo motor or spindlemotor is used. This configuration can be implemented only whenthose motors, detectors built into motors, and amplifiers that arespecified by FANUC are used. When an abnormality related to safetyoccurs, the dual check safety function stops operation safely.

The dual check safety function ensures safety with the power turnedon, so that an operator can open the protection door to work withoutturning off the power. A major feature of the dual check safetyfunction is a very short time required from the detection of anabnormality until the power is shut off. A cost advantage of the dualcheck safety function is that external detectors and safety relays canbe eliminated or simplified.

1.OVERVIEW B-63494EN/01

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The dual check safety function consists of the following threefunctions:- 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, thisfunction should be used in the setup mode. If a position or speedmismatch is detected by a cross-check using two CPUs, power is shutoff (MCC off) to the motor drive circuit.

The European standard certification organization has certified thatthis safety function satisfies the European Safety Standard EN954-1Category 3.

IMPORTANTThe dual check safety function cannot monitor thestop state. For details, see the example of systemconfiguration.


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1.1 DIRECTIVE AND STANDARDS

1.1.1 Directives

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

DirectiveDirective 98/37/EC 1998 Safety of machineryDirective 89/336/EEC 1989 Electromagnetic compatibilityDirective 73/23/EEC 1973 Low Voltage Equipment

1.1.2 Related Safety Standards

To be compatible with the directives, especially the machine directive,the international standards and European standards need to beobserved.

Important safety standardsEN292-1 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-relatedparts of control systems –Part 1: General principles for design

EN1050 1996 Safety of machinery - Principles for riskassessment

EN60204-1 1997 Safety of machinery - Electricalequipment of machinesPart 1: General requirements

DIN V VDE0801 (1990) includingamendment A1(1994)

Principles for computers in safety-related systems

1.1.3 Risk Analysis and Evaluation

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


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1.1.4 Certification Test

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


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1.2 DEFINITION OF TERMS

1.2.1 General Definition of Terms

Reliability and safetyReliability and safety are defined by EN292-1 as follows:

Term DefinitionReliability Capability of a machine, machine component, or

equipment to perform its required function under aspecified condition for a specified period

Safety Capability of a machine to perform its function withoutinjuring the health under a condition of use for an intendedpurpose specified in the operator's manual and allow itstransportation, installation, adjustment, maintenance,disassembly, and disposal

1.2.2 Definition of Terms Related to the Safety Function

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

Safe stopWhen a safe stop occurs, power to the drive section is shut off. Thedrive 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 (motorcontactor)If an external force is applied (such as a force applied onto a verticalaxis), an additional measure (such as a mechanical brake) must besecurely implemented to protect against such a force.

Safe speedFeature for preventing the drive section from exceeding a specifiedspeed. A measure must be implemented to prevent a set limitationspeed from being changed by an unauthorized person.

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


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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

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

EvaluationThe safety function is monitored independently by a CNC CPU andmonitor CPU or by a CNC CPU and spindle CPU. Each CPU cross-checks data and results at certain intervals.

ResponseIf the monitoring function detects an error, the CNC CPU and monitorCPU switch off the MCC via independent paths to shut off the powerto the feed axis and spindle.


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

The dual check safety function satisfies the requirements of Category3 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 isimplemented using the two-channel configuration shown below.

Monitoring of servo motor and spindle motor movement

CNCCPU

CNCCPU

MonitorCPU

MonitorCPU

Motor detector signalDoor switch signal

Magneticcontactor

Shut off power

Shut off power

CNC controller

Cross-checkof data andresults

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

Cross-monitoring using 2 CPUsTwo CPUs built into the CNC are used to cross-monitor the safetyfunction. Each CPU is periodically checked for errors. If one systemfails, the servo system and spindle can be stopped safely.

Power shutoff via two pathsIf an error is detected, the power is shut off via two power shutoffpaths. The paths need to be tested for built-up failures within a certaintime.

Input signal safetySafety-related input signals such as the protection door lock/unlocksignal is monitored doubly. If a mismatch between the twooccurrences of a signal is detected, the power to the motor drivecircuit is shut off. This cross-check is constantly made.


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Output signal safetyA signal is output (via two paths) to the relay used to shut off thepower to the motor drive circuit. An error is detected by a MCC offTest. For detection of built-up failures, a MCC off Test needs to beconducted at certain intervals. This MCC off Test is not mandatorywhen machining is performed with the protection door closed.

1.3.2.1 Latent error detection and cross-check

Detection of latent errorsThis detection function can detect latent software and hardware errorsin a system that has a two-channel configuration. So, the safety-related portions of the two channels need to be tested at least oncewithin an allowable period of time for latent errors.An error in one monitoring channel causes a mismatch of results, sothat a cross-check detects the error.

CAUTIONForced detection of a latent error on the MCC shutoffpath must be performed by the user through a MCCoff Test (after power-on and at intervals of aspecified time (within 24 hours)).When the system is operating in the automatic mode(when the protection door is closed), this detectionprocessing is not requested as mandatory.

Cross-checkA latent safety-related error associated with two-channel monitoringcan be detected as a result of cross-checking.For numeric data, an allowable difference between the two channelsis set in a parameter. (For example, an allowable cross-checkeddifference is set for the actual position.)

NOTEAn error detected as the result of forced latent errordetection or cross-checking leads to a safety stopstate. (See Chapter ?.).


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1.3.2.2 Safety monitoring cycle and cross-check cycle

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

The cross-check cycle represents a cycle at which all data subject tocross-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 offTest is conducted. This test is essential to dual check safety. A MCCoff Test must be conducted at specified times (after power-on and atintervals of 24 hours) to check that the MCC shutoff paths operatenormally. A MCC off Test is conducted once on the CNC side andonce on the monitor side. When a MCC off Test becomes necessary,the CNC outputs a MCC off Test execution request signal to thePMC.

NOTEThe machine tool builder is to warn and prompt theoperator to conduct a MCC off Test when a MCC offTest execution request signal is output. A MCC offTest 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 terminationWhen a MCC off Test is completed, the MCC off Test executionrequest signal is turned off. After the MCC off Test execution requestsignal is turned off, turn off the test mode signal.


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1.3.2.4 Error analysis

Error analysisThe table below indicates the results of system error analysiscontrolled by the dual check safety function.

Error analysis when the protection door is openError Cause Action

Spindle safetyexcessivespeed

Amplifier or control unitfailure, operation error, etc.

Safety limitation speedmonitoring functionEN60204-1 Category 1/0stop

Excessive feedaxis speed



Feed axissafety machineposition error



Input/outputsignal error

Wiring error, control unitfailure, etc.


Error analysis when the protection door is closedError Cause Action

Input/outputsignal error

Wiring error, control unitfailure, etc.


1.3.2.5 Remaining risks

The machine tool builder is to make a failure analysis in connectionwith the control system and determine the remaining risks of themachine.

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 cannotbe activated if any one of the components of the control or driveis not powered on.

b) Interchanged phases of motor connections, reversal in the signalof encoder and reversal mounting of encoder can cause anincrease in the spindle speed or acceleration of axis motion. Ifabnormal speed detected, system controlled to brake to zerospeed, but no effective for above error. MCC off is not activateduntil the delay time set by parameter has expired. Electricalfaults can also result in the response described above(componentfailure too).


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c) Faults in the absolute encoder can cause incorrect operation ofthe safety machine position monitoring function.

d) With a 1-encoder system, encoder faults are detected in a singlechannel, but by various HW and SE monitoring functions. Theparameter related to encoder must be set carefully. Depending onthe error type, a category 0 or category 1 stop function accordingto EN60204-1 is activated.

e) The simultaneous failure of two power transistors in the invertermay cause the axis to briefly(motion depend on number of polepairs of motor)Example:

A 6-pole synchronous motor can cause the axis to move bya maximum of 30 degrees. With a lead-screw that is directlydriven by, e.g.20mm per revolution, this corresponds to amaximum linear motion of approximately 1.6mm.

f) When a limit value is violated, the speed may exceed the setvalue briefly or the axis/spindle overshoot the setpoint positionto a greater or lesser degree during the period between errordetection and system reaction depending on the dynamicresponse of the drive and the parameter settings(see SectionSafety-Functions)

g) The category 0 stop function according to EN60204-1 (definedas STOP A in Safety Integrated) means that the spindles/axes arenot braked to zero speed, but coast to a stop (this may take a verylong time depending on the level of kinetic energy involved).This must be noted, for example, when the protective doorlocking mechanism is opened.

h) Drive power modules and motors must always be replaced by thesame equipment type or else the parameters will no longer matchthe actual configuration and cause Dual check Safety to respondincorrectly.

i) Dual check Safety is not capable of detecting errors inparameterization and programming made by the machinemanufacturer. The required level of safety can only be assuredby thorough and careful acceptance.

j) There is a parameter that MCC off test is not to be made in theself 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 stopresponse is measured.

k) Safety machine position monitoring function does not apply torotation axis.

l) During machine adjustment, an exact motion may be executedincorrectly untie the safety functions setup correctly and confirmtest is completely.


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1.4 GENERAL INFORMATION

The following requirements must be fulfilled for the Dual-CheckSystem:• 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, confirmationtest regarding safety functions can be performed accoding toChapter 8.

• Programming in ladder logic should be referred to programmingmanual (B-61863E).

TrainingFANUC Training Center provides versatile training course for theperson who is concerned with hardware installation, maintenance andoperation. FANUC recommend studying and learning in the trainingcenter how efficiently operate FANUC products.There are 3 CNC training course.

[CNC ELEMENTARY COURSE]Provides basics of CNC functions, operation and programming. Thecourse is recommended before taking more specialized trainingcourses 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 andinspect CNC, also how to restore it promptly if a trouble shouldoccur. MAIN ITEMS OF TRAINING• Function and configuration of Power Unit• Function and configuration of CNC system• Include AC servo and AC spindle• Self-diagnosis function• Interface between CNC and the machine tools• Data saving and restoring operation• Trouble shooting


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[CNC SE INTERFACE COURSE]Training course offered to the engineers who design CNC machinetools or CNC application system for the first time. This course is alsosuitable for customers who provide to retrofitting, to develop anoriginal 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 registrationYamanakako-mura, Yamanashi Prefecture : 401-0501, JAPANPhone : 81-555-84-6030Fax : 81-555-84-5540Internet:www.fanuc.co.jp/eschool

2.SYSTEM CONFIGURATION B-63494EN/01

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2 SYSTEM CONFIGURATIONThe dual check safety function has the following components.

Applicable CNCFANUC 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 : 4 maximum- Series 18i/180is/180i : 6 maximum- Series 16i/160is/160i : 8 maximum

Number of spindle controlled axes- Series 21i/210is/210i : 2 maximum- Series 18i/180is/180i : 2 maximum- Series 16i/160is/160i : 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

B-63494EN/01 2.SYSTEM CONFIGURATION

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Detector systemThe 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

3.SAFETY FUNCTIONS B-63494EN/01

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3 SAFETY FUNCTIONS

B-63494EN/01 3.SAFETY FUNCTIONS

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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, thesafety functions are enabled, and the protective door can be unlocked.While the protective door is open, the active safety functions assuresafety. When the request to open the protective door is canceled, theprotective door is locked, and the safety functions are disabled.

The dual check safety function provides these safety functions whilethe protective door is open, as described above. Some of the safetyfunctions continue working while the protective door is closed.

WARNINGEach machine tool builder should take measures toassure safety while the protective door is closed andto ensure safety related to a rotation axis and travelaxis. At the same time, safety measures for theFANUC servo motor or spindle motor need to betaken, while the door is open.

The dual check safety function has the following safety functions:

Safe-related I/O signal monitoringThis 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 doorlock/open/close state, and power-down are checked in redundantmode. If the two corresponding inputs do not match, the systemjudges that an abnormal event has occurred. The power-down (MCCoff) signal is output in redundant mode (from two paths). Whether thetwo-path output is normal is judged in a MCC off Test.

Safe speed monitoringThis function checks that the rotation speeds of the servo motor andspindle motor are within a predetermined speed range, using twoCPUs in redundant mode. If a speed exceeding the range is detected,the system judges that an abnormal event has occurred.


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Safe machine position monitoringThis function checks that the position on a servo axis is within aspecified range, using two CPUs in redundant mode. If a positionexceeding the range is detected, the system judges that an abnormalevent has occurred.

If an abnormal event (safety error) is found, the dual check safetyfunction shuts off the power to the motor driving circuit, using thetwo independent CPUs. The state in which the servo or spindle motorstops because of power-down is referred to as the safe stop state. If asafety error results in the safe stop state, the operator must turn off theCNC, remove the cause of the error, then turn on the CNC again. Theuser must conduct a MCC off Test every 24 hours in order to detect apotential cause of error.

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


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Protectivedoor

Emergency

stop

Servo motor

Spindlemotor

Power-down(MCC)

CNCCPU

MonitorCPU

Spindle CPU

PSM

SVM

SPM

Safe speed monitoring

Safe speed monitoringSafe machine positionmonitoring

Door lock/open/closemonitoring Cross-check

Cross-check

CNC

Dual monitoring of MCCDual power-downDetection of potential cause of error byMCC off test

I/O, safe speed of theservo motor, andmachine position arechecked by the CNCCPU and monitorCPU in redundantmode.

The safe speed of thespindle motor ischecked by the CNCCPU and spindleCPU in redundantmode.

