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1. 162 9 2 CROSS CHECK DATA SCREEN tede 163 9 3 FLOW MONITORING SCREEN Z uu netto Eie ta pe nca et e Ranch 167 9 4 FEED LIMIT MONITORING SCREEN 168 9 5 SAFE MACHINE POSITIONING MONITORING SCREEN 170 9 6 SAFETY POSITION ERROR MONITORING SCREEN 171 9 7 DIAGNOSIS SGREEN tis atop a terere nee 172 10 SAMPLE SYSTEM 175 10 1 SAMPLE CONFIGURATION neis ut p debo tute but da 176 10 1 1 Example of Configuration Using a Single MCC eese 176 10 1 2 Example of Configuration Using Multiple MCGS 177 10 2 SAMPLE CONNECTIONS 178 10 2 1 Emergency Stop Signal ESP 178 10 2 2 Guard Open Request Signal sese 179 10 25 Test Mode Signal 179 10 24 Guard Open Inhibit Signal OPIHB Monitoring Result Signal RSVx RSPs Safety check Request Signal VLDVx VLDPSs a a 180 10 2 5 MCC Off Signal MCF MCFVx MCFPs DCALM MCC Contact State Signal SMC ASS a asya yake 184 10 3 EXAMPLE OF nennen 1
2. Link 3 COP10B To 27 Servo Amp D To 2 Spindle Amp 3 SAFETY FUNCTIONS CZ2 COP10A JF1 Spindle Excitation Off BiSVSP signal 2 EXOF2 JA7B JX6 JA7A JYA2 TB2 I O Unit Guard State CPb1 signal SGOPN DIA Unit Spindle Rotation CPD1 Enable Switch signal SPEN JD1B ae Is JD1A 61 3 SAFETY FUNCTIONS B 64303EN 4 01 Connection JX4 of aiSP and I O Link 3 or Connection JX6 of BiSVSP and I O Link 3 Semiconductor based insulated output Half pitch connector Hirose Electric Connector case FI40B 20S CVS5 Unit Contact open Excitation on Contact closed Excitation off Specification of contact output of the aiSP or BiSVSP 3 20 5 Restrictions System configuration Circuit type Polarized photocoupler Rated voltage 30 VDC or less Output current DC 40 mA or less Saturation voltage 1 5 V or less at an output current of 40 mA N CAUTION If the connector is connected incorrectly the 24 V power externally supplied can damage the internal circuitry of the aiSP and piSVSP Use special care when connecting the connector To use this function the following ai series spindle amplifiers BiSVSP series supporting the func
3. eee 188 BASIC PRINCIPLE OF DUAL CHECK 5 lt F gt BEFORE USING THE SAFETY FUNCTION 15 Features of Dual Check Safety Brake Configuration esee FEED LIMIT MONITORING SCREEN Brake Test FLOW MONITORING SCREEN Brake Test Procedure lt G gt lt C gt GENERAL E 240 Certification Test ie eset 3 General Definition of Terms see 4 Compliance with the Safety Standard 5 GENERAL INFORMATION eee 10 COMPONENTS LIST eee 225 Pu PM Guard Open Inhibit Signal OPIHB Monitoring Connections iue tb e 51 60 Result Signal RSVx RSPs Safety check Request CPU SELF TEST eee 43 Signal FVLDVx VLDPSs eerte 180 CRC CHECK FUNCTION 44 Guard Open Request Signal 179 CROSS CHECK DATA SCREEN 163 Cs CONTOUR CONTROL eee 211 lt H gt D HARDWARE COMPONENTS 226 D Hardware Components for Other Units 227 DATATYPE uniti bens 111 DEFINITION OF TERMS eee 4 lt l gt Definition of Terms Related to the Safety Function 4 I O SIGNALES eremo ntm rS 79 D
4. 19 3 5 Mash pra eis brat Hc 29 3 6 SAFE SPEED MONITORING 30 3 7 SAFE MACHINE POSITION MONITORING 32 3 8 MCC ORR TEST 13 21 at td Ranked 34 3 9 SAFETY POSITION SWITCH FUNCTION 37 3 10 SAFETY RELATED PARAMETERS CHECK FUNCTION 39 3 11 PARAMETER LOCK FUNCTION 39 3 12 SEFETY POSITION ERROR MONITORING FUNCTION 40 313 AMPLIFIER CIRCUIT MONITORING FUNCTION 41 3 14 SAFETY BRAKE SIGNAL OUTPUT FUNCTION 42 3 15 CPU SELF TEST FUNCTION 43 3 16 RAM CHECK FUNCTION 44 TABLE OF CONTENTS B 64304EN 4 01 317 CRO CHECK FUNGTION OS iine phe a hoe e oen icon 44 3 18 SAFE STOP MONITORING sedata dione tette cite mte de ins 45 3 19 SAFE SERVO STOP 46 3 19 1 Monitoring of the Excitation Off Signal esee 47 3 19 2 User Ladder Processing tede qe ROO ERREUR EE ane
5. Pulse width of Z 50 _ Input Impedance Input Frequency aoee e apes The position accuracy depends on the quality of the signal from the encoder 247 B 64303EN 4 01 INDEX INDEX Directives Standards and Technical Conditions for 3rd lt Number gt Party Servo Spindle Motors amp Encoders when Applying 2 path Control T Series sss 108 FANUC GE Fanuc Dual check Safety 239 lt A gt DUAL BRAKE MONITOR FUNCTION 63 A B Phase Sine wave Interface Connected to FANUC lt Es GE Fanuc Interpolation Circuit sss 244 EMERGENCY STOP eene 29 Acceptance Test and Report for Safety Functions 148 Emergency Stop Signal 178 ALARM MESSAGE 153 Encoder with FANUC GE Fanuc Serial Interface 244 AMPLIFIER CIRCUIT MONITORING FUNCTION 41 Error analysis eerte ertet nein 8 APPLICATION OF OTHER FUNCTIONS 186 EXAMPLE OF 185 APPLICATION eee 13 Example of Configuration Using a Single MCC 176 Assignment of Programmable Safety I O Signals 50 59 Example of Configuration Using Multiple MCCGSs 177 lt B gt EXTERNAL
6. 5 1 3 1 Features of Dual Check Safety enne enne 5 1 3 2 Compliance with the Safety Standard asss 5 1 3 2 1 Latent error detection and cross check 7 1 3 2 2 Safety monitoring cycle and cross check cycle 7 1 3 2 3 Error 3e er ete bete e p Eee ede 8 1 3 2 4 Remaining TISKS 5 e eese iet eee puede ener p eee deed 8 1 4 GENERAL INFORMATION 10 SYSTEM CONFIGURATIOLNN 11 SAFETY FUNCTIONS 12 3 1 APPLICATION RANGE soos Soc vinci deer 13 3 2 BEFORE USING THE SAFETY FUNCTION 15 3 2 1 Important Items to Check Before Using the Safety Function 15 3 2 2 MCC off Test of the Safe Stop 15 3 3 asun a MMe See 16 3 3 1 Stopping the Spindle Motor 16 3 3 2 Stopping the Servo Motoru uu a a A L A p M i a A baa h ls 17 3 3 3 SLOP States NM D E 17 3 4 SAFE RELATED SIGNAL MONITORING
7. I Input type Data type 4 EDPx 5 EDMx Parameter input Bit axis In cutting feed an external deceleration signal in the direction for each axis 15 0 Invalid 1 Valid In cutting feed an external deceleration signal in the direction for each axis 1s 0 Invalid 1 Valid N CAUTION In rapid traverse JOG feed and manual handle feed external deceleration is enabled regardless of the settings of bits 4 EDPx and 5 EDMx of parameter No 1005 192 B 64303EN 4 01 11 APPLICATION OF OTHER FUNCTIONS 7 6 5 4 3 2 1 0 EX3 Input type Parameter input Data type Bit path 0 EX2 External deceleration function setting 2 is 0 Invalid 1 Valid 1 EX3 External deceleration function setting 3 is 0 Invalid 1 Valid 1426 External deceleration rate setting 1 in cutting feed 1440 External deceleration rate setting 2 in cutting feed 1443 External deceleration rate setting 3 in cutting feed Input type Parameter input Data type Real path Unit of data mm min inch min degree min machine unit Minimum unit of data Depend on the increment system of the reference axis Valid data range Refer to the standard parameter setting table C When the increment system is IS B 0 0 to 999000 0 Set an external deceleration rate for cutting feed or positioning of linear interpolation type 000 1427 External deceleration rate setting 1 for each axis in rapid traverse 144
8. it 1 1 1 1 1 1 The issue of an alarm is suppressed with a timer 1 I I 1 An alarm condition is detected for the period until spindle excitation is turned off 1 1 after Spindle Rotation Enable Switch signal SPEN1 is switched from on to off However by setting a timer on the ladder side ensure that no alarm is detected during this period 2 The excitation on state EXOF1 0 or EXOF2 0 Contact open is set when the Spindle Excitation signal SFRA G70 5 or SRVA G70 4 or the orientation command ORCMA G70 6 is set to 1 The G signal is applicable to the first spindle 57 3 SAFETY FUNCTIONS B 64303EN 4 01 e At power on time EXOFA is not output normally until the serial spindle is started So EXOFI input to the dual monitoring function 1s forcibly masked to 1 by setting a timer Timing chart 2 Processing at power on time EXOFA x To be input by a PMC ladder EXOF1 At power on time this signal is forcibly setto 1 by a ladder for a certain time until the serial spindle is started Processing on the DCS PMC side e If EXOF1 0 or EXOF2 0 contact open spindle excitation on for a certain time when SGOPN is 0 door open and SPEN Is 0 Spindle Rotation Enable Switch signal turned off an error is assumed to issue a 1st channel or 2nd channel alarm Timing chart 3 Error judgment processing by the DCS PMC side ladd
9. ORCMx Speed command SFRx SRVx ORARx Safe speed Level switching To monitor the stop status of the spindle use a sequence as shown below By monitoring the orientation completion signal ORARx interrupt the power of the spindle motor with the power interruption signal MPOFx and emergency stop signal ESPx if there is a deviation from the stop position ORCMx ORARx MPOFx ESPx N CAUTION This sequence uses the spindle orientation function to monitor the stop status of the spindle If there is a deviation from the stop position since an excessive load is applied to the spindle a large reaction force is generated When the deviation is greater than or equal to the orientation completion level excitation is turned off and the output torque is immediately reduced to zero 224 B 64303EN 4 01 12 COMPONENTS LIST 1 2 COMPONENTS LIST 225 12 COMPONENTS LIST 12 1 12 1 1 Series 0i MODEL D CNC Control unit Description Main board A1 HARDWARE COMPONENTS Specification Number A20B 8200 0541 Remarks Main board A3 A20B 8200 0543 Axes control card A1 A20B 3300 0635 Axes control card A2 A20B 3300 0638 Axes control card A3 A20B 3300 0637 Axes control card B2 A20B 3300 0632 Axes control card B3 A20B 3300 0631 gt OO FROM SRAM module 1 FR
