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OPERATORS MANUAL

B-63494EN/01

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

In this manual we have tried as much as possible to describe all 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 STANDARDS1.1.1 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 EvaluationAccording 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 TestCertification of the dual check safety function

The 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 TERMS1.2.1 General Definition of TermsReliability and safety

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

Reliability Capability of a machine, machine component, orequipment 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 FunctionSafe-related I/O signal

Safe-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 SAFETY1.3.1 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 INFORMATIONThe 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- series servo amplifier- series spindle amplifier- series power supply module- i series servo amplifier- i series spindle amplifier- i series power supply module

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

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

Software- Dual check software

B-63494EN/01 2.SYSTEM CONFIGURATION

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Detector systemThe detectors below can be used.

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

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

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 RANGEThe 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 FUNCTION3.2.1 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 FunctionA 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 STOP3.3.1 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 MotorBecause 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 StatesThe 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 MONITORINGA 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 Dual input monitoringSGD Guard state signal Dual input monitoringGDL Guard lock state signal Dual input monitoring*SMC MCC contact state signal Dual input monitoringMCF MCC on enable signal Duplicated outputORQ Guard open request

signal Input

OPT Test mode signal Input*LGD Guard unlock signal OutputRQT MCC off Test execution

request signal 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 STOPThe 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 MONITORINGWhen 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 MONITORINGWhile 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 TESTA 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 LCDmounted

type controlunit and display

unit (exceptunit with data

server function)

Standalonetype control

unit

LCDmountedtype controlunit with PC

and data serverfunctions

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

of the unitStorageTransport

20C to 60C

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 lessVibrationNonoperating 1.0 G or lessOperating Up to 1000 m Up to 1000 mMeters above

sea level Nonoperating 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 series must be installed in a sealed type cabinetto satisfy the following environmental requirements:

(1) Ambient TemperatureAmbient temperature of the unit :0 to 55C (at operation)-20 to 60C (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 DIAGRAM4.1.1 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 foroperators panel

JD1B CE56JD1A CE57

Machineoperators

panel

I/O module forconnector panel

JD1B CB150JD1A

To next I/O unit

Powermagnetics

cabinet

200VAC 2

SPMJA7B JYA2JA7A CZ2

PSMCX1A CX3CZ1 CX4

TB1

TB1 CXA2A

CXA2B

200VAC 3

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:

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

G008 *ESPG

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

G191 *SMC1 GDL1 SGD1 ORQ OPT

CNCPMC #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 ConnectionPower 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 VDC10%

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 AttachmentExternal 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 ListInstallation conditions

Ambient temperatureof the unit

Operating 0C to 55CStorage, transportation -20C to 60C

Temperature variation 1.1C /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 supplycapacity Remarks

24V10% 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 A or less

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

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5 I/O SIGNALS

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5.1 OVERVIEWThe 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 and . 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 SIGNALSEmergency stop signal*ESP1 ( for loader control), *ESPG ,*ESP2

[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).