Dual monitoring of protective door state

Protective door

lock signal

Power-down

Dual monitoring of MCC

Dual monitoring of emergency stopsignal

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 outputOutput signal for shutting off the power (turning the MCCoff)To detect the potential cause of an abnormal state of thisoutput, a MCC off Test must be made.

• Spindle motorSafe speed monitoring

• Servo motorSafe speed monitoringSafe machine position monitoring


- 20 -

3.2 BEFORE USING THE SAFETY FUNCTION

3.2.1 Important Items to Check Before Using the Safety Function

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

• If an absolute-position detector is used, and reference positionreturn has been performed once, reference position data is storedin the CNC memory. In this case, the user need not make areference position check.

• If an incremental pulse coder is being used, reference positiondata is lost each time the power to the CNC is turned off andthen back on. So, after the power is turned on, another referenceposition 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 ornot yet activated (option bit).

3.2.2 MCC off Test of the Safe Stop Function

A MCC off Test of the safe stop function monitors the contact state ofthe electromagnetic contactor (MCC), compares the state with acommand to the electromagnetic contactor, and checks that the safestop function works normally. The test must be carried out by the userof the machine. This test must be carried out when the CNC is turnedon 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 previoustest is completed, a guard open request (protective door open request)is not accepted until the test is performed.


- 21 -

3.3 STOP

3.3.1 Stopping the Spindle Motor

Because the spindle motor is an induction type motor, power-downduring rotation causes the motor to continue rotating for a certainamount of time. From a safety standpoint, the motor may have to bestopped immediately. If the CNC detects an error and judges that thespindle can be controlled, it waits until the rotation of the spindlestops, then shuts off the power. This wait period can be specified as asafety parameter. For this safety parameter, two different values canbe specified. One value is used when the safety function is active (thedoor is open), and the other value is used otherwise. The values mustbe determined in consideration of the stop period calculated from thespindle speed.

To implement the function, the CNC CPU and monitor CPUindividually incorporate a timer function. Normal operation of the twoCPUs are mutually checked to ensure the safety of the timers.

To speed down and stop the spindle, the PMC must input the spindleemergency stop signals (*ESPA(G71.1), *ESPB(G75.1), and so on).When this signal is input, the spindle slows down and stops. (ALadder program for inputting this signal in case of alarm must becreated.) The emergency stop input (connector CX4) of the PSM hasthe same effect. If the emergency stop signal is connected toemergency stop input (connector CX4) of the PSM, the spindle slowsdown and stops in the emergency stop state.

If this processing is not performed, power-down causes the spindlemotor to continue rotating at the speed prior to power-down (andeventually stopping in the end).

CAUTIONThe CNC outputs a DO notifying of an alarm. Ifnecessary, the spindle should be stopped. Becausethe DO output is not duplicated, this DO may not beoutput when a single failure is detected. In that case,the speed cannot be reduced, but the MCC is finallyshut off and brought into the safe stop state.If a spindle amplifier alarm or any other state inwhich the spindle motor cannot be controlled isencountered, immediate power-down is carried out.


- 22 -

3.3.2 Stopping the Servo Motor

Because the servo motor is a synchronous motor, power-down resultsin a dynamic brake stop. The dynamic brake stop is electric braking inwhich the excited rotor is isolated from the power source and thegenerated electric energy is used up in the winding. Additionalbraking 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-relatedsignal or speed monitoring is detected, the CNC automaticallyspecifies a command to zero the speed and reduces the speed to zero(controlled stop). After the motor slows down and stops, the power isturned off, and the motor is brought into the dynamic brake stop state.To slow down and stop the motor, some parameters must be specifiedin the CNC. If those parameters are not specified, the motor isimmediately brought into the dynamic brake stop state. In somecircumstances where a controlled stop cannot be made, a dynamicbrake stop is unconditionally made.

3.3.3 Stop States

The following stop states are possible:

Safe stop stateThe power to the motor is shut off (MCC off state). If the spindlemotor can be controlled, the power is shut off after the spindle motoris 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 astop and then brought into the dynamic brake stop state. If the motorcannot be controlled, the motor is immediately brought into thedynamic brake stop state.If the power is shut off immediately, the spindle motor continues atthe same speed prior to the abnormal event and eventually comes to astop. If the spindle motor can be slowed down to a stop, the operationis performed as instructed by the PMC and then the power is shut off.

IMPORTANTThe time period until the signal for shutting off thepower (turning off the MCC) is output depends onthe parameter. Different parameters are used in thesafety monitoring state and in other states.

Safety parameter number Name1947 MCC off timer 1 If the protective door

is closed1948 MCC off timer 2 If the protective door

is opened


- 23 -

Controlled stop stateThe 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 isactive if the condition for enabling the safety function is satisfied (thedoor is open). If a further abnormal event occurs, the motor is broughtinto the safe stop state.

WARNING1 The machine tool builder must design the machine

so that the machine is kept in the stop state if thepower to the servo motor driving circuit is shut off.Example) Brake mechanism that would not drop thevertical axis after the power is shut off

2 If the power to the spindle motor driving circuit is shutoff, the spindle motor continues rotating at the speedbefore the power-down and eventually comes to astop. A measure must be taken so that this coastingdoes not affect safety.


- 24 -

3.4 SAFE-RELATED I/O SIGNAL MONITORING

A set of safe-related I/O signals are connected to the I/O Link and theservo FSSB through separate paths. The two independent CPUsindividually check the input signals. If a mismatch between twocorresponding signals is found, the system enters the safe stop state.The following safe-related I/O signals are monitored or output inredundant 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 mustconnect these signals to both the I/O module and the FSSB I/O.

IMPORTANTIf the safety input signals, except for emergency stopinput signals, are connected to the I/O module, aLadder program must be created to establish a one-to-one relationship between the actual input (X) andthe 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 asignal state changes, the pair of signals may not match for someperiod because of a difference in response. The dual check safetyfunction checks whether a mismatch between the two signalscontinues for a certain period of time, so that an error resulting fromthe difference in response can be avoided. The check period must bespecified as a safety parameter.

Parameter No. Name1945 Safe-related input signal check timer

The following signals are not defined as safe-related I/O signals andare not duplicated. The signals, however, are necessary for thesystem.

- 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 systemconfiguration in Chapter 10.


- 25 -

CNCCPU

MonitorCPU

I/O LINK

FSSB

I/O UNIT

FSSB I/O

DI

DI

DO

DO

Cross check

MachineCNC

Duplicated I/O

Symbol Signal name I/O address*ESP Emergency stop signal <X008#4> <DI+000#0> Dual input monitoringSGD Guard state signal <G191#4> <DI+001#4> Dual input monitoringGDL Guard lock state signal <G191#5> <DI+001#5> Dual input monitoring*SMC MCC contact state signal <G191#6> <DI+001#6> Dual input monitoringMCF MCC on enable signal <F191#1> <DO+000#1> Duplicated outputORQ Guard open request

signal<G191#3> Input

OPT Test mode signal <G191#2> Input*LGD Guard unlock signal <F191#0> OutputRQT MCC off Test execution

request signal<F191#2> 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 aswell.

2. SGD Guard state signal (input)The signal is provided for double monitoring of the protective doorstate. The signal is connected so that it is normally set to 1 while theprotective door is closed and locked (door open) and set to 0otherwise (door close). These states are implemented by thecombination of the safety door and safety relays. The CNC monitorsthese 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.


- 26 -

4. *SMC MCC contact state signal (input)The MCC contact state is monitored in redundant mode. In normaloperation, the MCC is active, and whether the contact of a relay isclosed cannot be detected. In the test mode, a closed contact of a relaycan be detected.

5. MCF MCC on enable signal (output)With this signal, the MCC is shut off from both the I/O Link side andthe FSSB side.

Signals other than safe-related I/OThe following signals are not safe-related signals (are not checked inredundant mode) but are important signals in the system. The machinetool builder must create an appropriate Ladder program.

IMPORTANTThe 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 andspeed. If both the machine position and speed are within the saferange, the guard unlock signal (*LGD) is set to 1 (guard unlockenabled). The machine tool builder must provide an output signal thatopens the actual protective door through the PMC. Connect the signaloutput.

7. OPT Test mode signal (input)When the signal is input, a MCC off Test is executed. The MCC offTest checks whether the contact of the MCC is closed. When carryingout the MCC off Test manually, execute a MCC off Test by the PMCand 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, asignal to unlock the actual protective door should be output throughthe PMC.If the protective door is unlocked while the signal is set to 0, an alarmoccurs and brings the motor into the safe stop state.

CAUTIONWhen the signal is set to 1, there is a time delay(depending on the Ladder program) before the signalto unlock the actual protective door is output.Meanwhile, the protective door is locked, and safetyis ensured. If an error is found as a result of speedcheck or machine position check during that period,*LGD becomes 0. If a single failure occurs in thisstate and if the actual protective door is unlocked, analarm occurs.


- 27 -

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 doorshould 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 offTest must be executed.

Guard open request signal and guard unlock signal

24V

X

Door open request

Ladder

Ladder

ORQ-IORQ

LGDLGD-O

G

F Y

Protective door

CNC (PMC)

The figure shows a sample connection of the protective door openrequest switch and the guard unlock signal. In the normal state, thefollowing state transition takes place before the safety monitoringstate is established.

State transitionORQ-I ORQ *LGD *LGD-O

A 0 0 0 0 A protective door open request is not made, and thedoor is locked.

Normal operatingstate

B 1 0 0 0 A guard open request is made.C 1 1 0 0 The request is transferred to the CNC.D 1 1 1 0 A safe speed check and a machine position check

prove that there is no failure and that the CNC canenter the safe state.

E 1 1 1 1 The actual safety door is unlocked.Operations can be performed with the door open.

Safety functionenabled

D 1 1 1 0 The door is closed and locked again.F 0 1 1 0 The guard open request is canceled.G 0 0 1 0 The request is transferred to the CNC.A 0 0 0 0 The CNC exits from the safe state.

IMPORTANTIf the CNC detects that the protective door is open(SGD is set to 0) while ORQ is set to 0, the CNCjudges that an abnormal event has occurred andenters the safe stop state. This can occur, forinstance, when the door happens to open (or to beunlocked) while machining is in progress with theprotective door open


- 28 -

Timing diagram from door close state to door open state

The following diagram shows the timings at which the door is openedand closed again.

ORQ

*LGD

*LGD_P1(Actual door unlock signal)

SGD_PSGD2

Door closed Door opened

(1) (2) (3) (4) (5)

t

Door closed

ORQ_P

Actual door status

(1) When the guard open request signal (ORQ) is input, it checksthat 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 unlocksignal. This example assumes that the protective door has anelectromagnetic lock mechanism. While the door is open, theunlock 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. CAUTIONReserve a time of 100 ms or longer (t in the figure)from when the door is closed (locked) until the guardopen request signal (ORQ) goes off. If this timerequirement is not satisfied, an alarm may be raisedwhen the door is closed (locked).

(5) When ORQ goes off, the CNC turns *LGD off.


- 29 -

3.5 EMERGENCY STOP

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

CAUTIONTo enable the function to slow down and stop theservo motor, the corresponding parameter must bespecified. If the parameter is not specified, the motorimmediately enters the dynamic brake stop state.The spindle motor slows down and stops asinstructed by the PMC (Ladder program). If the PMCdoes not instruct this, the motor maintains the highspeed prior to the power-down and coasts. If anillegal speed is specified because of a failure on thePMC side while the safety function is active (theprotective door is open), the CNC enters the safestop state.

WARNINGIn the emergency stop state, the guard unlock signalbecomes 1 (the door opens). In the emergency stopstate, the processing to open or close the protectivedoor depends on the Ladder program created by themachine tool builder. For instance, if the protectivedoor should not be opened in the emergency stopstate, a Ladder program of the processing must becreated.

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

IMPORTANTEmergency Stop Button must fulfil the StandardIEC60947-5-1.This is mandatory.


- 30 -

3.6 SAFE SPEED MONITORING

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

CAUTIONIf an illegal speed is detected, the MCC is shut offafter the time specified in the parameter.

IMPORTANT1 The period from when an error is detected until the

MCC is shut off can be specified in a parameter. Theperiod is reserved to stop the spindle safely. A largevalue means that a long time is needed to shut off theMCC. In this parameter, different values can bespecified and used when the safety function isenabled (the protective door is open) and disabled(normal operation is performed). The value of theparameter for the former case must be carefullyspecified.

2 A gear ratio, ball screw, and the like must be carefullyselected so that a safe speed can be kept on the feedaxis.

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

WARNINGThe safe speed monitoring function monitors whetherthe traveling speed exceeds a specified limit. Thefunction cannot monitor the stop state (zero speed).If an error causes a movement on the feed axis at aspeed lower than the safe speed range while theprotective door is open, for instance, the functioncannot detect this state. The machine must bedesigned so that this state does not affect the safetyof the machine system.


- 31 -

3.7 SAFE MACHINE POSITION MONITORING

While the door is open, the dual check safety function checks whetherthe position on each feed axis is within the safe machine positionrange defined by safety parameters. If it detects a machine positionbeyond the safety range, the dual check safety function immediatelyenters the safe stop state.

The user of the machine must first carry out a reference positionreturn in order to obtain the initial position. If the reference positionreturn is not carried out, the check function is disabled. This checkfunction is enabled after the reference position is established. (Thefunction cannot be disabled by any means after the reference positionis established.) A safe machine position limit on each feed axis isspecified in a safety parameter.