10. 202 1143 1 Detals on signals is nne e aec epa 202 11 4 3 2 Signal address ua chsh ua e RAE EUR A AN DARGA Bh gus 203 EAA Pat metets SR ee a ie Ete ee ert ie age Re 203 11 5 OS GONTOUR CONTRO aaeei aenean abu tt tapes cce 211 211 1155 2 Specifications une tien nae ees 212 TABLE OF CONTENTS B 64304EN 4 01 115 3 Signals eed eee e e dede qa 213 15 33 Details on amp enals 2 nere e RR E I 213 11 5 3 2 Signaladdrz ess iine poma ee UR Dent ERES 214 1154 Parameters oS ner ee en re SO ER 215 11 6 SPINDLE ten dee Ec cete ce o epe 218 11 6 SOVERVIS nei esc t P EU ree 218 11 6 2 ueteres ertet iP TI en PC eene HIE SEE nece as 218 11 60 93 Signals eie Ett o esent ree e uay Qum a ate se bored kanaa 219 11 6 3 1 Details on signals tue sn aan oo ROE AoE 219 11 6 3 2 Signal address eee RERO ETT IS 220 11 64 Parameters u iere re metit etie i ect pires 221 11 6 5 Sequence eene rre P beds e Re ERE ERE RE OS 224 12 COMPONENTS LIST 225 121 HARDWARE COMPONENTS sese eren nnne nennen 226 121 1 Senes 0C MODEL Dik eee br tm eh mereri te ri te e eerie iua 226 12 1 2 Hardware Compo
11. 206 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 5 6 7 TRVs ESIs IMBs The rotation direction for spindle positioning is 0 1 Same as the specified sign Opposite to the specified sign NOTE When a serial spindle is used this parameter is invalid for the specification of a rotation direction for the orientation command The unit of rapid traverse rate on the spindle positioning axis is 0 1 Not increased by a factor of 10 Increased by a factor of 10 When the spindle positioning function is used half fixed angle positioning based on M codes uses 0 1 Specification A Specification B In the case of half fixed angle positioning based on M codes three types of spindle positioning operations can occur 1 2 3 The spindle rotation mode is cleared then the mode is switched to the spindle positioning mode After switching to the spindle positioning mode spindle orientation operation is also performed Spindle positioning 15 performed in the spindle positioning mode The spindle positioning mode is cleared then the mode 15 switched to the spindle rotation mode In the case of specification A Operations 1 to 3 are specified using separate M codes 1 Specified using an M code for switching to the spindle positioning mode See parameter No 4960 2 Specified using M codes for specifying a spindle positioning angle See parameter No 4962
12. 185 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 1 1 APPLICATION OF OTHER FUNCTIONS 186 B 64303EN 4 01 11 1 OVERVIEW 11 APPLICATION OF OTHER FUNCTIONS The Dual Check Safety function becomes easier to use when combined with various other functions This section describes the functions Part of the section assumes the use of the Dual Check Safety function Therefore if the function is not used the specifications described in the chapter may differ Since only a summary is provided for each function refer to the Connection Manual Function B 64303EN 1 or other documents for detailed specifications Section 11 2 describes combination with external deceleration Section 11 3 describes combination with spindle output control by the PMC Section 11 4 describes combination with spindle positioning Section 11 5 describes combination with Cs contour control and Section 11 6 describes combination with spindle orientation 187 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 11 2 EXTERNAL DECELERATION 11 2 1 Overview The Dual Check Safety function uses the CNC CPU and monitor DSP to separately monitor the speed of the feed axis safe speed monitoring function When the safe speed is exceeded by some axes with the protective door closed after a guard open request is input RS Vx 0 the protective door needs to be locked by the ladder program to prevent it from opening When the safe speed is exc
13. 139 6 PARAMETERS B 64303EN 4 01 13918 Tolerance value for position deviation to be monitored in brake test Input type Data type Unit of data Valid data range Input type Data type Unit of data Valid data range NOTE When this parameter is set the power must be turned off before operation is continued Parameter input Integer axis Detection unit 0 to 999999999 This parameter sets a tolerance value for position deviation to be monitored in a brake test on each axis In a comparison made between a travel distance and position deviation when brake control is exercised the normal range spans from the reference position deviation plus the setting of this parameter to the reference position deviation minus the setting of this parameter If a value not within the normal range 15 detected alarm DS0039 or DS0040 15 issued When 0 Is set in this parameter the setting of 100 is assumed Normal position deviation range E Tolerance value Tolerance value kapa Reference position deviation position deviation relative to a specified value Position deviation monitor time t2 in brake test NOTE When this parameter is set the power must be turned off before operation is continued Parameter input Integer axis msec 0 to 32767 This parameter sets time t2 for position deviation monitoring in a brake test on each axis During this time torque is applied to the brake When 0 is
14. 3 Specified using M codes for clearing spindle positioning operation See parameter No 4961 In the case of specification B When M codes for specifying a spindle positioning angle are specified operations 1 to 3 are performed successively See parameter No 4962 However spindle orientation operation of 1 is not performed 207 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 M code specifying the spindle orientation Input type Parameter input Data type 2 word spindle Valid data range to 97 Set an M code for switching to the spindle positioning mode NOTE 1 Do not set M code that duplicates other M codes used for spindle positioning 2 Do not set an M code used with other functions such as M00 05 30 98 and 99 and M codes for calling subprograms M code s the spindle positioning mode Input type Parameter input Data type 2 word spindle Valid data range 6 to 97 Set an M code for canceling the spindle positioning mode on the spindle positioning axis NOTE 1 Do not set M code that duplicates other M codes used for spindle positioning 2 Do not set an M code used with other functions such as M00 05 30 98 and 99 and M codes for calling 208 B 64303EN 4 01 11 APPLICATION OF OTHER FUNCTIONS M code for specifying a spindle positioning angle Input type Data type Valid data range Parameter input 2 word spindle
15. 7 6 5 4 3 2 1 0 spo qp Input type 6 Data type DCE NOTE When at least one of these parameters is set the power must be turned off before operation is continued Parameter input Bit Dual Check Safety function is 0 inactive 1 active This parameter invalidates Dual Check Safety function temporarily In the system with Dual Check Safety function this parameter is used when the system set up without wiring and ladder related with Dual Check Safety in order to set up other function 120 B 64303EN 4 01 6 PARAMETERS NOTE 1 When Dual Check Safety function is used this parameter must be set to 1 If Dual Check Safety function is ordered and this parameter is 0 an alarm DS0022 is displayed at power on This alarm can be reset by pushing CAN and RESET key on MDI at the same time When the Dual Check Safety function is disabled almost safety related functions become disabled Only the following functions become enabled when the Dual Check Safety function is disabled e MCC Off signal for each machine group The state of Off signal on the and DCS PMC sides changes depending on the state of the emergency stop signal on the PMC side the state of the emergency stop signal on the DCS PMC side has no effect The MCC off Test is disabled Brake signal BRKx for each axis Brake signal BRKx operates only on the
16. al PS 26 068 6140 026 al PS 30 al PS 37 068 6140 030 068 6140 037 al PS 55 068 6140 055 al PSn series Resistance regeneration type al PSR 3 068 6115 003 al PSg 5 5 Spindle Amplifier Series Name Model Name al SP 2 2 A AO06B 6115 H006 Specification Number AO6B 61 41 HOO2 Hxxx Remarks al SP 5 5 A AO6B 6141 HOO6 Hxxx al SP 11 TYPE A A06B 6141 H011 Hxxx al SP 15 TYPE A A06B 6141 H015 Hxxx al SP 22 TYPE A A06B 6141 H022 Hxxx al SP 26 TYPE A A06B 6141 H026 Hxxx al SP 30 TYPE A A06B 6141 H030 Hxxx al SP 37 TYPE A A06B 6141 H037 Hxxx al SP 45 TYPE A A06B 6141 H045 Hxxx al SP 55 TYPE A A06B 6141 H055 Hxxx al SP 2 2 TYPE B A06B 6142 H002 Hxxx al SP 5 5 TYPE B A06B 6142 H006 Hxxx al SP 11 TYPE B A06B 6142 H011 Hxxx al SP 15 TYPE B A06B 6142 H015 Hxxx al SP 22 TYPE B A06B 6142 H022 Hxxx al SP 26 TYPE B A06B 6142 H026 Hxxx al SP 30 TYPE B A06B 6142 H030 Hxxx al SP 37 TYPE B A06B 6142 H037 Hxxx al SP 45 TYPE B A06B 6142 H045 Hxxx al SP 55 TYPE B A06B 6142 H055 Hxxx Note xxx 580 231 12 COMPONENTS LIST Servo Amplifier Series Name Model Name al SV 4 Specification Number A06B 6117 H101 B 64303EN 4 01 Remarks al SV 20 AO6B 6117 H103 al SV 20L
17. see 244 Servo Motors Driven by FANUC GE Fanuc Servo Amplifier tcc nee RR 244 Signal address 192 198 203 214 220 SIGNAL ADDRESS eere 81 Signals es ERE 191 197 202 213 219 SIGNALS pente en eg 87 SOEIWARE 5se gae I 230 Specifications 189 196 200 212 218 Spindle Speed Position Feedback Sensor Embedded in 243 Spindle Motors Driven by FANUC GE Fanuc Spindle Amplif ier 243 SPINDLE ORIENTATION 218 SPINDLE OUTPUT CONTROL BY THE 195 SPINDLE POSITIONING T SERIES 199 SPINDLES RUND UBER 243 STANDARD PARAMETER STTING TABLES 113 START UP nni na 147 START UP OF THE SAFETY FUNCTION 150 START UP OPERATION 148 STOR s dte IP RU Rand 16 Stop 17 Stopping the Servo 17 Stopping the Spindle Motor sss 16 Suspension and Restart of Brake Test 67 SYSTEM eee 11 Test Mode Signal OPT 179 Troubleshooting one repeteret 152 User Ladder Processing eee 49 57 sumo upa EQ uonpa
18. 8002 0 V N3 0 7v9 8 IWANVIN NOLLO3NNOO NSS T3300W 70 S9u9S ONNVA UOISIA9H B 64303EN 4 01 B 64303EN 4 041
19. Break signal timer 3717 Motor number to each spindle 3797 0 Enable safety function for each spindle 4372 Safety speed 1 on each spindle 4438 Safety speed 2 on each spindle 4440 Safety speed 3 on each spindle 4442 Safety speed 4 on each spindle 4448 Speed regarded as spindle stop for Dual Check Safety 13821 Safety speed 1 on each axis 13822 Safety speed 2 on each axis 13823 Safety speed 3 on each axis 13824 Safety speed 4 on each axis 13825 Speed regarded as axis stop for Dual Check Safety 13831 Safety position 1 direction on each axis 13832 Safety position 1 direction on each axis 13833 13834 Safety position 2 direction on each axis Safety position 2 direction on each axis 13835 13836 Safety position 3 direction on each axis 13837 Safety position 4 direction on each axis 13838 151 Safety position 3 direction on each axis Safety position 4 direction on each axis 7 START UP Step 4 Step 5 Step 6 Step 7 Step 8 7 2 2 7 2 3 B 64303EN 4 01 If alarm SV0478 or SV0496 occurs set the parameter No 2212 4 is set to 1 and then set to 0 Then turn off the CNC and the amplifier And turn on the CNC and the amplifier Execution of general machine tests Axis and spindle optimization Dual Check Safety f
20. When the NC accepts brake test execution a test is conducted on the brake test target axes simultaneously By combining the states of two Safety Brake signals BRKx PMC DCS PMO three patterns of test are conducted on each axis in the order from test 1 to test 3 as indicated below Test 1 Test 2 Test 3 BRKx PMC 0 0 1 BRKx DCS PMC 0 1 0 State of brake Applied Applied Applied Upon normal completion of test on all test target axes the Brake Test Execution Request signal RQBT 15 set to 0 If an error occurs during test alarm DS0039 or DS0040 is issued Even if alarm DS0039 or DS0040 is issued servo motor excitation is kept In this state however automatic operation cannot be continued Retract the axes to a safe position by manual operation then turn off the power Next take action for the brake in trouble To conduct another brake test perform a reset operation once to clear the alarm state beforehand Upon normal completion of test set the Brake Test Start signal STBT to 0 64 B 64303EN 4 01 3 SAFETY FUNCTIONS Brake test timing chart Brake Test Start 1 signal STBT Brake Test Executionl Request signal RQBT 0 BRKx DCS 1 Axis by axis BRKx PMC Axis by axis Under test est sequence lt 1 gt lt 2 gt lt 3 gt lt 4 gt lt 5 gt lt 6 gt NOTE 1 Seta travel distance speed command and tolerance for position deviation to be used for a brake tes
21. Cross Spindle Motor State monitor ladder check CNC CPU Contact output Magnetic Cut command and check signal contactor Servo Excitation Off signal 2 AS2 2 46 B 64303EN 4 01 Safety function 3 SAFETY FUNCTIONS When the protective door is open the safety function monitors whether the power to the servo motor is turned off without turning off the magnetic contactor connected to the power supply or the input power supply of the main circuit of the servo amplifier If an error is detected during monitoring the magnetic contactor of the power supply 15 turned off to turn off the power to the main circuit 3 19 1 Monitoring of the Excitation Off Signal Assign the two Excitation Off signals AS2 1 and AS2 2 output from the SV as Programmable Safety I O signals to check signal matching Moreover monitor whether the excitation on and excitation off states are normal by using two types of ladders namely PMC ladder and DCS PMC ladder If an error is detected secure safety by turning off the magnetic contactor of the ai PS to turn off the power to the main circuit When additionally using a function for rotating the servo axis by power with the door open assign the two switch signals SVENI and SVEN2 output from the servo axis rotation enable switch as Programmable Safety I O signals to check signal matchin
22. MCF to 1 Test Mode signal input OPT lt PMC Gn191 2 gt for each machine group When this signal is input MCC off Test is carried out MCC off Test checks whether the contact of the MCC is abnormally closed or not MCC Off Test Execution Request signal RQT notifies that MCC off Test should be executed Input this signal while servo ready signal SA is set to 1 When MCC off Test is carried out by manual operation input this signal after preparing to carry out MCC off Test by PMC 89 5 SIGNALS Classification Function Operation B 64303EN 4 01 Input signal Single signal This signal notifies CNC to enter MCC off Test mode 0 Not enter MCC off Test mode 1 Enter MCC off Test mode Test Mode signal OPT through I O Link 3 PROFIBUS DP is not provided When this signal OPT is set to 1 CNC turns on off MCC in various combinations with MCC Off signals MCF PMC MCF DCS PMC And CNC checks whether MCC Contact State signals SMC PMC SMC DCS PMC are input in proper combination corresponding to the combination with MCC Off signals However MCC off Test should not be carried out in case of emergency stop state servo alarm state or spindle alarm state If MCC off Test is not completed within the time specified by the parameter No 1946 a servo alarm SV0488 occurs N CAUTION While MCC off Test is being carried out do not turn Test Mode signal OPT to 0 The MCC sha
23. Parameter input Bit spindle Each safety check of Dual Check Safety function for the specified spindle is 0 carried out 1 not carried out Set 1 to this bit for the spindle that is not required to apply Dual Check Safety NOTE When these parameters are set the power must be turned off before operation is continued Parameter input Word spindle min 0 to 32767 Set a safe speed for each spindle in terms of motor speed In case Dual Check Safety function is activated CNC and Spindle always check the speed of each spindle motor When it is detected that revolution speed of spindle exceeds safety speed limit Monitoring Result signal RSPs is set to 0 Moreover if the safety check is carried out Safety Check Request signal VLDPs 0 an alarm SP0757 CNC side or SP9069 Spindle side occurs Safety Speed can be set up to 4 data Which speed should be selected is decided by Safety Speed Selection signal SPAs SPBs Please refer more detail to the description about Safety Speed Safety Position Selection signal 127 6 PARAMETERS B 64303EN 4 01 7 6 5 4 3 2 1 0 ae al nus Input type Parameter input Data type spindle 1 CTLSTP When the safe speed over alarm is detected 0 Performs a free running stop 1 Performs a controlled stop When the motor speed is reduced to the zero speed detection signal SST level or less excitation is turned off 4448 Stop
24. and then the power is shut off N CAUTION To enable the function to slow down and stop the servo motor the corresponding parameter must be specified If the parameter is not specified the motor immediately enters the dynamic brake stop state The spindle motor slows down and stops as instructed by the PMC Ladder program If the PMC does not instruct this the motor maintains the high speed prior to the power down and coasts If an illegal speed is specified because of a failure on the PMC side while the safety function is active the protective door is open the CNC enters the safe stop state N WARNING In the emergency stop state the processing to open or close the protective door depends on the Ladder program created by the machine tool builder For example when the protective door is prohibited from being opened in the emergency stop state when for example the spindle rotates at a speed not allowed in situations where the protective door is open that is a speed exceeding the safe speed limit the processing needs to be implemented by the ladder program IMPORTANT Emergency Stop Button must fulfill the Standard IEC60947 5 1 This is mandatory 29 3 SAFETY FUNCTIONS B 64303EN 4 01 3 6 SAFE SPEED MONITORING If the safe speed range is exceeded while the protective door is open the Dual Check Safety function immediately enters the stop state If each axis or spindle is not stopped the Dual Check Safety fu