CAUTIONThe safe machine position monitoring function doesnot keep monitoring the specified range. Only afterthe function detects that a position on a feed axisexceeds the range, the system enters the safe stopstate. Accordingly, in the safe stop state, anovertravel has occurred on the feed axis. The traveldistance depends on the traveling speed and otherconditions.

At power-on, the safety function does not work. After power-on, theCNC checks whether a reference position return is completed. If thereference position return is completed and if the protective door isopen, safe machine position monitoring and safe speed monitoring areperformed. Then, the safety functions start working. If the referenceposition return is not completed, safe machine position monitoringcannot be performed because the coordinates are not set. In this state,the machine position monitoring function is disabled. After areference position return is made, this function is enabled. Dependingon the safety parameter setting, however, an alarm may be raised. Toavoid this alarm, specify the safe machine position parameters beforemaking a reference position return.


- 32 -

3.8 MCC OFF TEST

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

IMPORTANTCarry out the MCC off Test with the protective doorclosed. Because the test shuts off the MCC, preparethe system for mechanical MCC shut-off beforestarting the MCC off Test.

B-63494EN/01 4.INSTALLATION

- 33 -

4 INSTALLATIONExcept FSSB I/O module, the hardware installation such as fieldwiring, 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 (A-72937/E).

Degree of IP protection:Servo Motors: IP55Spindle Motors: IP54 with oil-seal, IP40 without oil-sealServo and Spindle amplifiers: IP1xCNC and other accessories: Ipxx

NOTEServo/Spindle amplifiers, CNC are to be installed inIP54 protected cabinets.

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

Environmental conditions for CNC unitsCondition LCD–mounted

type controlunit and display

unit (exceptunit with data

server function)

Stand–alonetype control

unit

LCD–mountedtype controlunit with PC

and data serverfunctions

Operating 0°C to 58°C 0°C to 55°C 5°C to 53°CAmbientTemperature

of the unitStorageTransport

–20°C to 60°C

Normal 75% RH or less, no condensation 10% to 75% RH,no condensation

Humidity

Short period(lessthan 1 month)

95% RH or less, no condensation 10% to 90% RH,no condensation

Operating 0.5 G or lessVibrationNon–operating 1.0 G or lessOperating Up to 1000 m Up to 1000 mMeters above

sea level Non–operating Up to 12000 m Up to 12000 mEnvironment 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.)

4.INSTALLATION B-63494EN/01

- 34 -

Environmental conditions for servo amplifier

The servo amplifier α series must be installed in a sealed type cabinetto satisfy the following environmental requirements:

(1) Ambient TemperatureAmbient temperature of the unit :0 to 55°C (at operation)-20 to 60°C (at keeping and transportation)

(2) HumidityNormally 90% RH or below, and condensation-free

(3) VibrationIn operation : Below 0.5G

(4) AtmosphereNo corrosive or conductive mists or drops should depositdirectly on the electronic circuits.


- 35 -

4.1 OVERALL CONNECTION DIAGRAM

4.1.1 For One-path

Mother board

LCD

display unit

I/O-LINK(JD1A)

24 VDC powersupply

24V-IN(CP1A)

24V-OUT(CP1B) To I/O device

MDI UNITCK2

CK1

Soft key cable

MDI(CA55)

R232(JD36A)

R232(JD36B)

RS-232C I/O device

RS-232C I/O deviceTouch panel

HDI(JA40) High-speed skip input

Distribution-typeI/O boardCPD1

JD1

JD1

JA3

Operator'spanel

I/O unit, etc.CPD1

JD1

JD1

Powermagneticscabinet

24VDC

24VDC

Manualpulse generator


- 36 -

Mother board

LCD

display unit

SPDL(JA41) JA7B

JA7A

JY2

TB2

Spindle motorSecond spindle

FSSB(COP10A) Axis 1servo motor

COP10B

COP10A

TB2

JF1

SPM

SVM

COP10B

COP10A

TB2

JF1SVMAxis 2servo monitor

COP10B

COP10A

TB2

JF1SVMAxis 3servo motor

COP10B

COP10A

JF101

JF102

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

JF103

JF104

JA4A

Linear scale axis 2

Linear scale axis 3

Battery for absoluteposition detector

Separate detector interface unit

COP10B

COP10A

CB155A

CB156A

FSSB I/O

CP11A

CP11APowermagneticscabinet

DC24V

24VDC

SV-CHK(CA54) Servo check board


- 37 -

4.1.2 For Two-path

Main boardI/O Link (JD44A)

SPDL (JA41)

FSSB (COP10A-1)

I/O module foroperator’s panel

JD1B CE56JD1A CE57

Machineoperator’s

panel

I/O module forconnector panel

JD1B CB150JD1A

To next I/O unit

Powermagnetics

cabinet

200VAC 2φ

SPMJA7B JYA2JA7A CZ2

PSMCX1A CX3CZ1 CX4

TB1

TB1 CXA2A

CXA2B

200VAC 3φ

Safe-related and other signals

Spindle motor

MCC

Emergencystop

To next SPM (JA7B)

SVM1COP10B JF1COP10A CZ2

TB1

TB1 CXA2A

CXA2B

Servo motor

To next SVM (COP10B)

Axis control card


- 38 -

Separate detectorinterface unit

COP10B JF101COP10A JF102

JF103JF104JA4A

From previous SVM (COP10A)

SeparatedetectorSeparatedetectorSeparatedetectorSeparatedetectorBattery

FSSB I/O moduleCOP10B CB155COP10A CB156

Powermagnetics

cabinet

Safe-related signals


- 39 -

Sub CPU board

SPDL (JA41)

FSSB (COP10A-1)

SPM

JA7B JYA2

JA7A CZ2

TB1 CXA2B

Spindle motor

SVM1

COP10B JF1

COP10A CZ2

TB1

TB1 CXA2A

CXA2B

Servo motor

Separate detectorinterface unit

COP10B JF101

COP10A JF102

JF103

JF104

JA4A

Separate detector

Separate detector

Separate detector

Separate detector

Battery

FSSB I/O module

COP10B CB155

COP10A CB156

Powermagnetics

cabinet

Safe-related signals

Axis control card

To next SPM (JA7B)

to next SVM (COP10B)

From previous SVM (COP10A)


- 40 -

4.2 DI/DO CONNECTION (VIA THE PMC)

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

PMC→→→→CNC #7 #6 #5 #4 #3 #2 #1 #0

G008 *ESPG

PMC→→→→CNC #7 #6 #5 #4 #3 #2 #1 #0

G191 *SMC1 GDL1 SGD1 ORQ OPT

CNC→→→→PMC #7 #6 #5 #4 #3 #2 #1 #0

F191 RQT MCF1 *LGD

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


- 41 -

4.3 DI/DO CONNECTION (VIA THE FSSB)

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

4.3.1 FSSB I/O Connection

Power supply connection

CP11AAMP Japan1-178288-3 (Housing)1-175218-5 (Contact)

0V(2)

+24V(1)

External power supply

External power supply

CP11A1 +24V2 0V3

Select a one that matchesthe pins of the externalpower supply.

24 VDC stabilizedpower supply24 VDC±10%

Cable

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

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


- 42 -

DI/DO connection

RV

RV

RV

RV

RV

RV

RV

RV

+24V CB155A(A01)CB155A(B01)

CB155A(A02)

Pin No.

*ESP2

SMC2

GDL2

SGD2

Signal name

CB155A(A07)

CB155A(B07)

CB155A(A08)

CB155A(B08)

CB155A(A09)

CB155A(B09)

CB155A(A10)

DOCOM CB155A(B06)

CB155A(A11)

Pin No.

Signal name

DV

+24V stabilizedpower supply

+24V 0V

Relay

DVMCF2

CB155A(A17,B17)

CB155A(B11) Relay

For the meanings of the above signals, see Chapter 6,"OPERATION."


- 43 -

4.3.2 FSSB I/O Attachment

External dimensions

CP11ACP11B

Upper:CB156ALower:CB155A

COP10A COP10B


- 44 -

Screw attachment

Mounting holemachining diagram


- 45 -

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

Working space around the I/O unit


- 46 -

Attachment to a DIN rail

Detachment

Attachment

DIN rail

DIN rail

Attachment1. Hook the unit over the top of the DIN rail.2. Press the unit down until it snaps into place.

Detachment1. Pull down the lock section with a standard screwdriver.2. Pull the lower part of the unit toward you.

CAUTIONWhen detaching the unit, be careful not to damagethe lock section by applying excessive force.When attaching or detaching the unit, hold theupper and lower parts of the unit, if possible, toprevent force from being applied to the side (wherethe cooling rents are provided) of the unit.


- 47 -

4.3.3 FSSB I/O Specification List

Installation conditionsAmbient temperature

of the unitOperating 0°C to 55°CStorage, transportation -20°C to 60°C

Temperature variation 1.1°C /minute maximum

Humidity

Normally Relative humidity 75% or lessShort term (no more than one month)

Relative humidity 95% or lessVibration Operating 0.5G or less

Atmosphere

Normal machining plant environment (Check isrequired if the unit is to be used in anenvironment exposed to relatively high levels ofdust or coolant, or a relatively high concentrationof organic solvents.)

Other conditions

(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 aboveand below the unit. Do not install equipmentthat dissipates much heat under this unit.

Power supply capacitySupply voltage Power supply

capacity Remarks

24V±10% is fed from the CP11Aconnector of the basic module.±10% includes momentaryvariations and ripples.

0.3A+7.3mAxDI Number of DI pointsin DI = ON state

Input signal specificationsContact capacity 30 VDC, 16 mA or more

Leakage current betweenopen contacts 1 mA or less (when the voltage is 26.4 V)

Voltage drop across closedcontacts

2 V or less (including a cable voltagedecrease)

Delay timeReceiver delay time: 2 ms (MAX)In addition, the FSSB transfer period andladder scan period need to be considered.

Output signal specificationsMaximum load current at

ON time200 mA or less including momentaryvariations

Saturation voltage at ONtime 1 V (MAX) when the load current is 200 mA

Dielectric voltage 24 V +20% or less including momentaryvariations

Output leakage current atOFF time 20 µA or less

Delay timeDriver delay time: 50 µs(MAX)In addition, the FSSB transfer period andladder scan period must be considered.

5.I/O SIGNALS B-63494EN/01

- 48 -

5 I/O SIGNALS

B-63494EN/01 5.I/O SIGNALS

- 49 -

5.1 OVERVIEW

The dual check safety function provides two input paths and twooutput paths for safe-related signals (safety signals).For input signals (safety input signals), two paths are used: one pathfor input to the CNC via the PMC, and the other for input to themonitor via the FSSB. The CNC and monitor exchange the safetyinput signals with each other at all times to check each other. If amismatch is found between a safety input signal via one path and thesame signal via the other path, the signal is assumed to be 0. If such astate lasts for the period set in a parameter or more, the CNC andmonitor independently detect an alarm. (Dual-check for safety inputsignals)For output signals (safety output signals), two paths are used: onepath for output from the CNC via the PMC, and the other for outputfrom the monitor via the FSSB. The MCC-on enable signal (MCF) isoutput via these two paths. When both a signal via one path and thesame signal via the other path are 1, the signal is assumed to be 1. Ifeither 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, theMCC 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 andaddresses <via PMC> and <via FSSB>. Then, for an input signal, itsclassification, function, and operation are described, in this order. Foran output signal, its classification, function, and output condition aredescribed 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, seeSubsection 5.2.2.


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5.2 SIGNALS

Emergency stop signal*ESP1 <X008#4>(<X1000#7> for loader control), *ESPG <G008#4>,*ESP2 <DI+000#0>

[Classification] Input signal[Function] Stops machine movement immediately in an emergency.

[Operation] When emergency stop signal (*ESP) is set to 0, the CNC is reset, andan emergency stop occurs. In general, emergency stop signal (*ESP)is specified by the pushbutton switch B contact. When an emergencystop occurs, the servo ready signal SA is set to 0.When emergency stop signal (*ESP) is set to 0, the emergency stopmode is set with the dual check safety function. In this mode, theMCC contact state signal (*SMC) is checked. When *SMC = 0(MCC-on state ), the guard unlock signal (*LGD) is set to 0 (todisable guard unlocking). When *SMC = 1 (MCC-off state), the guardunlock signal (*LGD) is set to 1 (to enable guard unlocking).

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

Test mode signalOPT <G191#2>

[Classification] Input signal[Function] 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.

[Operation] When test mode signal (OPT) is 1, the CNC performs safety outputsignal MCC off Test processing. (MCC-on enable signals(MCF1/MCF2) is output in various patterns, and a test is conducted tosee if an appropriate MCC contact state signals (*SMC1/*SMC2)pattern is input, respectively.) In the emergency stop state or while aservo or spindle alarm is present, the MCC off test processing is notperformed.If a MCC off Test is not completed within the time set in parameterNo. 1946, servo alarm No. 488 is issued.


- 51 -

CAUTION1 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 ontool posts 1 and 2 under one-CPU two-path control or on tool posts 2 and 3 undertwo-CPU three-path control.

4 If the MCC off test processing is in progress on one of different paths sharing theMCC under multi-path control, the remaining paths sharing the MCC should ignore aVRDY 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 ontool post 1 and is not tested by the MCC off test on tool post 2. MCF2 via the FSSBconnected to tool posts 2 and 3 under two-CPU three-path control is tested by theMCC off test on tool post 2 and is not tested by the MCC off test on tool post 3.