25. hejo 7 o ep cu s a s sjem 10 20 5V 7 Connection between the I O Link branching adapter for three channels and each channel The connection between the I O Link branching adapter for three channels and each channel is the same as that for the conventional FANUC I O Link However keep the following in mind Connector JD44A 1 outputs I O Link channel 1 and channel 2 signals and connector JD44A 2 outputs I O Link channel 2 and channel 3 signals Connector is dedicated to I O Link channel 3 1 When the FANUC I O Link is branched to three channels normal I O cables are used for JD44A 1 JD44A 2 and JD1A Channel 1 corresponds to JD44A 1 channel 2 corresponds to JD44A 2 and channel 3 corresponds to JDIA 2 When channels 1 and 2 are extended together the I O Link branching adapter A20B 1007 0680 must be connected to JD44A 1 to branch channel 1 and channel 2 at the end of the adapter is used as channel 3 JD44A 2 is not used 3 When channels 2 and 3 are extended together the I O Link branching adapter A20B 1007 0680 must be connected to JD44A 2 to branch to channel 2 and channel 3 at the end of the adapter JD44A 1 is used as channel 1 JDIA is not used 74 B 64303EN 4 01 4 INSTALLATION 1 When three channels are branched I O Link branching adapter for three channels JD44A 1 Channel 1 JD44A 2 L H gt channel 2 J
26. 068 6117 153 al SV 40 068 6117 104 al SV 40L 068 6117 154 al SV 80 AO6B 6117 H105 al SV 80L AO6B 6117 H155 al SV 160 AO6B 6117 H106 al SV 160L AO6B 6117 H156 al SV 360 AO6B 6117 H109 al SV 4 4 AO6B 6117 H201 al SV 4 20 068 6117 203 al SV 20 20 068 6117 205 al SV 20 20L A06B 6117 H255 al SV 20 40 AO6B 6117 H206 al SV 20 40L AO6B 6117 H256 al SV 40 40 068 6117 207 al SV 40 40L 068 6117 257 al SV 40 80 A06B 6117 H208 al SV 40 80L A06B 6117 H258 al SV 80 80 068 6117 209 al SV 80 80L 068 6117 259 al SV 80 160 AO6B 6117 H210 al SV 160 160 AO6B 6117 H21 1 al SV 4 4 4 068 6117 301 al SV 20 20 20 068 6117 303 al SV 20 20 40 Detector a series Pulsecoder Module Name a1A1000 068 6117 304 Specification Number A860 2000 T3x1 Remarks a1A16000 A860 2001 T3x1 111000 A860 2005 T3x1 4 A860 0374 T3x3 164 A860 0379 T3x3 Spindle sensor 1 2 A860 2110 V001 aiM A860 2100 V001 alBZ A86L 0050 0024 x Sensor head only The specification number of the sensor unit is 860 2120 al CZ A860 2140 Tx11 A860 216x Tx1 1 232 B 64303EN 4 01 High Resolution Serial Output Circuit Modul
27. 1020 as the axis name of an axis to be subject to spindle positioning To set the servo axis number of the spindle positioning axis with parameter No 1023 use a negative value the number of a spindle to be subject to spindle positioning Switching to spindle positioning mode Positioning command Orientation is required when spindle positioning is performed for the first time after the spindle motor is used as a normal spindle or when spindle positioning is resumed after the spindle positioning is suspended Orientation is the function for stopping the spindle at a fixed position The grid shift function can be used to shift the orientation position from 0 to 360 degrees parameter No 4073 Orientation can be specified by the M code set in parameter No 4960 The direction of orientation is set in RETSV bit 4 of parameter No 4000 The position where orientation is completed is assumed as the program zero point However the coordinate system setting G92 for G code system B C or G50 for G code system A or automatic coordinate system setting bit 0 ZPR of parameter No 1201 can be used to change the program zero point There are two types of spindle positioning semi fixed angle positioning and optional angle positioning 200 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 Semi fixed angle positioning Optional angle positioning Semi fixed angle positioning is specified with an M code parameter No
28. 81 5 3 SIGNALS A csi noit 87 5 4 PROGRAMMABLE SAFETY SIGNAL 107 5 5 NOTE ON 2 PATH CONTROL T SERIES 108 5 5 1 2spath Control T Seri s rct ri cen 108 6 PARAMETERS III Sisaqa 109 6 1 OVERVIEW thet Saa a oe asia A 110 6 2 DATA TYPE 111 6 3 REPRESENTATION OF PARAMETERS 112 6 4 STANDARD PARAMETER STTING 113 6 5 PARAMETERS 25 21 89 cott tota hu 115 6 6 PROFIBUS DP PARAMETER 145 f iode iin tiet aee 147 7 1 START UP OPERATION tic toto reete rte edic teo sting eie 148 7 1 1 Acceptance Test and Report for Safety Functions 148 7 2 START UP OF THE SAFETY FUNCTION 150 7 2 1 Initial Startzup itane eR ae ESO EO eA N Rae 150 7 2 2 Series 2nd and Subsequent Machines Startup esee 152 T23 Troublesh otin t et 152 8 ALARM 153 B 64303EN 4 01 TABLE OF CONTENTS 9 DIAGNOSIS u 161 9 1 MCC OFF TEST STATUS
29. A Directives Standards and Technical Conditions for 3rd Party Servo Spindle Motors amp Encoders when Applying FANUC B 64303EN 4 01 APPENDIX GE Fanuc Dual check Safety Attachment 1 Specification of 3rd Party Spindle Encoders The GE Fanuc SPM does not include the terminating resistor like e g Siemens Depending on the sensor supply voltage and the sensor output impedance the signal amplitude varies In order to match the sensor output signals with the amplifier input requirement the terminating resistor might be necessary See table on following page for required signal specs If the terminating resistor is required place it outside the SPM MA 3rd Party ut Sensor gt Rt is defined by gt the specification of the 3rd party sensor Z Phase Signal Type B ME M2 of MZ MZ Threshold level A B Phase Signal ov Type A 2 5V ov E eee Z Z 0 Threshold level 245 A Directives Standards and Technical Conditions for 3rd Party Servo Spindle Motors amp Encoders when Applying FANUC GE Fanuc Dual check Safety A B Phase Signals Maximum Frequency APPENDIX Check Terminal Symbol Signal Amplitude MA MA MB MB PA1 and PB1 from JY2 Signal Offset Signal Amplitude Difference MA MB MB PA2 and PB2 from JY5 Phase Offset MA MA MB MB Z Phase Signal Pulse Width MZ MZ Check Termi
30. Guard lock switch RY1 RY2 RY3 Link 3 I O UNIT DCS PMC Safety relay X00m n Ladder Guard state program SGOPN Guard Lock 180 B 64303EN 4 01 10 SAMPLE SYSTEM CONFIGURATION OPERATING PRINCIPLE This section describes the operation of various guard monitoring limit switches with lock mechanism and safety relays State transition of components SGOPN SW1 SW2 SW3 RY1 RY2 RY3 VLDVx VLDPs j uate esed CLOSE CLOSE CLOSE ON ON OFF Protection door locked p a closed CLOSE CLOSE OFF ON OFF Protection door unlocked Guard opened Protection door unlocked OREN OPEN OPEN OFF GEE ON Guard opened Protection doot baked OPEN OPEN CLOSE OFF OFF ON casad CLOSE CLOSE CLOSE ON ON OFF Protection door locked In a normal operation the transition of 1 2 3 4 1 and so on is repeated detects whether RY 1 and RY2 contacts are made If an unusual event is detected SGOPN input is turned off NOTE The VLDVx and VLDPs signals monitor the state of the protective door and their states affect the Dual Check Safety function The illustrated sample system determines that the protection door is open sets VLDVx and VLDPs to 0 when the guard is unlocked When the guard open request signal ORQ is accepted CNC will negate the guard open inhibit signal Machine tool builder can create the signal to re
31. If a value not within the valid data range is set each axis is assumed to belong to the first path If the rotation tool control function based on a servo motor is enabled the servo motor used as a tool rotation axis is treated as a spindle So the path to which the tool rotation axis belongs needs to be set 1023 Servo axis number of each axis NOTE When this parameter is set the power must be turned off before operation is continued Input type Parameter input Data type Byte axis Valid data range 0 to Number of controlled axis Set the servo axis for each control axis Usually set to same number as the control axis number The control axis number is the order number that is used for setting the axis type parameters or axis type machine signals With an axis for which Cs contour control spindle positioning is to be performed set spindle number as the servo axis number Example When exercising Cs contour control on the fourth controlled axis by using the first spindle set 1 For tandem controlled axes or electronic gear box EGB controlled axes two axes need to be specified as one pair So make a setting as described below Tandem axis For a master axis set an odd 1 3 5 7 servo axis number For a slave axis to be paired set a value obtained by adding 1 to the value set for the master axis EGB axis For a slave axis set an odd 1 3 5 7 servo axis number For a dummy axis to be paired
32. The check period must be specified as a safety parameter Parameternumber Name 1945 Safe related input output signal check timer The following signals are not defined as safe related I O signals and are not duplicated The signals however are necessary for the system e Input signal for making a protective door open request e Input signal for starting the test mode e Output signal for requesting a MCC off Test 19 3 SAFETY FUNCTIONS B 64303EN 4 01 This section briefly describes the signals For details see Chapter 5 SIGNALS For specific connections see the sample system configuration in Chapter 10 SAMPLE SYSTEM CONFIGURATION Machine l O LINK or PROFIBUS DP CNC Note3 4 DCS PMC Note1 LINK Dual Check Safety PMC DCS PMC For the PMC refer to PMC PROGRAMMING MANUAL B 64393EN When Link and PROFIBUS DP are connected to DCS PMC at the same time the X Y signals cannot be allocated to PROFIBUS DP Please activate Broken wire detection of the slave which connect with PROFIBUS network as Safety related I O As for detail please refer to Section 6 6 PROFIBUS DP parameter settings A CAUTION Ladder functional instruction MOVB MOVD and MOVW cannot be used with ladder for Dual Check Safety PMC Use MOVN instead of them IMPORTANT Some signals related to the Dual Check Safety function are set for each machine group With the FS0i D the number of mach
33. is awaited before starting the next test 66 B 64303EN 4 01 3 SAFETY FUNCTIONS Brake test timing chart Next test Valid Torque limit Invalid BRKx 1 PMC DCS PMC command Command Distance speed Cancel Command POSNo command command command Monitored Error monitor Not monitored 3 21 4 Suspension and Restart of Brake Test Suspension based on STBT 0 A brake test is suspended by setting the Brake Test Start signal STBT to 0 during the test When the signal is set to 0 the test sequence being executed is suspended and the Safety Brake signal BRKx and torque limit are returned to the original states Suspension based on an emergency stop or servo alarm If a brake test is suspended for an emergency stop or servo alarm the brake test is forcibly terminated even during a test sequence and operation for returning the Safety Brake signal BRKx and torque limit to the original states is performed after reset based excitation During a brake test ensure that brake control is exercised by monitoring the Servo Ready signal SA Fn000 6 as well as the Safety Brake signal BRKx Suspension based on a reset or mode switching If a brake test is suspended for a reset or mode switching the test sequence under execution is suspended However operation for returning the Safety Brake signal BRKx and torque limit to the original states 1s not performed The test is restarted by setting the Brake Test Star
34. two independent CPUs individually check the input signals If a mismatch between two corresponding signals is found the system enters the safe stop state The following safe related I O signals are monitored or output in redundant mode e Emergency stop input signal e Protective door state input signal Request to monitor for each axis e Input signal for selecting safety speed monitoring and safety position monitoring Input signal for monitoring the MCC contact state Output signal for turning off the MCC power down Output signal for position switch Output signal for brake control User defined safe related I O signals In order to setup double monitoring system machine tool builder must connect safety signals to both I O Link 1 2 and Link 3 PROFIBUS DP IMPORTANT If the safety input signals except for Emergency Stop input signals are connected to the I O module a Ladder program must be created to establish a one to one relationship between the actual input X and the input to the CNC G The duplicated signals are always checked for a mismatch regardless of whether the safety function is active or not When a signal state changes the pair of signals may not match for some period because of a difference in response The Dual Check Safety function checks whether a mismatch between the two signals continues for a certain period of time so that an error resulting from the difference in response can be avoided
35. 1 0 ath axis 3rd axis 2nd axis tst axis 7 6 5 4 3 2 1 0 th axis ath axis rd axis 2nd axis tst axis DCS PMC m k 1 x 20 7 6 5 4 3 2 1 0 sth axis ath axis axis 2nd axis tet axis 7 6 5 4 3 2 1 0 L sth ants ath axis axis 2nd axis tst axis 86 B 64303EN 4 01 5 3 SIGNALS Emergency Stop signal input 5 SIGNALS ESP lt X0008 4 gt lt DCS PMC X0008 4 gt for each machine group ESP lt PMC Gn008 4 gt lt DCS PMC G019 m 4 gt for each path Classification Function Operation This is Emergency Stop signal The Emergency Stop signal must be connected to the Emergency Stop input of the amplifier Input signal Dual signal Stops machine movement immediately in an emergency 0 Emergency stop state 1 Normal state When Emergency Stop signal ESP is set to 0 the CNC is reset and the system enters emergency stop state machine tool builder must output a signal to shut off directly the MCC when MCC Off signal is set to 0 In emergency stop state a machine tool builder must check MCC Contact State signal SMC If SMC signal is 0 MCC is on a machine tool builder must not release the guard lock signal of protective door In general Emergency Stop signal ESP is specified by the pushbutton switch B contact When an emergency stop occurs the
36. 2 Servo off signal SVF1 to 5 Gn126 0 to 4 MCC Off Test Execution Request signal During the MCC off Test Fn191 2 Power failure backup module ready signal Contact on RDY contact output Contact off 36 B 64303EN 4 01 3 SAFETY FUNCTIONS 3 9 SAFETY POSITION SWITCH FUNCTION It is checked whether the machine position is within the range of safety position switch The checked result is outputted to the Safety Position Switch signal The correspondence between axes and each signal is specified by the parameters In case of 1 path system up to 32 points can be specified In the case of a 2 path system based on the T series up to 64 points can be set When a machine position of controlled axis is within a range which is specified by the safety parameters this signal is output Parameter Parameter setting value setting value The signals are output after establishment of the reference position The signal is not output before the completion of return to reference position The machine position is the actual machine position which is calculated using feedback of position detector not the commanded position The comparison of position for safe position switch is executed in detection unit If the machine position equals parameter setting value the safe position switch signal is output The safe position switch signal is not output for axis which the Dual Check Safety bit 6 DCN of pa
37. 4 01 SPINDLE 9 DIAGNOSIS The data that are related to the safety limitation feed of the spindle and the Dual Check Safety function are displayed PAGE Press the page key 1 the screen of the Safety limitation feed of the spindle shown below appears pa Ps ja The following items a to d are displayed for every spindle axis 0 Not Monitoring 1 Monitoring b FEED LMT In the Safety feed limit 1 to 4 Set by the parameter No 4372 4438 4442 to 4444 the safety limit feed that is selected by the Safety speed Safety Position Selection signal A B SPAx SPBx is displayed c UNIT Unit of the feed d ACT FEED Current actual feed rate NC side and Spindle side 169 9 DIAGNOSIS B 64303EN 4 01 9 5 SAFE MACHINE POSITIONING MONITORING SCREEN The data that are related to the safe machine positioning monitoring of the Dual Check Safety function are displayed Press the MCHN POS soft key The screen shown below appears UI J TRI The following items a to c are displayed for every servo axis a MNT b RANGE c MCHN POS 170 0 Not Monitoring 1 Monitoring The reference position 15 not established In the safety machine position 1 to 4 Set by the parameter No 13830 to 13838 the upper limit value and lower limit value of the safety machine position that are selected by the Safety speed Safety Position Sele
38. 4 1 OVERALL CONNECTION DIAGRAM In case of using the 2 channel I O link CNC Main board 3ch Link branching I O LINK JD51A adapter JD51B LINK 1 2 0 L JD44A 1 general I O safety related I O Manual pulse Distribution type generator board LINK 3 E pane Safety related l O UNIT etc CPD1 JD1B Power magnetic JDIA cabinet UNIT etc Power magnetic cabinet Above shows only the 2 channel I O link for the safety related I Os of the Dual Check Safety Function As for the other connections please refer to the Connection manual 4 INSTALLATION B 64303EN 4 01 Using the third channel The Dual Check Safety system use 1 Link channel 3 When using channel 3 use the 1 Link branching adapter for three channels to branch the FANUC Link Link branching adapter for three channels Link channel 1 and JD51A 01 41 JD51B JD44A 1 gt channel 2 Link channel 2 and JDA4A2 channel 3 JD1A gt vo Link channel The connection after the I O Link branching adapter for three channels is the same as that for the conventional FANUC Link Link branching adapter for three channels A20B 1008 0360 4 B 64303EN 4 01 4 INSTALLATION Connection between the CNC and I O Link branching adapter for three channels VO Link branching adapter for three channels JD51A JD51B such as PC