WARNINGWhile 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 astate that the turning on or off of the MCC will not cause a problem.

MCF1 (PMC)

1 2 3 4 5

MCF2 (FSSB)

*SMC1 (PMC)

Timer

Test No.

Timer limit

Test completionTest start

*SMC2 (FSSB)

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

MCF1 (PMC)

1 2 3 4

MCF2 (FSSB)

*SMC1 (PMC)

Timer

Test No.

Timer limit

Alarm !!

Test start

*SMC2 (FSSB)

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


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Guard open request signalORQ <G191#3>

[Classification] Input signal[Function] 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.

[Operation] When the guard open request signal (ORQ) is 1, the CNC, monitorand spindle software make a machine position check and safe speedcheck. 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 setguard unlock signal (*LGD) to 0 (to disable guard unlocking). (Inemergency stop state, however, the guard unlock signal (*LGD) is setto 1.)See Subsection 5.4.

Guard state signalSGD1 <G191#4>, SGD2 <DI+001#4>

[Classification] Input signal[Function] This signal posts the guard open/closed state to the CNC and monitor

with the dual check safety function.0: Guard open state1: Guard closed state

[Operation] This input signal is used together with safety input signals such asguard open request signal (ORQ) to determine a safety signal modethat specifies the operation of the CNC, monitor, and spindle software.For details, see Subsection 5.4.Input this signal according to the guard state.

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

Guard lock state signalGDL1 <G191#5>, GDL2 <DI+001#5>

[Classification] Input signal[Function] This signal posts the guard lock state to the CNC and monitor with the

dual check safety function.0: Guard unlocked state1: Guard locked state

[Operation] This signal is usually not used, but please input same signal (GDL1)both via PMC and via FSSB all time because dual-check for guardlock state signal (GDL2) is executed by CNC and monitor.


- 53 -

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

[Classification] Input signal[Function] This signal posts the MCC state to the CNC and monitor with the dual

check safety function.0: MCC-on state1: MCC-off state

[Operation] When the MCC contact state signals (*SMC1 and *SMC2) are 1 inthe 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 ifthe MCC-on enable signals (MCF1/MCF2) operates normally inMCC off Test mode.Input this signal according to the MCC state.

Guard unlock signal*LGD <F191#0>

[Classification] Output signal[Function] 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.

[Output condition] In the following cases, this signal is set to 1 (to enable guardunlocking):• 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 ispositioned within the safety area, and MCC off Test executionrequest signal (RQT) is 0

In cases other than the above, this signal is set to 0 (to disable guardunlocking).

MCC-on enable signalMCF1 <F191#1>,MCF2 <DO+000#1>

[Classification] Output signal[Function] 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 MCCis tuned on.

[Output condition] In the following cases, this signal is set to 0 (to prevent the MCC frombeing turned on):• When a safety-related alarm is issued• When the emergency stop state is issuedIn cases other than above, this signal is state to 1 (to enable the MCCto be turned on).


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MCC off Test execution request signalRQT <F191#2>

[Classification] Output signal[Function] This signal requests that MCC off Test mode be set, and a check is

made to determine whether the safety output signals (MCC-on enablesignal (MCF)) operate normally. When MCC off Test executionrequest signal (RQT) is set to 1, set MCC off Test mode and conducta safety output signal MCC off Test as soon as possible.When MCC off Test execution request signal (RQT) is 1, guardunlock signal (*LGD) is set to 0 to disable guard unlocking even ifsafety signal mode B (state in which a guard open request is input,and the guard is closed) is set and the conditions including speed aresatisfied.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 requestsignal (RQT) is set to 1, guard unlock signal (*LGD) is 0 to disableguard 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 asa parameter screen. (On some screens, no warning is displayed.)MCC off Test execution request signal (RQT) is not output via theFSSB.

[Output condition] 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.

CAUTION1 If the current date and time lags behind the date and

time of the previously completed MCC off Test dueto a clock change or the like, it is assumed that 24hours have elapsed since the previous MCC off Test.

2 From February 28 to March 1, the elapse of 24 hoursmay be assumed even if 24 hours has not elapsedafter the completion of the previous MCC off Test.

3 MCC must have forced guided contacts and mustfulfil the Standard IEC60204 and the standard IEC255.This is mandatory.

In the following case, this signal is set to 0:• A MCC off Test is completed.


- 55 -

5.3 SIGNAL ADDRESSES

Via the PMC#7 #6 #5 #4 #3 #2 #1 #0

X008 *ESP1

(For loader control) #7 #6 #5 #4 #3 #2 #1 #0

X1000 *ESP1

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

G008 *ESPG

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

G191 *SMC1 GDL1 SGD1 ORQ OPT

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

F191 RQT MCF1 *LGD

Via the FSSB#7 #6 #5 #4 #3 #2 #1 #0

DI+0000 *ESP2

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

DI+001 *SMC2 GDL2 SGD2

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

DO+000 *BRK MCF2

CAUTION1 The signals of shaded boxes are duplexed.2 Emergency stop signals (*ESP) via the PMC

<X008#4> (<X1000#7> for loader control) and viathe FSSB <DI+000#0> are checked each other(dual-check for safety input signals), but *ESP viathe 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 theFSSB are directly processed by the monitor CPU.None of the signals is processed by the PMC.


- 56 -

5.4 SAFETY SIGNAL MODES

Depending on the safety input signal state, the CNC, monitor, andspindle software internally have one of the six modes (safety signalmodes) indicated in the table below.

Safety signal mode Safety signal state Machine stateEmergency stop mode *ESP = 0 Emergency stop stateMCC off Test mode OPT = 1 State for conducting a MCC off TestSafety signal mode A ORQ = 0, and SGD = 1 Normal operation stateSafety signal mode B ORQ = 1, and SGD = 1 State in which a guard open request

is input, and the guard is closedSafety signal mode C ORQ = 1, and SGD = 0 State in which a guard open request

is input, and the guard is openSafety signal mode D ORQ = 0, and SGD = 0 Abnormal state (state in which the

guard is open although no guardopen request is input.)

In general, safety signal mode transitions are made as describedbelow.Usually, safety signal mode A is set. In safety signal mode A, guardunlock signal (*LGD) is 0, and the guard is locked.When an emergency stop is required, emergency stop mode is set. Inemergency stop mode, the MCC contact state signal (*SMC) ischecked. 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 enableguard 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 processingis performed. (MCC-on enable signal (MCF) are output in variouspatterns, and a test is conducted to determine whether appropriateMCC contact state signal (*SMC) patterns are input respectively.)When the guard is to be opened, safety signal mode B is set. In safetysignal mode B, the CNC, monitor, and spindle software check themachine position and the speed on each axis. If safety is assured,guard unlock signal (*LGD) is set to 1 to enable the guard to beopened.When the guard is opended in safety signal mode B after guard unlocksignal (*LGD) is set to 1, safety signal mode C is set. In safety signalmode C, the CNC, monitor, and spindle software check the machineposition and the speed on each axis. If an abnormality is detected, analarm is issued, MCC-on enable signal (MCF) is set to 0, and theMCC is turned off.Safety signal mode D represents an abnormal state in which the guardis open although no guard open request is made. In safety signal modeD, an alarm is issued, the MCC-on enable signal (MCF) is set to 0,and the MCC is turned off.


- 57 -

5.5 NOTES ON MULTI-PATH CONTROL

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

5.5.1 Two-CPU Two-Path Control (Without Axis Change betweenPaths)

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

CNCCPU

MonitorCPU

Safety area 1 Guard MCC and so on


cross-check

MAIN BOARD

CNCCPU

MonitorCPU



cross-check

SUB BOARD

Path 2Path 1

DI1M

DO1M

DI1C

DO1C

DI2M

DO2M

DI2C

DO2C


- 58 -

5.5.2 Two-CPU Two-Path Control (With Axis Change betweenPaths)

If there is an axis change between paths under two-CPU two-pathcontrol, a single group of safety areas can be provided. Two FSSB I/Ounits, that is one unit for each path, are required. (The two FSSB I/Ounits are required although just one group of safety areas is provided.)Two groups of safety input signals are cross-checked. The first groupconsists 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 post2 (DI2C: X008#4, G1191) and a safety signal input to the FSSB I/Ounit connected to tool post 2 (DI2M). Because just one group of safetyareas 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 safetyareas, 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 totool post 2 (DO2M) to the single group of safety areas.

CNCCPU

MonitorCPU

Safety area Guard MCC and so on


cross-check

MAIN BOARD

CNCCPU

MonitorCPU

cross-check

SUB BOARD

Path 1 Path 2

DI1M

DO1M

DI1C

DO1C

DI2M

DO2M

DI2C

DO2C


- 59 -

5.5.3 One-CPU Two-Path Control

A single group of safety areas can be provided under one-CPU two-path control. A single FSSB I/O unit is required.Two groups of safety input signals are cross-checked. The first groupconsists 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 secondgroup 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). Becausejust a single group of safety areas is provided, these three safety inputsignals (DI1C, DI2C, and DIM) should be equal.The following three safety output signals should be provided to thesingle 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).

CNCCPU

MonitorCPU



cross-check

MAIN BOARD

Path 1

Path 2DIM

DOM

DI2C

DO1CDI1C

DO2C


- 60 -

5.5.4 Two-CPU Three-Path Control

Under two-CPU three-path control, two groups of safety areas can beprovided: one group for tool post 1 and the other group for tool posts2 and 3. Two FSSB I/O units are required: one unit for tool post 1 andthe other unit for tool posts 2 and 3. (The two FSSB I/O units arerequired although just a single group of safety areas is provided.)

Three groups of safety input signals are cross-checked. The firstgroup 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 toolpost 1 (DI1M). The second group consists of a safety signal input totool post 2 (DI2C: X008#4, G1192) and a safety signal input to theFSSB I/O unit connected to tool posts 2 and 3 (DI2M). The third groupconsists 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 posts2 and 3 (DI2M). Because the second and third groups share the samesafety area, the three safety input signals (DI2C, DI3C, and DI2M)should be equal.

Safety output signals should be provided to the safety areas, asfollows: Provide a safety signal output from tool post 1 (DO1C: F191)and a safety signal output from the FSSB I/O unit connected to toolpost 1 (DO1M) to the safety area of tool post 1. Provide a safety signaloutput from tool post 2 (DO2C: F1191), safety signal output from toolpost 3 (DO3C: F2191), and safety signal output from the FSSB I/Ounit connected to tool posts 2 and 3 (DO2M) to the single group ofsafety areas of tool posts 2 and 3.

CNCCPU

MonitorCPU



cross-check

MAIN BOARD

CNCCPU

MonitorCPU



cross-check

SUB BOARD

Path 2

Path 3

Path 1

DI1M

DO1M

DI1C

DO1C

DI2M

DO2M

DI3C

DO2CDI2C

DO3C


- 61 -

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 CPUboard and sub-CPU board. Besides the FSSB unit for the machine, asingle FSSB unit is required for the loader. (Even if the machine andloader share a single safety area, the single FSSB I/O unit for theloader is required.)The following safety input signals are cross-checked by the loader: asafety signal input to the loader (DILC: X1000#7, G191) and a safetysignal input to the FSSB I/O unit connected to the loader (DILM).Provide the following safety output signals to the safety area of theloader: a safety signal output from the loader (DOLC: F191) and asafety signal output from the FSSB I/O unit connected to the loader(DOLM).

CNCCPU

MonitorCPU



cross-check

MAIN BOARD

CNCCPU

MonitorCPU



cross-check

LOADER BOARD

DI1M

DO1M

DI1C

DO1C

DILM

DOLM

DILC

DOLC

6.PARAMETERS B-63494EN/01

- 62 -

6 PARAMETERS

B-63494EN/01 6.PARAMETERS

- 63 -

6.1 OVERVIEW

The parameters related to the dual check safety function (safetyparameters) are protected by a code (No. 3225) for the safetyparameters. The value of a safety parameter cannot be modifiedunless the same value as the code for the safety parameters is set asthe key (No. 3226) for the safety parameters.The safety parameters are stored in two locations on the CNC. TheCNC, monitor, and spindle software check the matching of theparameters stored at the two locations. If a mismatch is found, analarm is issued.

If the setting of a safety parameter is modified, the power must beturned off then back on. The new setting of the parameter becomeseffective 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, seeChapter 5.

Section 6.3 describes the parameters related to the use of the FSSBI/O unit.

Section 6.4 describes the functions that require special parametersettings.


- 64 -

6.2 PARAMETERS

1023 Servo axis number for each axis

[Data type] Byte axis[Valid data range] 1, 2, 3, ..., number of controlled axes

Set which servo axis corresponds to each controlled axis. Usually, setthe same value for a controlled axis number and servo axis number.A controlled axis number represents an array number for an axis typeparameter or axis type machine signal.For details of the setting, refer to the description of FSSB setting inthe connection manual (function part).

CAUTIONTo use the dual check safety function, the first servoaxis is required. To use the dual check safetyfunction under multi-path control, the first servo axiscannot be changed between paths. Specificrequirements are as follows.For one-path control, one-CPU two-path control,and loader control:

Tool post 1 (or loader) must have an axis forwhich parameter No.1023 is set to 1.

For two-CPU two-path control and two-CPU three-path control:

Tool post 1 must have an axis for whichparameter No.1023 is set to 1, and tool post 2must have an axis for which parameter No.1023is set to 9.

1829 Positional deviation limit during a stop for each axis

[Data type] Word axis[Unit of data] Detection unit

[Valid data range] 0 to 32767Set a positional deviation limit for each axis at stop time.If a positional deviation limit during a stop is exceeded at stop time, aservo alarm No.410 is issued, and an immediate stop (same as anemergency stop) is performed.In the dual check safety function, the CNC and monitor always checkthe position deviation amount on each axis. If the monitor detects thatthe position deviation limit is exceeded during a stop, a servo alarmNo.474 is issued only in safety signal mode C (state in which a guardopen request is input and the guard is open).


- 65 -

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

[Data type] 2-word axis[Unit of data] Detection unit

[Valid data range] 0 to 99999999Set a positional deviation limit during movement for each axis insafety 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 duringmovement, 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 checkthe position deviation amount on each axis. If the monitor detects thatthe position deviation limit is exceeded during moving, a servo alarmNo.475 is issued only in safety signal mode C (state in which a guardopen request is input and the guard is open).When the guard is open, axis movement is performed at a speed notexceeding the safe speed. So, usually, set a value smaller than apositional deviation limit during movement (parameter No. 1828).

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

1902 0 DCE 0 STP

[Data type] BitSTP When the power is turned on, a MCC off test is:

0: Conducted. (The warning "PLEASE EXECUTE MCC OFFTEST" is displayed at power-on, and MCC off Test executionrequest signal (RQT) is output.)

1: Not conducted.

CAUTION1 The STP parameter is used temporarily, for

example, when a MCC off Test is not to be made atpower-on as in the case of machine adjustment.Usually, set STP = 0.

2 Even when STP = 1, a MCC off Test is required if thepower is turned 24 hours or more after thecompletion of the previous MCC off Test.

WARNINGSet STP = 0 after the STP parameter is usedtemporarily as in the case of machine adjustment.

DCE The dual check safety function is:0: Disabled.1: Enabled.


- 66 -

CAUTIONUsually set the DCE = 1 in the dual check safetyfunction. The system cannot start-up because MCC-on enable signal (MCF) = 0 when the DCE = 0.

WARNINGAlways set bits 5 and 7 of parameter No.1902 to 0. Ifone of these bits is set "1", the safety functions maybe executed incorrectly.

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

1904 DCN

[Data type] Bit axisDCN The checks of the target axis by the dual check safety function are:

0: Made.1: Not made.

CAUTION1 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 gearbox or electronic gear box 2-pair.

WARNINGThe checks by the dual check safety function are notmade on an axis for which the DCN bit is set to 1. Setthe DCN bit to 0 for normal axes.

1942 Safety speed for each axis

[Data type] 2-word axis[Unit of data]

[Valid data range]Valid data rangeIncrement

system Unit of dataIS-A, IS-B IS-C

Millimeter machine 1 mm/min 0 to 240000 0 to 100000Inch machine 0.1 inch/min 0 to 96000 0 to 48000Rotation axis 1 deg/min 0 to 240000 0 to 100000

Set a safe speed for each axis.The CNC and monitor always check the velocity command of eachaxis in the dual check safety function. If the safe speed is exceeded onone axis at least, the guard unlock signal (*LGD) is brought to 0, todisable guard unlocking. The state in which the safe speed is notexceeded on any axis is one condition for setting the guard unlocksignal (*LGD) to 1 (to enable guard unlocking).


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If the safe speed is exceeded in safety signal mode C (state in which aguard open request is input and the guard is open), a servo alarmNo.476 or No.494 is issued for the corresponding axis.

CAUTIONThe checks are made on the basis of the speedconverted to the detection unit. Accordingly, acalculation error may occur.

1943 Safe machine position of each axis (+ direction)

1944 Safe machine position of each axis (- direction)

[Data type] 2-word axis[Unit of data]

Increment system IS-A IS-B IS-C UnitMillimeter machine 0.01 0.001 0.0001 mmInch machine 0.001 0.0001 0.00001 inch

[Valid data range] -99999999 to 99999999Set a safe machine position for each axis.The CNC and monitor always check the machine position on eachlinear 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 whosemachine position is not in the safe machine position (safe machineposition (- direction) ≤ machine position ≤ safe machine position (+direction)), the guard unlock signal (*LGD) is set to 0 to disableguard unlocking. The state in which the machine positions of alllinear axes are within the safe machine positions is one condition forsetting the guard unlock signal (*LGD) to 1 (to enable guardunlocking). If the machine position on a linear axis exceeds the safemachine position in safety signal mode C (state in which a guard openrequest is input and the guard is open), a servo alarm No.477 orNo.495 is issued.

CAUTIONThe checks are made on the basis of the machineposition to the detection unit. Accordingly, acalculation error may occur.

WARNING1 CNC and monitor check the machine position of

each linear axis, and not check it of each rotationaxis.

2 CNC and monitor check the machine position of onlyeach axis whose reference position is established,and not check it of each axis whose referenceposition is not established.


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1945 Safety input signal check timer

[Data type] Word[Unit of data] ms

[Valid data range] 0 to 32767For input signals related to the dual check safety function (safetyinput signals), two paths are used: one path for input to the CNC viathe PMC, and the other for input to the monitor via the FSSB. TheCNC and monitor exchange the input signals with each other at alltimes to check each other. If a mismatch greater than the time set inthis parameter is detected between an input signal via one path andthe same signal via the other path, a servo alarm No.479 or No.486 isissued. If a value of less than 16 is specified, a specification of 16 msis assumed.

CAUTIONSet identical values in parameters No.1945 for thefollowing: two tool posts under two-CPU two-pathcontrol with axis change between paths, two toolposts under one-CPU two-path control, or tool posts2 and 3 under two-CPU three-path control.

1946 MCC off Test timer


[Valid data range] 0 to 32767When 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 offTest is not completed within the time set in this parameter, a servoalarm No.488 is issued.If a value of less than 0 is specified, a specification of 10000 ms isassumed.

1947 MCC-off timer 1

1948 MCC-off timer 2


[Valid data range] 0 to 32767When the MCC-on enable signal (MCF) needs to be set to 0 (MCCoff) with the dual check safety function for a cause such as an alarmor emergency stop, the CNC and monitor set MCC-on enable signal(MCF) to 0 when an MCC-off timer value has elapsed after the alarmor 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 spindlemotor will continue to rotate (free-run) and stop after time. When the


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spindle motor should stop as quickly as possible, please use theseparameters and control the spindle motor to stop, and after that cutMCC off.

State Timer usedWhen a spindle alarm is issued No timer is used.When the guard is closed MCC-off timer 1 (No. 1947)When the guard is open MCC-off timer 2 (No. 1948)

CAUTIONSet identical values in parameters No.1947 for thefollowing: two tool posts under two-CPU two-pathcontrol with axis change between paths, two toolposts under one-CPU two-path control, or tool posts2 and 3 under two-CPU three-path control. Setidentical values in parameters No.1948 likewise.

1950 Brake signal timer


[Valid data range] 0 to 32767

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

CAUTIONSet identical values in parameters No.1950 for thefollowing: two tool posts under two-CPU two-pathcontrol with axis change between paths, two toolposts under one-CPU two-path control, or tool posts2 and 3 under two-CPU three-path control.

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

1959 0 0 0 0 0 0 0 0

[Data type] Bitset all bits to 0.

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


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2078 Monitor conversion factor (numerator) of each axis

2079 Monitor conversion factor (denominator) of each axis

[Data type] Word axisSet the following values.No.2078/No.2079 =Lowest possible terms of the feedback pulse count of built-in pulsecoder per motor revolution over one million CAUTION

1 The monitor in the dual check safety function takes inthe feedback of the built-in pulse coder. Even if aseparate position detector is used, set parametersNo.2078 and No.2079 to the values calculated on thebasis of the feedback pulse count of the built-in pulsecoder.

2 Changing parameter No.2078 or No.2079 will not causea P/S000 alarm (PLEASE TURN OFF POWER).However, when making this change, turn off the power.The changed parameter value takes effect after thepower is turned on again.

3 Parameters No.2078 and No.2079 are cleared if thestandard servo parameter setting (turning on or off thepower when the DGPR bit (bit 1 of parameter No.2000)is set to 0) is selected. After making the standard servoparameter setting, set parameters No.2078 andNo.2079 again.

4 Set both parameters No.2078 and No.2079 to 0 for theslave axis under tandem control.

5 Parameters No.2078 and No.2079 are used also for thedual position feedback function.

3225 Code for safety parameters

[Data type] 2-word [Valid data range] 0 to 99999999

Set a code (password) for protecting against modifications toparameters related to the dual check safety function (safetyparameters). When a code for safety parameters is set, the parametersare locked. At this time, the setting (code) is not displayed but isblank, and safety parameter input is disabled. If an attempt is made toinput data in a locked safety parameter, the result indicated in thetable below is produced, depending on the method of input. Noattempt is successful.

Input method ResultMDI input Warning "WRITE PROTECT"G10 (programmable parameter input) P/S231 FORMAT ERROR IN G10 L50Input via the reader/puncher interface No alarm is issued, but parameter

input is disabled.


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Input through a window Completion code 7 (write protect)

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

3226 Key for safety parameters

[Data type] 2-word[Valid data range] 0 to 99999999

When the same value as the code for safety parameters is set in thisparameter, the key is opened to enable modifications to the safetyparameters. The value set in this parameter is not displayed. When thepower is turned off, the value set in this parameter is cleared,resulting in the locked state.

CAUTIONOnce a key is set, the key must be cancelled ormemory must be cleared before the safetyparameters can be modified. Moreover, the code forthe safety parameters cannot be modified. Be carefulwhen setting a code for safety parameters.

4372 Safe speed of each spindle

[Data type] Word[Unit of data] min-1

[Valid data range] 0 to 32767Set a safe speed for each spindle in terms of motor speed.With the dual check safety function, the CNC and spindle softwarealways 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 isgreater than the safe speed, guard unlock signal (*LGD) is set to 0 todisable guard unlocking. The state in which the speeds of all spindlemotors are within the safe speeds is one condition for setting guardunlock signal (*LGD) to 1 (to enable guard unlocking).In safety signal mode C (state in which a guard open request is inputand the guard is open), if a spindle speed exceeds the safe speed, aspindle alarm No.757 (No.767) or AL-69 is issued for thecorresponding spindle.


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6.3 PARAMETERS RELATED TO THE USE OF FSSB I/O UNIT

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

1902 FMD

[Data type] Bit

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

CAUTIONWhen using the dual check safety function, set theFMD bit to 1, to select manual setting 2 mode.

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

1905 IO2 IO1

[Data type] Bit axisIO1 A first FSSB I/O unit is:

0: Not used.1: Used.

IO2 A second FSSB I/O unit is:0: Not used.1: Used.

CAUTION1 The FSSB I/O unit and separate detector interface

unit (pulse module) are handled as units of the sametype on the FSSB. The term "first unit" or "secondunit" used in the following description means that theunit is the first or second one when counteddisregarding the difference between the FSSB I/Ounit and separate detector interface unit. If oneFSSB I/O unit and one separate detector interfaceunit are connected and if the separate detectorinterface unit is closer to the CNC on the FSSB thanthe FSSB I/O unit, for instance, the FSSB I/O unit isreferred to as the "second unit."

2 The FSSB I/O unit is controlled on the first servoaxis. Set IO1 (or IO2) to 1 for an axis for whichparameter No.1023 is set to 1 (to 9 for tool post 2under two-CPU two-path control or two-CPU three-path control). For the other axes, set both IO1 andIO2 to 0.


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

[Data type] Byte[Valid data range] 0 to 7, 16, 40, 48

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

CAUTIONThe FSSB I/O unit and separate detector interfaceunit (pulse module) are handled as units of the sametype on the FSSB. The term "first unit" or "secondunit" used in the following description means that theunit is the first or second one when counteddisregarding the difference between the FSSB I/Ounit and separate detector interface unit. If oneFSSB I/O unit and one separate detector interfaceunit are connected and if the separate detectorinterface unit is closer to the CNC on the FSSB thanthe FSSB I/O unit, for instance, the FSSB I/O unit isreferred to as the "second unit."


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6.4 FUNCTIONS THAT REQUIRE SPECIAL PARAMETERSETTINGS

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)=1No.2078=0No.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, setthe 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.1023The first servo axis cannot be changed between paths.Accordingly, set parameter No.1023 to 1 for the axis of toolpost 1 and to 9 for the axis of tool post 2.

No.1945, No.1947, No.1948, No.1950Set identical values for the two tool posts.

• One-CPU two-path controlNo.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.

B-63494EN/01 7.START-UP

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7 START-UP

7.START-UP B-63494EN/01

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7.1 START-UP OPERATION

The machine tool builder has to do tests for insulation and protectivebonding. Testing must be performed according to Chapter 19.2 and19.3 of the standard IEC 60204-1 by an appropriately authorizedperson and recorded.

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

Insulation resistance testsThe insulation resistance measured at 500 V d.c. between the powercircuit conductors and the protective bonding circuit is to be not lessthan 1MΩ. For further details, please refer to Chapter 19.3 of IEC60204-1.

7.1.1 Acceptance Test and Report for Safety Functions

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

Acceptance reportA qualified person is to check each dual check safety function andrecord the test results in a check report.

MOTEWhen modifying dual check safety function data,conduct an additional check test on the modifieddual check safety function and record the test resultsin a check report.

Safe-related I/O monitoring testData cross-check operation is tested with the I/O device connectordetached.