39. 4960 Six values Mx to M x 5 can be specified and x needs to be set in parameter No 4962 in advance By specifying the number n of used M codes in parameter No 4964 any of the values from Mx to M x n 1 not exceeding M x 255 1 255 ways can be specified The positioning angles corresponding to the values are shown in the table below The value of base rotation angle y is set in parameter No 4963 The rotation direction is set in bit 1 IDM of parameter No 4950 Incremental specification is always assumed Example y 30deg y 30 deg 2y 60 deg 90 deg 4y 120 deg 5y 150 deg 6y 180 deg Indexing angle ny 30 x n deg Optional angle positioning is specified by an axis angle followed by a signed value Use the G00 mode to specify this positioning Example C 1000 The minimum setting unit is 0 001 degrees and the allowable specification range is between 999999 999 degrees and 999999 999 degrees A command with a decimal point is also allowed The position of the decimal point denotes the degree position Example C35 0 C35 deg Feedrate and acceleration deceleration type Spindle positioning reset The feedrate used in positioning is the rapid traverse rate set in parameter No 1420 An override of 100 50 25 or FO parameter No 1421 can be applied to the rapid traverse rate Liner acceleration deceleration is used as the acceleration deceleration type Switching fr
40. 6 to 9999999 Two methods are available for specifying spindle positioning One method uses axis address for arbitrary angle positioning The other use an M code for half fixed angle positioning This parameter sets an M code for the latter method In this parameter set an M code to be used for half fixed angle positioning based on M codes Six M code from Ma to M a 5 are used for half fixed angle positioning when a is the value of this parameter e When the number of M codes is set in parameter No 4964 let a be the value set in parameter No 4962 and let be the value set in parameter No 4964 Then M codes from Ma to M a f 1 are used as M codes for half fixed angle positioning based on M codes The table below indicates the relationship between the M codes and positioning angles Example Positioning angle Positioning angle when 30 p represents the number of M codes set in parameter No 4964 When parameter No 4964 is set to 0 B 6 0 represents the basic angular displacement set in parameter No 4963 NOTE 1 Do not set an M code that duplicates other M codes used for spindle positioning 2 Do not set an M code used with other functions such as M00 05 30 98 and 99 and M codes for calling 209 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 Basic angle for half fixed angle positioning Input type Data type Unit of data Minimum unit of data Valid
41. C243 Key with both symbol and English indicated Three point pressing supported Machine operator s panel Sub panel A A02B 0236 C232 Machine operator s panel Sub panel B A02B 0236 C233 Machine operator s panel Sub panel B1 A02B 0236 C235 Machine operator s panel Sub panel C A02B 0236 C234 Machine operator s panel Sub panel C1 A02B 0236 C236 Small Machine operator s panel A02B 0299 C152 M T 227 12 COMPONENTS LIST Description Small Machine operator s panel B Specification Number A02B 0309 C151 M T B 64303EN 4 01 Remarks Operator s panel connection unit source DO A A16B 2202 0731 DI DO 64 32 Operator s panel connection unit source DO B A16B 2202 0730 DI DO 96 64 Handy machine operator s panel Interface unit for Handy machine operator s panel A02B 0259 C221 A A02B 0259 C220 FANUC LINK connection unit A A20B 2000 0410 Electrical Optical I F FANUC LINK connection unit B A20B 2000 041 1 Electrical Electrical I F FANUC LINK connection unit A20B 2000 0412 Optical Optical FANUC Link AS i converter for AS I Ver 2 0 0817 001 Link AS i converter for 5 2 1 A03B 0817 C002 42 I O Link signal divider 2ch A20B 1007 0680 43 I O Link signal divider 3ch A20B 1008 0360 44 l O unit base module ABU10A A03B 0
42. EXOF2 G F User ladder Timing chart provided in the next section User ladder Timing chart provided in the next section B 64303EN 4 01 Gn191 3 ORQ Gn751 0_ VLDPs Gn754 0_ SPAs RSPs ESPA Fn751 0 Gn071 1 Safety I O Fn047 4 EXOFA EXOF1 Rxxx b SPEN1 lt 18 Rxxx c channel error G 003 m 0 VLDPs G 006 m 0 SPAs Programmable Safety Ryyya EXOF2 56 Ryyy b SPEN2 lt Ryyyd 2 channel error B 64303EN 4 01 3 SAFETY FUNCTIONS 3 20 2 User Ladder Processing Processing on the PMC side Timing chart 1 With the Guard Open Request signal ORQ the spindle is stopped then the excitation off state EXOF 1 is confirmed Next the locking of the protective door guard lock signal is released If EXOF1 0 or EXOF2 0 contact open servo excitation on for a certain time 1 when SGOPN 15 0 door open and SPEN Is 0 Spindle Rotation Enable Switch signal turned off an error is assumed to issue 1st channel or 2nd channel alarm Error judgment processing by the PMC side ladder Spindle being rotated Protective door open Protective door closed ORQ ESPA MRDYA EXOF1 excitation on pez I I lt Error state 1 Tet Guard Unlock signal SGOPN Protective Door Open State signal SPEN1 1 t channel error Set to 0 if normal O points are monitored
43. PMC F 003 m to x DCS PMC 14 ROT MCC Off Test Execution Request signal lt Fn191 2 gt PMC Output Servo F 0184m 0 to 4 gt DCS PMC 2 3 SAFETY FUNCTIONS B 64303EN 4 01 Safe related I O 1 ESP Emergency Stop signal input This signal is Emergency Stop signal and is monitored in redundant mode The signal is connected to the ESP input of the servo amplifier as well 2 SGOPN Guard State signal Machine side input signal The signal is provided for double monitoring of the protective door state The signal is connected so that it is normally set to 1 while the protective door is closed and locked door closed and set to 0 otherwise door opened These states are implemented by the combination of the safety door and safety relays The PMC ladder for safety check must check the state of axes by asserting the Safety Request signal when a protective door is open 3 VLDVx VLDPs Safety Check Request signal input These signals are monitored in redundant mode These signals request safety check when a protective door is open These signals are prepared for each axis and each spindle CNC monitors these signals If safe speed range of a servo motor is exceeded in the door open state the system enters the controlled stop state If an axis 15 still not stopped the system enters the safe stop state If safe speed range of a spindle motor is exceeded in the door open state the spindle moto
44. Programming in ladder logic should be referred to PMC programming manual B 64393EN Training FANUC Training Center provides versatile training course for the person who is concerned with hardware installation maintenance and operation FANUC recommend studying and learning in the training center how efficiently operate FANUC products There are 3 CNC training course CNC ELEMENTARY COURSE Provides basics of CNC functions operation and programming The course is recommended before taking more specialized training courses to gain best effects MAIN ITEMS OF TRAINING CNC functions Configuration of CNC Configuration and function of servo system Basic programming of CNC Part programming of milling machine Part programming of turning machine Introduction of Custom Macro function More information and course registration Yamanakako mura Yamanashi Prefecture 401 0501 JAPAN Phone 81 555 84 6030 Fax 81 555 84 5540 Internet www fanuc co jp eschool 10 B 64303EN 4 01 2 SYSTEM CONFIGURATION SYSTEM CONFIGURATION The Dual Check Safety function has the following components Applicable CNC FANUC Series 01 D Amplifier Motor and For details on applicable amplifiers motors and 1 units see Chapter 12 COMPONENTS LIST NOTE The servo amplifiers and servo motors connected to the CNC via the I O link interface do not support the Dual Check Safety function 11 3 SA
45. SIGNALS B 64303EN 4 01 7 6 5 4 3 2 1 0 rer opm 7 6 5 4 3 2 1 0 mue mer 7 6 5 4 3 2 1 0 pae We cm p 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 Fn751 RSP2 RSP1 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 sks BRK4 BRK3 BRK2 3 4 2 755 spsos spso7 spsos spsos spso4 spsos 502 5 0 4 3 2 1 0 756 SPS16 SPSi5 SPS13 spsi2 spst1 spsto spso9_ 4 2 4 2 4 2 7 7 7 3 0 7 7 6 1 6 6 1 757 spsza sPS23 sps22 SPS21 SPS20 8 519 spsiz_ 6 1 6 1 0 3 0 58 SPS32 spsat 3530 SPS29 2528 spsz7 SPS26 sps2s_ 3 0 rues roses poses poses POSE2 pose 5 5 5 5 5 HE 82 B 64303EN 4 01 5 l O SIGNALS Via I O Link 3 or PROFIBUS DP DCS PMC m 0 20 NC path number 1 x 20 7 6 5 4 3 2 1 0 xoos _ 7 6 5 4 3 2 1 0 sel I 7 6 5 4 3 2 1 0 G001 m 7 6 5 4 3 2 1 0 vtpva viov vtpv 7 6 5 4 3 2 1 0 o 1 _ 7 6 5 4 3 2 1 0 G004 m SVA5 SVA4 SVA3