MCC off Test checkThe test mode signal is used to check that a MCC off Test isconducted.Negative test:

Conduct a MCC off Test by disconnecting the MCC contactsignal (input). Check that an alarm is issued and the MCCremains to be shut off.


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

Safe machine position monitoring testA positional limit test is conducted by making many differentmovements.A positional limit is placed at the center of an axis, and the position ismoved at many different speeds in a rapid traverse mode. Thus, thedistance traveled on the axis until stop state is set by a stop responseis measured. The machine tool builder is to determine a safety limitstop position including a safety margin.

Data modificationThe user needs to enter the correct password before setting safetyparameters with the system. After a safety parameter is modified, acheck test needs to be conducted on the related safety function, andthe test results need to be recorded in a report.


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7.1.2 Start-up of the Dual Check Safety Function

7.1.2.1 Initial start-up

Main flowDisable dual checksafety functionMachine start-up

FSSB I/O setting Safety parameterinput

Step 1Initial stateFirst, check that the machine starts up normally when the dual checksafety function is disabled.

Preparation 1 Disable the dual checksafety function.

Bit 6 of PRM No. 1902 = 0

Preparation 2 Disable output (MCF), fromI/O, that indicates MCC isturned off.

Connect the relay fordriving based on I/O output

CAUTIONWhen the dual check safety function is disabled, theMCC on enable signal (MCF) is not output. So, makea connection to temporarily disable MCF. To enablethe dual check safety function, reset the temporaryconnection.

Step 2FSSB I/O settingMake the same settings as for the pulse module.Example: When a two-axis amplifier is set as slave 1, and FSSB I/Ounit is set as slave 2Make the settings indicated in the table below.

Parameter setting MeaningBit 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 amplifierNo. 1911 = 1 Sets the value of parameter No. 1023 less 1

when the slave is an amplifierNo. 1912 = 16 16 when the slave is a FSSB I/O unitNos. 1913 to 1919 = 40 40 when there is no slave


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Step 3Safety parameter inputEnable the dual check safety function, and enter the safetyparameters.

Preparation 1 Enable the dual check safetyfunction.

Bit 6 of PRM No. 1902= 1

Preparation 2 Enables output (MCF), from I/O,that indicates MCC is turned off. Enable I/O output.

Set the safety parameters indicated in the table below.Parameter

settingMeaning

1942 Safe speed on each axis1943 Safe machine position (+ direction) on each axis1944 Safe machine position (- direction) on each axis1945 Timer for safety input signal check1946 Timer for MCC off Test1947 Timer 1 for MCC off1948 Timer 2 for MCC off1838 Positional deviation limit value in mode C2078 Dual position feedback conversion coefficient (numerator)2079 Dual position feedback conversion coefficient (denominator)4372 Safe speed on each spindle

Step 4If 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 5Execution of general machine testsAxis and spindle optimizationDual check safety function adjustment (safe speed, safe machineposition)

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

Step 7Parameter preservationSave all parameters including the safety parameters. The parametersare used to start up the series.

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


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7.1.2.2 Series start-up

The parameters for the safety monitoring function are transferredtogether with other parameters to the CNC as in the case of normalseries start-up. Perform a safety function check test in addition to thenormal start-up procedure.

7.1.3 Troubleshooting

Alarms related to the safety function are output on the ALARMscreen.Correct the cause of trouble according to the chapter describingalarms and messages in this manual. When a component related to thesafety function is to be replaced, an authorized person must conduct asafety function check test.

B-63494EN/01 8.MAINTENANCE

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8 MAINTENANCE

8.MAINTENANCE B-63494EN/01

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8.1 SAFETY PRECAUTIONS

This section describes the safety precautions related to the use ofCNC units. It is essential that these precautions be observed by usersto 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 mustbe 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 toolbuilder.Before checking the operation of the machine, take time to becomefamiliar with the manuals provided by the machine tool builder andFANUC.

CAUTIONMaintenance on a live system requires carefulplanning, adherence to operating and maintenanceprocedures, and the appropriate permits andpermissions.These matters are the responsibility of theowner/operator of the system and are outside thescope of this document.

TRAININGFANUC Training Center provides versatile training course for theperson who is concerned with hardware and software installation,maintenance and operation. FANUC recommend studying andlearning how efficiently operate FANUC products.

QUALIFIED PERSONNELOnly qualified personnel should be allowed to specify, apply, install,commissioning, operate, maintain, or perform any other functionrelated to the products described in the product manuals. Examples ofsuch 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 particularequipment.


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MAINTENANCE PARTS TO BE MAINTAINED PERIODICALLY

• Memory backup battery replacement

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

NOTEThe CNC uses batteries to preserve the contents ofits memory, because it must retain data such asprograms, offsets, and parameters even whileexternal power is not applied.If the battery voltage drops, a low battery voltagealarm is displayed on the machine operator's panelor CRT screen.When a low battery voltage alarm is displayed,replace the batteries within a week. Otherwise, thecontents of the CNC's memory will be lost.To replace the battery, see the procedure describedin Section 2.10 of the maintenance manual B-63005EN.

WARNINGS RELATED TO CHECK OPERATION

WARNING1. 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. Whenchecking the operation, stand away from the machine toensure that your clothing does not become tangled in thespindle or other components.

(2) When checking the operation, perform idle operationwithout workpiece. When a workpiece is mounted in themachine, a malfunction could cause the workpiece to bedropped or destroy the tool tip, possibly scatteringfragments throughout the area. This presents a seriousdanger of injury. Therefore, stand in a safe location whenchecking the operation.


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2. When checking the machine operation with the power magneticscabinet 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 electricshock. Before starting any check of the operation, confirmthat the cover is mounted on the high-voltage section. Whenthe high-voltage section itself must be checked, note thattouching a terminal presents a severe danger of electricshock.

(2) Within the power magnetics cabinet, internal units presentpotentially injurious corners and projections. Be carefulwhen working inside the power magnetics cabinet.

3. Never attempt to machine a workpiece without first checking theoperation of the machine.Before starting a production run, ensure that the machine isoperating correctly by performing a trial run using, for example,the single block, feedrate override, or machine lock function orby operating the machine with neither a tool nor workpiecemounted. Failure to confirm the correct operation of the machinemay result in the machine behaving unexpectedly, possiblycausing damage to the workpiece and/or machine itself, or injuryto the user.

4. Before operating the machine, thoroughly check the entered data.Operating the machine with incorrectly specified data may resultin the machine behaving unexpectedly, possibly causing damageto the workpiece and/or machine itself, or injury to the user.

5. Ensure that the specified feedrate is appropriate for the intendedoperation. Generally, for each machine, there is a maximumallowable feedrate. The appropriate feedrate varies with theintended operation. Refer to the manual provided with themachine to determine the maximum allowable feedrate. If amachine is run at other than the correct speed, it may behaveunexpectedly, possibly causing damage to the workpiece and/ormachine itself, or injury to the user.

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


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WARNINGS RELATED TO REPLACEMENT

WARNING1. 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 turnedoff, power may continue to be supplied to the serve section.In such a case, replacing a unit may damage the unit, while alsopresenting a danger of electric shock.

2. When a heavy unit is to be replaced, the task must be undertakenby two persons or more. If the replacement is attempted by onlyone person, the replacement unit could slip and fall, possiblycausing injury.

3. After the power is turned off, the servo amplifier and spindleamplifier may retain voltages for a while, such that there is adanger of electric shock even while the amplifier is turned off.Allow at least twenty minutes after turning off the power forthese residual voltages to dissipate.

4. When replacing a unit, ensure that the new unit has the sameparameter and other settings as the old unit. (For details, refer tothe manual provided with the machine.) Otherwise,unpredictable machine movement could damage the workpieceor the machine itself, and present a danger of injury.

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

WARNINGS RELATED TO PARAMETERS

WARNING1. When machining a workpiece for the first time after modifying a

parameter, close the machine cover. Never use the automaticoperation function immediately after such a modification.Instead, confirm normal machine operation by using functionssuch as the single block function, feedrate override function, andmachine lock function, or by operating the machine withoutmounting a tool and workpiece. If the machine is used beforeconfirming that it operates normally, the machine may moveunpredictably, possibly damaging the machine or workpiece, andpresenting a risk of injury.

2. The CNC and PMC parameters are set to their optimal values, sothat those parameters usually need not be modified. When aparameter must be modified for some reason, ensure that youfully understand the function of that parameter before attemptingto modify it. If a parameter is set incorrectly, the machine maymove unpredictably, possibly damaging the machine orworkpiece, and presenting a risk of injury.


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8.2 ALARMS AND MESSAGES

8.2.1 Overview

Alarms related to the dual check safety function cannot be cancelledby a reset. To cancel the alarms, turn off the power, remove thecauses of the alarms, then turn on the power again.

For information about emergency stop mode, MCC off Test mode,and safety signal modes A/B/C/D, see Chapter 5.


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8.2.2 Servo Alarms

No. Meaning Description364 n AXIS: SOFT PHASE

ALARM(INT)The servo control software detected an abnormal data skip in a velocityfeedback signal on axis n (axis 1 to axis 8).Replace the α pulse coder, or take measures to correct noise on the feedbackcable.

402 SERVO ALARM: SV CARDNOT EXIST

The axis control card is not provided.This alarm will be issued also if the eight-axis control card dedicated to dualcheck safety function (5DSP card) is mounted on a machine without the dualcheck safety function.

403 SERVO ALARM : CARD/SOFTMISMATCH

For the axis control card, the correct servo software is not installed in flashmemory.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 andmonitor software in flash memory.

410 SERVO ALARM : n AXISEXCESS ERR

The CNC detected that the positional deviation during a stop on axis n (axis 1to 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.

411 SERVO ALARM : n AXISEXCESS ERR

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 where a guard open request isinput, 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.

453 n AXIS:SPC SOFTDISCONNECT ALARM

The servo control software detected an alpha pulse coder signal error on axisn (axis 1 to axis 8).Replace the alpha pulse coder.

470 n AXIS:ILLEGAL RAM (MNT) An error occurred in a monitor RAM check.Replace the axis control card.

471 n AXIS:SPC SOFTDISCONNECT (MNT)

The monitor detected an alpha pulse coder signal error on axis n (axis 1 toaxis 8).Replace the α pulse coder.

473 n AXIS:SOFT PHASEALARM(INT/MNT)

The monitor detected an abnormal data skip in a velocity feedback signal onaxis n (axis 1 to axis 8).Replace the α pulse coder, or take measures to correct noise on the feedbackcable.

474 n AXIS:EXCESS ERROR(STOP:MNT)

The monitor detected that the positional deviation during a stop on axis n (axis1 to axis 8) exceeded the setting (parameter No. 1829) in safety signal modeC (state in which a guard open request is input, and the guard is open).Confirm a proper value is set to parameter No. 1829.

475 n AXIS:EXCESS ERROR(MOVE:MNT)

The monitor detected that the positional deviation during movement on axis n(axis 1 to axis 8) exceeded the setting (parameter No. 1838) in safety signalmode 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.


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No. Meaning Description476 n AXIS:ILLEGAL SPEED CMD.

(MNT)The monitor detected that the specified speed on axis n (axis 1 to axis 8)exceeded the safe speed (parameter No. 1942) in safety signal mode C (statein 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 machineimmediately stops, and a pulse for adjusting the coordinates is generated.Accordingly, this alarm can be issued.

477 n AXIS:ILLEGAL MACHINEPOS.(MNT)

The monitor detected that the machine position on axis n (axis 1 to axis 8) isnot in the safety area (parameter No. 1943 and No. 1944) in safety signalmode 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. 1943and No. 1944, and operation is done in the safety area.A machine position check is carried out just on a linear axis on which thereference position has already been established. No machine position checkis made on a rotation axis or a linear axis on which the reference position hasnot yet been established.

478 n AXIS:ILLEGAL AXIS DATA(MNT)

The monitor detected that an error occurred on axis n (axis 1 to axis 8) duringaxis data transfer.If the alarm occurs after performing axis number setting for the servoamplifier, set parameter No.2212#4 to 1, and reset the bit to 0, and then turnoff the power of the entire system.In the other case, replace the servo amplifier the alarm occurred.

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

480 n AXIS:ILLEGAL SAFETYMODE (MNT)

The monitor detected that safety signal mode D (state in which the guard isopen although no guard open request is input) was set, or the guard is openwhen guard unlock signal (*LGD) is not output.In the former, the alarm is issued for all axes. In the latter, the alarm isissued only for the first servo axis (axis for which parameter No.1023 is set to1 or, for tool post 2 under two-CPU two-path control or two-CPU three-pathcontrol, an axis for which parameter No.1023 is set to 9). Check if the guardstate signal(SGD) is correctly connected.If an alarm is issued in safety mode C (state in which a guard open request isinput and the guard is open), guard unlocking is disabled. Accordingly, thisalarm may be issued.

481 n AXIS:SAFETY PARAMERROR (MNT)

The monitor detected that a safety parameter error occurred with axis n (axis1 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

482 n AXIS:AXIS NUMBER NOTSET (MNT)

The monitor detected that the axis number of axis n (axis 1 to axis 8) is not setwith the servo amplifier.Turn off the power of the entire system. Then an axis number is automaticallyset.

483 MONITOR SAFETYFUNCTION ERROR

An error occurred in safety 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.Replace the axis control card.


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No. Meaning Description484 n AXIS:SERVO SAFETY

FUNCTION ERRAn 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.

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

487 ILLEGAL SAFETY MODE(CNC)

The CNC detected that safety signal mode D (state in which the guard is openalthough no guard open request is input) was set, or the guard is open whenguard 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 isinput and the guard is open), guard unlocking is disabled. Accordingly, thisalarm may be issued.

488 SAFE TEST OVER TIME A MCC off Test was not completed within the set time (parameter No. 1946).Check the MCC contact.

489 SAFETY PARAM ERROR(CNC)

The CNC detected a safety parameter error.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

490 CNC SAFETY FUNCTIONERROR

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 CNC RAM test.4 An error occurred in a CNC CPU test.5 Test at power-up was not executed.Replace the CPU card.

491 LOCAL BUS TEST ERROR An error occurred in a local bus test. The mother board may be faulty.Replace the mother board.

492 F-BUS TEST ERROR An error occurred in an F-BUS test. The mother board or option board may befaulty.The F-BUS test is carried out if a sub-CPU board or loader board is used.

494 n AXIS:ILLEGAL SPEED CMD.(CNC)

The CNC detected that the specified speed on axis n (axis 1 to axis 8)exceeded the setting (parameter No. 1942) in safety signal mode C (state inwhich 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 machineimmediately stops, and a pulse for adjusting the coordinates is generated.Accordingly, this alarm can be issued.


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No. Meaning Description495 n AXIS:ILLEGAL MACHINE

POS.(CNC)The CNC detected that the machine position on axis n (axis 1 to axis 8) is notin 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. 1943and No. 1944, and operation is done in the safety area.A machine position check is carried out just on a linear axis on which thereference position has already been established. No machine position checkis made on a rotation axis or a linear axis on which the reference position hasnot yet been established.

496 n AXIS:ILLEGAL AXIS DATA(CNC)

The CNC detected that an error occurred on axis n (axis 1 to axis 8) duringaxis data transfer.If the alarm occurs after performing axis number setting for the servoamplifier, set parameter No.2212#4 to 1, and reset the bit to 0, and then turnoff the power of the entire system.In the other case, replace the servo amplifier the alarm occurred.

497 n AXIS:SAFETY PARAMTRANS ERROR

A safety parameter transfer error occurred on axis n (axis 1 to axis 8).Replace the CPU card or the axis control card.

498 n AXIS:AXIS NUMBER NOTSET (CNC)

The CNC detected that the axis number of axis n (axis 1 to axis 8) is not setwith the servo amplifier.Turn off the power of the entire system. Then an axis number is automaticallyset.


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8.2.3 Serial Spindle Alarms

No. Meaning Description749 S-SPINDLE LSI

ERRORIt is serial communication error while system is executing after power supply on.Check optical cable connection between main CPU board and spindle amplifier printedboard.Replace optical cable, main CPU board, option 2 board or spindle amplifier printedboard.If this alarm occurs when CNC power supply is turned on or when this alarm can not becleared even if CNC is reset, turn off the power supply also turn off the power supply inspindle side.

755 SPINDLE-1 SAFETYFUNCTION ERROR

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.

756 SPINDLE-1 ILLEGALAXIS DATA

For the first spindle, the CNC detected a mismatch between the spindle amplifierconnection 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 thesetting on the spindle amplifier side.

757 SPINDLE-1 SAFETYSPEED OVER

For the first spindle, the CNC detected that the speed of the spindle motor exceeded thesafe speed (parameter No. 4372) in safety signal mode C (state in which a guard openrequest is input, and the guard is open).Alternatively, for the first spindle, the CNC detected a mismatch between the CNC andspindle 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.

765 SPINDLE-2 SAFETYFUNCTION ERROR

Same as alarm No. 755. (For the second spindle)

766 SPINDLE-2 ILLEGALAXIS DATA


767 SPINDLE-2 SAFETYSPEED OVER


7n16 SPN n :S-SPINDLEERROR (AL-16)

See the description of AL-16 in Subsection 8.2.4. (For the n-th spindle)


















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8.2.4 Alarms Displayed on the Spindle Unit

No. Meaning DescriptionAL-16 RAM Alarm An error occurred in a spindle RAM test.

Replace spindle amplifier module.AL-69 Safety speed over 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 openrequest 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.

AL-70 Illegal axis data The spindle software detected a mismatch between the spindle amplifier connectionstate and spindle amplifier hardware setting.If this alarm is issued because the spindle amplifier configuration is changed, correct thesetting 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 thesetting on the spindle amplifier side.

AL-71 Safety parameter error 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

AL-72 Mismatch the results ofmotor speed check

The spindle software detected a mismatch between the CNC result of the motor speedcheck and the spindle result of it.Replace the CPU card or spindle amplifier module.

AL-74 CPU test alarm An error occurred in a spindle amplifier CPU test.Replace spindle amplifier module.

AL-75 CRC alarm An error occurred in a spindle ROM CRC test.Replace spindle amplifier module.

AL-76 Inexecution of safetyfunctions

Any safety function was not executed.Replace spindle amplifier module.

AL-77 Mismatch the results ofaxis number check

The spindle software detected a mismatch between the CNC result of the axis numbercheck and the spindle result of it.Replace the CPU card or spindle amplifier module.

AL-78 Mismatch the results ofsafety parameterscheck

The spindle software detected a mismatch between the CNC result of the safetyparameters check and the spindle result of it.Replace the CPU card or spindle amplifier module.

AL-79 Inexecution of safetyfunctions at power-up

The safety functions at power-up for spindle were not executed. Replace the spindleamplifier.Replace spindle amplifier module.


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8.2.5 System Alarms

No. Meaning Description900 ROM PARITY 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 ROM2 CRC error of the CNC, servo, or monitor ROMReinstall the indicated ROM in flash memory.

920 SERVO ALARM (1-4AXIS)

Servo alarm (first to fourth axis). A watchdog alarm condition occurred, or a RAM parityerror 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.

921 SERVO ALARM (5-8AXIS)

Servo alarm (fifth to eighth axis). A watchdog alarm condition occurred, or a RAM parityerror 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, ormonitor).If the 8-axes control card dedicated to dual check safety function (5DSP card) is usedwith the dual check safety function, a servo alarm (fifth to eight axis) is issued.Replace the axis control card.

973 NON MASKINTERRUPT

An NMI of an unknown cause occurred.If the 8-axes control card dedicated to dual check safety function (5DSP card) is usedwith the dual check safety function, this alarm is issued, even when a servo alarm(monitor) is issued.

8.2.6 Boot System Alarms

Message DescriptionROM PARITY ERROR:NC BASIC. HIT SELECT.

Parity error of the CNC basic ROM.When the dual check safety function is used:1. Parity error of the CNC basic ROM2. CRC error of the CNC basic ROMReinstall the CNC basic ROM in flash memory.

9.DIAGNOSIS B-63494EN/01

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9 DIAGNOSIS

B-63494EN/01 9.DIAGNOSIS

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9.1 OVERVIEW

The information of safety signal mode and safety input signal of thedual 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.

9.DIAGNOSIS B-63494EN/01

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9.2 DIAGNOSIS

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

Diagnosis No. 376 FMC FGL FGDThe current states of safety signals input via the FSSB are displayed.

FGD The state of the guard state signal (SGD2) is displayed.FGL The state of the guard lock state signal (GDL2) is displayed.FMC The state of the MCC contact state signal (*SMC2) is displayed.

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

Diagnosis No. 377 PMC PGL PGD PRQ PTSThe current states of safety signals input via the PMC are displayed.

PTS The state of the test mode signal (OPT) is displayed.PRQ The state of the guard open request signal (ORQ) is displayed.PGD The state of the guard state signal (SGD1) is displayed.PGL The state of the guard lock state signal (GDL1) is displayed.PMC The state of the MCC contact state signal (*SMC1) is displayed.

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

Diagnosis No. 378 ESP TST MDD MDC MDB MDAThe current safety signal mode is displayed.

MDA Safety signal mode AMDB Safety signal mode BMDC Safety signal mode CMDD Safety signal mode D

TST MCC off test modeESP Emergency stop mode

Diagnosis No. 379 Test number of MCC off testThe 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 modesignal (OPT), the test number increases by 1 from 0 as the MCC offtest proceeds. When the MCC off test is completed, the test number is128. When the test mode signal (OPT) is set to 0 to clear the MCC offtest mode, the test number is cleared to 0.

B-63494EN/01 10.SAMPLE SYSTEM CONFIGURATION

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10 SAMPLE SYSTEM CONFIGURATION

10.SAMPLE SYSTEM CONFIGURATION B-63494EN/01

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10.1 SAMPLE CONFIGURATION

10.1.1 For One-path


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10.1.2 For Two-path (When the main side and sub side use acommon MCC)


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10.1.3 For Two-path (When the main side and sub side useindependent MCCs and protection doors)


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10.2 SAMPLE CONNECTIONS

10.2.1 Emergency Stop Signal (*ESP1, *ESP2)

*ESP1(X008#4)

I/O-Link I/O UNIT

*ESP2(DI+000#0)

FSSB I/O UNIT

+24V

CX4ESP

PSM0V

NOTESUse a two-contact emergency stop button with a forced dissociationmechanism.Connect the emergency stop button to the PSM, as illustrated in thefigure. When the signal is input, the spindle slows down and stops.Input a power-down factor to [G008#4] other than the signal from theemergency stop button.Create a Ladder program so that [X008#4] becomes a factor of[G008#4].

X00n#n

I/O-Link I/O UNIT PMC

LadderprogramEmergency stop factor

other than emergencystop button

Emergency stopfactor

Machine side

X008#4Emergencystop button

*ESPG(G008#4)


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10.2.2 Guard Open Request Signal (ORQ)

X00n#n

I/O-Link I/O UNIT+24VGuard openrequest button 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 inoutput of *LGD.

• If the input of ORQ is canceled while the guard is open, the CNCenters a safely stopped status (state in which the guard is openalthough the guard open request signal is not input). Close theguard (SGD is set to 1), then cancel this signal.

10.2.3 Test Mode Signal (OPT)

X00n#n

I/O-Link I/O UNIT+24V

Test start button

PMC

Ladder program

OPT(G191#2)

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


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

+24V

SW1 SW2

SW3

0V

0V

X00n#nI/O Link I/O UNIT

SGD(DI+001#4)

FSSB I/O UNIT

Y00n#n

PMCSGD(G191#4)

*LGD(F191#0)

Ladderprogram

RY1

RY2

RY1

RY2

RY3

RY3RY3

RY1 RY2

Guard-monitoringlimit switch

Safety relay

[Sample control components]SW1/SW2:

Guard state monitoringswitch with forceddissociation mechanism

SW3:Guard lock switch

RY1, RY2, RY3:Safety relay

Guard closed


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OPERATING PRINCIPLEThis section describes the operation of various guard monitoring limitswitches with lock mechanism and safety relays.State transition of components

SW1 SW2 SW3 RY1 RY2 RY3 SGD1 Guard closed

Guard lockedCLOSE CLOSE CLOSE ON ON OFF 1

2 Guard closedGuard unlocked

CLOSE CLOSE OPEN OFF ON OFF 0

3 Guard openedGuard unlocked

OPEN OPEN OPEN OFF OFF ON 0

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

NOTESThis example does not use the guard lock state signal (GDL). If GDLis 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) affectsthe dual check safety function. The guard lock state signal (GDL)only indicates whether an input mismatch is found. The state of theGDL signal does not affect the dual check safety function.The illustrated sample system determines that the guard is open (setsSGD to 0) when the guard is unlocked.When the guard open request signal (ORQ) is accepted and when ithas been confirmed that the CNC is in a safe state, the guard unlocksignal (*LGD) is output. Based on this signal, use a Ladder programto create a guard unlock signal.


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

X00n#n

I/O Link I/O UNIT

FSSB I/O UNIT

Y00n#n

PMC

MCF1(F191#1)

*SMC2(DI+001#6)MCF(DO+000#1)

0V

PSM

+24V

200A

200B

UVW

0V

Electromagnetic contactor (MAIN MCC)

CX3MCC

*SMC1(G191#6)

NOTESWith 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 erroroccurs in the PSM, the PSM turns off the MCC.