46. SP The checking sequence is as follows Checking sequence for servo amplifier lt 1 gt When a servo amplifier is set up at the first time an alarm SV0498 is generated At that time the CNC transfers the CNC axis numbers to the SV and the SV keeps the data Then the power of all CNC system amplifiers are included must be turned off and on When an alarm is generated after the configuration of servo amplifiers is changed it is necessary to carry out the operation to send the CNC axis numbers to servo amplifiers Set the parameter No 2212 4 to 1 then return to 0 Then turned off the power of all CNC system amplifiers are included lt 2 gt After the power on the CNC and the SV start monitoring the CNC axis numbers The CNC monitors by comparing the CNC axis number kept by the CNC itself with that kept by the SV The SV monitors by comparing the CNC axis numbers kept by the SV with that sent by the CNC When some error is found an alarm SV0478 or SV0496 is output and MCC Off signal DCALM is turned to 0 Checking sequence for spindle amplifier lt 1 gt When spindle is set up the spindle numbers are transferred from the SP to the CNC lt 2 gt The CNC compares the spindle numbers kept by the CNC itself with that sent from spindle amplifier If inconsistency is found an alarm SP0756 is output and MCC Off signal DCALM is turned to 0 lt 3 gt The SP compares the spindle numbers with that kept by the
47. SVA2 SVA1 7 6 5 4 3 2 1 0 sves svea sves 2 7 6 5 4 3 2 1 0 coossm _ spea sesa _ sa2 spat 7 6 5 4 3 2 1 0 Gm k j 7 6 5 4 3 2 1 0 coem T T p T T T 6 5 4 3 2 1 _ ese 83 5 l O SIGNALS B 64303EN 4 01 F000 m 7 6 5 4 3 2 1 0 url 7 6 5 4 3 2 1 0 F001 m 7 6 5 4 3 2 1 0 avs rsv rsvs Rsv2 asv F002 m 7 6 5 4 3 2 1 0 o ns 7 6 5 4 3 2 1 0 MCFV5 MCFV4 MCFV3 MCFV2 MCFV1 F003 m F004 m 7 6 5 4 3 2 1 0 mom wcre2 ucFPi 7 6 5 4 3 2 1 0 Fom __ BRK3 BRK BRKI F007 m SPS08 5 507 i T d 1 d d ih 1 i T F008 m SPS15 SPS13 7 6 5 4 3 2 1 0 SPS24 sps23 sps22 sPS21 spszo sPst9 SPS18 8 817 F009 m 7 6 5 4 3 2 1 0 SPS32 8 531 spszo sps29 spszs 2527 5 526 sPs2s F010 m 7 6 5 4 3 2 1 0 Poss roses poses posez poset F018 m 7 6 5 4 3 2 1 0 rom 1 1 1 1l 84 B 64303EN 4 01 5 1 0 SIGNALS NOTE The signals with a background color are cross chec
48. Valid data range Parameter input Word spindle 0 to 32767 This parameter sets the velocity loop proportional gain for spindle orientation 221 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 Velocity loop integral gain on orientation HIGH gear Velocity loop integral gain on orientation LOW gear Input type Parameter input Data type Word spindle Unit of data Valid data range 0 to 32767 This parameter sets the velocity loop integral gain for spindle orientation Gear ratio HIGH gear 4057 Gear ratio MEDIUM HIGH gear 4058 Gear ratio MEDIUM LOW gear Gear ratio LOW gear Input type Parameter input Data type Word spindle Unit of data Motor speed per spindle rotation x 100 Valid data range 0 to 32767 These parameters set the gear ration between the spindle and spindle motor 4060 Position gain on orientation HIGH gear Position gain on orientation MEDIUM HIGH gear Position gain on orientation MEDIUM LOW gear Position gain on orientation LOW gear Input type Parameter input Data type Word spindle Unit of data 0 01 sec Valid data range 0 to 32767 These parameters set the position gain for orientation 4064 Modification rate of position gain on orientation completion Input type Parameter input Data type Word spindle Unit of data 1 Valid data range 0 to 1000 This data is used to set the modification rate of position gain on spindle orientation co
49. When emergency stop 15 released ESP signal is 1 MCC can be enabled MCF signal is 1 After that when MCC is turned on Safety Brake signal BRKx is turned to 1 after the time specified by the parameter No 1950 is elapsed 1 ESP 0 1 MCF 0 1 MCC 0 1 Timer for brake signal BRKx 555 NOTE Regular maintenance of a brake must be done 101 5 SIGNALS B 64303EN 4 01 Safety Position Switch signal output SPS1 to SPS32 lt PMC Fn755 to Fn758 gt lt DCS PMC F 007 m to F 010 m gt Classification Function Output condition Note This signal shows whether the machine position of a servo axis 15 within the range specified by the parameter or not Output signal Dual signal This signal notifies that the machine position of the axis specified by the safety parameter No 13880 to No 13911 is within the range specified by the safety parameter No 13920 to No 13951 No 13960 to No 13991 In case of single path system up to 32 points can be used When a two path system is used with the T series 32 points in the area for the second path can be additionally used Then up to 64 points can be used at maximum This signal notifies that the machine position of the axis specified by the safety parameter No 10501 to No 10532 is within the range specified by the safety parameter No 10533 to No 10564 No 10565 to 10596 NOTE In a two path system 64 points of sa
50. a value of less than 0 is specified it is assumed that 10000 ms is specified NOTE All paths are checked using the setting of this parameter 1948 MCC off timer NOTE When this parameter is set the power must be turned off before operation is continued Input type Parameter input Data type Word machine group Unit of data msec Valid data range 0 to 32767 e CNC CPU and PMC CPU set MCC Off signal MCFVx to 0 when an axis is not stopped within the time set by this parameter after Safe Speed Monitoring or Safe Machine Position Monitoring function of Dual Check Safety function detects abnormal condition e When there is no spindle spindle for which VLDPs 1 is set not being monitored for its safety MCC Off signal MCF for each machine group is set to 0 upon elapse of the time set in this parameter after an emergency stop is made e When a crosscheck alarm CPU self diagnosis alarm occurs MCC Off signal DCALM one for each system 15 set to 0 upon elapse of the time set in this parameter If a crosscheck alarm or CPU self diagnosis alarm related to the spindle occurs however the time set in this parameter takes no effect NOTE All paths are checked using the setting of this parameter 123 6 PARAMETERS B 64303EN 4 01 1950 Brake signal timer Input type Data type Unit of data Valid data range NOTE When this parameter is set the power must be turned off before o
51. at every sampling period When the minimum and maximum limit of position switch are given like above figure activated area is checked by the area shown in the upper figure above considering hysteresis if the state of position switch measured at last time is 0 And activated area is checked by the area shown in the lower figure above not considering hysteresis if the state of position switch measured at last time is 1 According to this it is possible to suppress frequent changing of position switch 130 B 64303EN 4 01 6 PARAMETERS When these parameters are set the power must be turned off before operation is continued Input type Parameter input Data type Real axis Unit of data mm min inch min degree min machine unit Minimum unit of data Depend on the increment system of the applied axis Valid data range Refer to the standard parameter setting table C When the increment system is IS B 0 0 to 240000 0 Set a safety speed for each axis in position control CNC and Servo always check the velocity command of each axis in Dual Check Safety function If an axis for which a speed higher than the safety speed is specified is detected the Monitoring Result signal RSVx is set to 0 Moreover if Safety Check request signal VLDVx is set to 0 an alarm SV0476 or SV0494 is generated for the corresponding axis A safety speed parameter for each axis in feed control is from No 13826 to No 13829 Up to 4 safety
52. boundary of the specified ranges machine position parameter setting value it is considered within the specified ranges When the setting of operation range is maximum operation range lt minimum operation range the safe position switch is not output If parameter No 13920 to No 13951 No 13533 to No 13564 are changed please turn the power of the machine off once 141 6 PARAMETERS Unit of data Minimum unit of data Valid data range B 64303EN 4 01 Minimum operation range of the 1st safe position switch Minimum operation range of the 32nd safe position switch Minimum operation range of the 33rd safe position switch Minimum operation range of the 64th safe position switch NOTE When these parameters are set the power must be turned off before operation is continued Parameter input Real mm inch degree machine unit Depend on the increment system of the reference axis 9 digits of minimum unit of data Refer to standard parameter setting table A But in case that CMR gt 1 data range becomes 1 CMR of 9 digits of minimum unit of data When the increment system is IS B and CMR 1 999999 999 to 999999 999 When increment system is IS B CMR 2 499999 999 to 499999 999 Whether to specify this parameter by using diameter value or radius value depends on whether the corresponding axis is based on diameter specification or radius specification These paramete