11.COMPONENTS LIST B-63494EN/01

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11 COMPONENTS LIST

B-63494EN/01 11.COMPONENTS LIST

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11.1 HARDWARE COMPONENTS

11.1.1 Hardware Components for Series16i/18i/21i/160i/180i/210i/160is/180is/210is-MODEL A

No. Description Specification numberOf primary component

Specification numberof secondary component Remarks

1 Main board A20B-8100-0130 A20B-8100-013XA20B-8100-054X

A20B-8100-014X

2 CPU card A20B-3300-0170 A20B-3300-0050A20B-3300-0260

A20B-3300-0070

3 Servo card A17B-3300-0200 A20B-3300-012XA20B-3300-024X

A20B-3300-020X

4 DRAM MODULE A20B-3900-0131 A20B-3900-003XA20B-3900-013X

A20B-3900-004X

5 SRAM MODULE A20B-3900-0060 A20B-3900-005XA20B-3900-002X

A20B-3900-006X

6 FROM MODULE A20B-3900-0011 A20B-3900-001X A20B-3900-007X

11.1.2 Hardware Components for Series16i/18i/21i/160i/180i/210i/160is/180is/210is-MODEL B



1 Main board A20B-8100-0660 A20B-8100-066XA20B-8100-079X

A16B-3200-042X

2 CPU card A20B-3300-0311 A20B-3300-031X A20B-3300-029X3 Servo card A20B-3300-0244

A17B-3300-0500A20B-3300-024X

4 FROM/SRAM MODULE A20B-3900-0160 A20B-3900-016XA20B-3900-018X

5 Power supply module A20B-8100-0720 A20B-8100-08516 Sub CPU board A20B-8002-0190 A16B-2203-07517 Loader control board A20B-8100-0830 A16B-2203-0740


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11.1.3 Hardware Components for Other Units



1 FSSB ADDITIONALDETECTOR INTERFACE

A20B-2100-0270

2 I/O module A20B-2100-0150A20B-2100-0410A20B-2100-0411A20B-2002-0470A20B-2002-0521

A20B-2002-0400A20B-2002-0401A20B-2100-0320A20B-2002-0520

3 I/O Unit base module A20B-9001-0020 A20B-9001-0040A20B-2000-0510

A20B-2000-0550

4 I/O Unit interface module A20B-8000-0410 A20B-8000-0420A20B-8000-0820

A20B-8000-0710

5 DC digital input module A20B-9000-0901A20B-9000-0902

A20B-9000-0970A20B-9001-0011A20B-9001-0281A20B-9000-0972A20B-9001-0490

A20B-9000-0971A20B-9001-0010A20B-8000-0341A20B-9001-0280A20B-8000-0510

6 DC digital output module A20B-9000-0921 A20B-9001-0220A20B-8000-0440A20B-9001-0490A20B-8000-0741A20B-9001-0681A20B-8000-0780

A20B-8002-0070A20B-8000-0510A20B-8000-0740A20B-9001-0680A20B-8000-0760

7 DC digital input/outputmodule

A20B-8000-0750A20B-8000-0730

A20B-8000-0751A20B-8000-0731

8 AC digital input module A20B-8000-0341 A20B-9001-09409 AC digital output module A20B-8000-0470

A20B-8000-0321A20B-8000-0480A20B-8000-0880

10 Relay output module A20B-9001-0200A20B-8000-0500

A20B-8000-0101

11 FSSB I/O module A20B-2100-0390


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11.2 SOFTWARE COMPONENTS

[i series MODEL A CNC software]Series / Version Functions

FS16i-TAFS160i-TAFS160is-TA

B1F2B1F4

CNC functions for lathe with up to 8 servoaxes and up to 2 spindle axes.


BEF2BEF4



DEF2DEF4


FS20i-TA D1F1 CNC functions for manual lathe with up to 2servo axes and up to 1 spindle axis

FS16i-MAFS160i-MAFS160is-MA

B0F2B0F4

CNC functions for machining center with upto 8 servo axes and up to 2 spindle axes.


BDF2BDF4



DDF2DDF4


FS20i-FA D0F1CNC functions for manual milling machinewith up to 4 servo axes and up to 1 spindleaxis.

[i series MODEL B CNC software]Series / Version Functions

FS16i-TBFS160i-TBFS160is-TB

B1H1 CNC functions for lathe with up to 8 servoaxes and up to 2 spindle axes.


BEH1 CNC functions for lathe with up to 6 servoaxes and up to 2 spindle axes.


DEH1 CNC functions for lathe with up to 4 servoaxes and up to 2 spindle axes.

FS16i-MBFS160i-MBFS160is-MB

B0H1 CNC functions for machining center with upto 8 servo axes and up to 2 spindle axes.

FS18i-MB5FS180i-MB5FS180is-MB5

BDH5CNC functions for machining center with upto 6 servo axes and up to 2 spindle axes.Simultaneously controlled axes : max 5 axes


BDH1CNC functions for machining center with upto 6 servo axes and up to 2 spindle axes.Simultaneously controlled axes : max 4 axes


DDH1 CNC functions for machining center with upto 4 servo axes and up to 2 spindle axes.


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[Monitor software]Series / Version Functions

Monitor 90A9 / 03 Monitor functionsMonitor 90B9 / 01 Monitor functions

[Servo control software]Series / Version Functions

Servo 90A5 / 01 Servo functionsServo 90B0 / 09 Servo functionsServo 90B7 / 04 Learning control

[Spindle software]Series / Version Functions

Spindle 9D20 / 10 Spindle functionsSpindle 9D50 / 04 Spindle functions


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11.3 SERVO AMPLIFIER

No. Description Module Name Specification number RemarksPSM-5.5 A06B-6077-H106PSM-11 A06B-6077-H111PSM-15 A06B-6087-H115PSM-26 A06B-6087-H126PSM-30 A06B-6087-H130PSM-37 A06B-6087-H137PSM-45 A06B-6087-H145PSM-55 A06B-6087-H155PSM-5.5i A06B-6110-H006PSM-11i A06B-6110-H011PSM-15i A06B-6110-H015PSM-26i A06B-6110-H026PSM-30i A06B-6110-H030

1 Power Supply Module(Standard)

PSM-37i A06B-6110-H037PSMR-1 A06B-6081-H101PSMR-3 A06B-6081-H103

2 Power Supply Module(Resister Discharge type)

PSMR-5.5 A06B-6081-H106SVM1-2 A06B-6096-H121SVM1-4 A06B-6096-H122SVM1-12 A06B-6096-H101SVM1-20 A06B-6096-H102SVM1-40S A06B-6096-H103SVM1-40L A06B-6096-H104SVM1-80 A06B-6096-H105SVM1-130 A06B-6096-H106SVM1-130S A06B-6096-H116SVM1-240 A06B-6096-H107SVM1-360 A06B-6096-H108SVM1-20i A06B-6114-H103SVM1-40i A06B-6114-H104SVM1-80i A06B-6114-H105SVM-160i A06B-6114-H106

3 Servo Amplifier Module(1 axis type)

SVM1-360i A06B-6114-H109SVM2-12/12 A06B-6096-H201SVM2-12/20 A06B-6096-H202SVM2-20/20 A06B-6096-H203SVM2-12/40 A06B-6096-H204SVM2-20/40 A06B-6096-H205SVM2-40/40 A06B-6096-H206SVM2-40/80 A06B-6096-H207SVM2-80/80 A06B-6096-H208SVM2-40L/40L A06B-6096-H209SVM2-4/4i A06B-6114-H201SVM2-20/20i A06B-6114-H205SVM2-20/40i A06B-6114-H206SVM2-40/40i A06B-6114-H207

4 Servo Amplifier Module(2 axes type)

SVM2-40/80i A06B-6114-H208


- 112 -

No. Description Module Name Specification number RemarksSVM2-80/80i A06B-6114-H209SVM2-80/160i A06B-6114-H210


SVM2-160/160i A06B-6114-H211SVM3-12/12/12 A06B-6096-H301SVM3-12/12/20 A06B-6096-H302SVM3-12/20/20 A06B-6096-H303SVM3-20/20/20 A06B-6096-H304SVM3-12/12/40 A06B-6096-H305SVM3-12/20/40 A06B-6096-H306SVM3-20/20/40 A06B-6096-H307SVM3-4/4/4i A06B-6114-H301SVM3-20/20/20i A06B-6114-H303


SVM3-20/20/40i A06B-6114-H304SPM-2.2-1 A06B-6102-H202#H520SPM-5.5-1 A06B-6102-H206#H520SPM-11-1 A06B-6102-H211#H520SPM-15-1 A06B-6102-H215#H520SPM-22-1 A06B-6102-H222#H520SPM-26-1 A06B-6102-H226#H520SPM-30-1 A06B-6102-H230#H520SPM-45-1 A06B-6102-H245#H520

6 Spindle Amplifier Module(SPM HRV Type I )

SPM-55-1 A06B-6102-H255#H520SPM-2.2-4 A06B-6102-H102#H520SPM-5.5-4 A06B-6102-H106#H520SPM-11-4 A06B-6102-H111#H520SPM-15-4 A06B-6102-H115#H520SPM-22-4 A06B-6102-H122#H520SPM-26-4 A06B-6102-H126#H520SPM-30-4 A06B-6102-H130#H520SPM-45-4 A06B-6102-H145#H520

7 Spindle Amplifier Module(SPM HRV Type IV )

SPM-55-4 A06B-6102-H155#H520SPM-2.2i A06B-6111-H002#H550SPM-5.5i A06B-6111-H006#H550SPM-11i A06B-6111-H011#H550SPM-15i A06B-6111-H015#H550SPM-22i A06B-6111-H022#H550SPM-26i A06B-6111-H026#H550

8 Spindle Amplifier Module(SPM HRV Type A )

SPM-30i A06B-6111-H030#H550SPM-2.2i A06B-6112-H002#H550SPM-5.5i A06B-6112-H006#H550SPM-11i A06B-6112-H011#H550SPM-15i A06B-6112-H015#H550SPM-22i A06B-6112-H022#H550SPM-26i A06B-6112-H026#H550

9 Spindle Amplifier Module(SPM HRV Type B )

SPM-30i A06B-6112-H030#H550

B-63494EN/01 INDEX

i-1

INDEX

AAAA

ALARMS AND MESSAGES ............................ 86

Alarms Displayed on the Spindle Unit ........... 92

APPLICATION RANGE................................... 17

BBBB

BASIC PRINCIPLE OF DUAL CHECK

SAFETY........................................................... 6

BEFORE USING THE SAFETY FUNCTION 20

Boot System Alarms ......................................... 93

CCCC

Certification Test ................................................ 4

Compliance with the Safety Standard (EN954-1,

Category 3) ...................................................... 7

COMPONENTS LIST..................................... 106

DDDD

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

Definition of Terms Related to the Safety

Function .......................................................... 5

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

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

DIAGNOSIS................................................ 94, 96

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

Directives ............................................................ 3

EEEE

EMERGENCY STOP........................................ 29

Emergency stop signal ..................................... 50

Emergency Stop Signal (*ESP1, *ESP2)....... 101

Error analysis ................................................... 10

ety monitoring cycle and cross-check cycle ....... 9

FFFF

Features of Dual Check Safety .......................... 6

For One-path............................................... 35, 98

For Two-path..................................................... 37

For Two-path (When the main side and sub side

use a common MCC) ..................................... 99

For Two-path (When the main side and sub side

use independent MCCs and protection doors)

...................................................................... 100

FSSB I/O Attachment....................................... 43

FSSB I/O Connection........................................ 41

FSSB I/O Specification List.............................. 47

FUNCTIONS THAT REQUIRE SPECIAL

PARAMETER SETTINGS............................ 74

GGGG

General Definition of Terms .............................. 5

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

Guard lock state signal..................................... 52

Guard open request signal ............................... 52

Guard Open Request Signal (ORQ)............... 102

Guard state signal ............................................ 52

Guard unlock signal.......................................... 53

Guard Unlock Signal (*LGD), Guard Lock State

Signal (GDL), Guard State Signal (SGD).. 103

HHHH

HARDWARE COMPONENTS....................... 107

Hardware Components for Other Units........ 108

Hardware Components for Series

16i/18i/21i/160i/180i/210i/160is/180is/210is-

MODEL A .................................................... 107

Hardware Components for Series

16i/18i/21i/160i/180i/210i/160is/180is/210is-

MODEL B .................................................... 107

IIII

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

Important Items to Check Before Using the

Safety Function ............................................. 20


- 2 -

Initial start-up .................................................. 78

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

LLLL

Latent error detection and cross-check ............. 8

Loader Control .................................................. 61

MMMM

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

MCC contact state signal ................................. 53

MCC off Test ....................................................... 9

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

MCC off Test execution request signal............ 54

MCC off Test of the Safe Stop Function.......... 20

MCC On Enable Signal (MCF), MCC Contact

State Signal (*SMC) ................................... 105

MCC-on enable signal ...................................... 53

Multi-path Control............................................ 74

NNNN

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

OOOO

One-CPU Two-Path Control ............................ 59

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

Overview ........................................................... 86

PPPP

PARAMETERS ........................................... 62, 64

PARAMETERS RELATED TO THE USE OF

FSSB I/O UNIT............................................. 72

RRRR

Related Safety Standards .................................. 3

Remaining risks................................................ 10

Risk Analysis and Evaluation............................ 3

SSSS

SAFE MACHINE POSITION MONITORING 31

SAFE SPEED MONITORING ......................... 30

SAFETY FUNCTIONS..................................... 16

SAFETY I/O MONITORING............................ 24

SAFETY PRECAUTIONS............................ 1, 82

Safety Signal Modes ......................................... 56

SAMPLE CONFIGURATION.......................... 98

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

SAMPLE SYSTEM CONFIGURATION ......... 97

Serial Spindle Alarms....................................... 91

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

Servo Alarms..................................................... 87

SERVO AMPLIFIER ...................................... 111

Signal Addresses............................................... 55

SIGNALS........................................................... 50

Simple Electronic Gearbox and Two Groups of

Electronic Gearboxes .................................... 74

SOFTWARE COMPONENTS ........................ 109

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

Start-up of the Safety Function ....................... 78

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

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

Stop States ........................................................ 22

Stopping the Servo Motor................................. 22

Stopping the Spindle Motor ............................. 21

System Alarms.................................................. 93

SYSTEM CONFIGURATION .......................... 14

TTTT

Tandem Control ................................................ 74

Test mode signal ............................................... 50

Test Mode Signal (OPT) ................................. 102

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

Two-CPU Three-Path Control.......................... 60

Two-CPU Two-Path Control (With Axis Change

between Paths).............................................. 58

Two-CPU Two-Path Control (Without Axis

Change between Paths) ................................ 57

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