53. cable may be defective or there may be an error in connection to the amplifier or another module Check the optical cable and the connection status SV5197 FSSB OPEN TIME OUT The CNC permitted the opening of the FSSB but the FSSB is not opened Check the connection between the CNC and amplifier Spindle Alarms to turn MCC off Signal MCFPs to 0 In case that the parameter No 10500 1 is set to 0 the MCC off Signal MCFPs of an alarm spindle is turned to 0 immediately when the alarm related to data communication or detector occurs The following table shows this kind of spindle alarm Number Message escription SP1220 NO SPINDLE AMP Either the cable connected to a serial spindle amplifier is broken or the serial spindle amplifier is not connected pec ENT CRC error communications error occurred in communications between the CNC and the serial spindle amplifier SPINDLE the serial spindle amplifier SPINDLE the serial spindle amplifier SPINDLE spindle amplifier SP1229 COMMUNICATION ERROR SERIAL communications error occurred between serial spindle amplifiers SPINDLE AMP motor Nos 1 and 2 or motor Nos 3 4 SP1245 COMMUNICATION DATA ERROR A communication data error was detected on the CNC SP1246 COMMUNICATION DATA ERROR A communication data error was detected on the CNC SP1247 COMMUNICATION DATA ERROR A communication data error was detected on the CNC S
54. case repeat the operation on the axis for which the alarm persists until it is cleared In the other case replace the servo amplifier where the alarm occurred SV0498 AXIS NUMBER NOT SET CNC The CNC detected that the axis number is not set with the servo amplifier Turn off the power to the entire system Then an axis number is automatically set SV1068 DUAL CHECK SAFETY ALARM The alarm which shut off the MCC system common occurred in the Dual Check Safety function V1069 EXCESS ERROR SERVO OFF The CNC detected that the positional deviation at servo off time exceeded CNC the parameter No 1840 setting value The Servo detected that the positional deviation at servo off time exceeded OFF SV DSP the parameter No 1840 setting value The CNC detected that the positional deviation during moving exceeded the parameter No 1838 No 1841 setting value Dual Check Safety The CNC detected that the positional deviation during stopping exceeded the parameter No 1839 No 1842 setting value Spindle Alarms SP alarm No Message J Description SP0755 SAFETY FUNCTION ERROR The CNC CPU detected that the safety function of the n th spindle was not executed Alternatively the result of CNC safety function checking did not match the result of spindle safety function checking SP0756 ILLEGAL AXIS DATA The CNC CPU detected that the connection state and the hardware setting of the spindle amplifier were incompatible on the n
55. check level NOTE When this parameter is set the power must be turned off before operation is continued Input type Parameter input Data type Word spindle Unit of data min Valid data range 0 to 32767 When the speed of the spindle motor is reduced to the speed specified by this parameter or less during free running or controlled stop operation due to the safe speed over alarm the motor is assumed to have stopped The setting value must be lower than the parameter Safe Speed for each spindle 7 6 5 4 3 2 1 0 jas NOTE When least one of these parameters is set the power must be turned off before operation is continued Input type Parameter input Data type Bit path 0 AVM Incase that a servo alarm occurs 0 MCC off signal MCFVXx is turned to 0 when some alarm occurs 1 MCC off signal MCFVx is turned to 0 when any alarm occurs In case that this parameter is set to 1 MCC off signal MCF Vx of all axes which belong to the same path as the alarm axis are turned to 0 when a servo alarm occurs 128 B 64303EN 4 01 1 APM 3 STP 6 PARAMETERS In case that a spindle alarm SPxxxx occurs 0 MCC off signal MCFPs is turned to 0 when some alarm occurs 1 MCC off signal MCFPs is turned to 0 when any alarm occurs In case that this parameter is set to 1 MCC off signal MCFPs of all spindles w
56. data range Parameter input Real spindle Degree Depend on the increment system of the applied axis 0 to 60 This parameter sets a basic angular displacement used for half fixed angle positioning using M codes 4964 Number of M codes for specifying a spindle positioning angle Input type Data type Valid data range Parameter input 2 word spindle 0 to 255 This parameter sets the number of M codes used for Half fixed angle positioning using M codes As many M codes as the number specified in this parameter starting with the M code specified in parameter No 4962 are used to specify half fixed angle positioning Let a be the value of parameter No 4962 and let B be the value of parameter No 4964 That is M codes from Ma to M a f 1 are used for half fixed angle positioning Setting this parameter to 0 has the same effect as setting 6 That is M code from Ma to 0 5 are used for half fixed angle positioning NOTE 1 Make sure that M codes from Ma to M 1 do not duplicate other M codes 2 Do not set an M code that duplicates other M codes used for spindle positioning Do not set an M code used with other functions such as M00 05 30 98 and 99 and M codes for calling subprograms 210 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 11 5 Cs CONTOUR CONTROL 11 5 1 Overview The Dual Check Safety function uses the CNC CPU and spindle DSP to separately monitor the spindle moto
57. each controlled axis Spindle type indicates that parameters are available for the maximum number of spindles and independent data can be set for each spindle The valid data range for each data type indicates a general range The range varies according to the parameters For the valid data range of a specific parameter see the explanation of the parameter 111 6 PARAMETERS B 64303EN 4 01 6 3 REPRESENTATION OF PARAMETERS Parameters of the bit type bit machine group type bit path type bit axis type and bit spindle type 7 6 5 4 3 2 1 0 tse A F M Data No Data Data 0 to 7 are bit positions Parameters other than the bit type parameters above n Mm Fh Data No Data NOTE 1 The parameters which are described here are related directly to Dual Check Safety function As for the other parameters please refer to the parameter manual B 64310EN A parameter usable for only one of the lathe system T series and machining center system M series is indicated using two rows as shown below When a row is blank the parameter is not usable with the corresponding series Basically set those parameters to O Example 1 Parameter HTG is a parameter common to the M and T series but Parameters RTV and ROC are parameters valid only for the T series 7 6 5 4 3 2 1 0 mv aef series Example 2 The following parameter is pro
58. function 13837 Safety machine position 4 for each axis direction 13838 Safety machine position 4 for each axis direction NOTE u lt o em ec 2 ct ga When these parameters are set the power must be turned off before operation is continued Input type Parameter input Data type Real axis Unit of data mm inch degree machine unit Minimum unit of data Depend on the increment system of the applied axis Valid data range 9 digits of minimum unit of data Refer to standard parameter setting table A But in case that CMR gt 1 data range becomes 1 CMR of 9 digits of minimum unit of data When the increment system is IS B and CMR 1 999999 999 to 999999 999 When the increment system is 15 and CMR 2 499999 999 to 499999 999 133 6 PARAMETERS B 64303EN 4 01 NOTE Whether to specify this parameter by using a diameter value or radius value depends on whether the corresponding axis is based on diameter specification or radius specification Set a safe machine position for each axis CNC and Servo always check the machine position on each axis Dual Check Safety function If the machine position is out of the safety machine range even on one axis Monitoring Result signal RSVx corresponding to that axis is set to 0 Moreover if Safety Check request signal VLDVx is set to 0 an alarm SV0477 or SV0495 is generated for the correspondin
59. i Output Signal 2 Output Signal 8 Link 3 Link 1 or or PROFIBUS DP Link 2 Operation The combinations of cross checking these signals are defined by using Safety parameters as follows Signal type Combination No CNC DCS PMC PMC PMC No 11950 No 11970 No 11951 No 11971 No 11952 No 11972 No 11953 No 11973 No 11954 No 11974 11955 11975 11956 11976 11957 11977 11960 11980 11961 11981 11962 11982 11963 11983 11964 11984 11965 11985 11966 11986 11967 11987 Output 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 105 5 SIGNALS B 64303EN 4 01 Brake Test Start signal input STBT lt PMC Gn193 2 gt for each machine group Classification Function Input signal Single signal Input signal for starting and suspending a brake test When this signal is switched from 0 to 1 a brake test is started Upon normal completion of brake test the Brake Test Execution Request signal RQBT 15 set to 0 So upon confirmation of RQBT set to 0 this signal 15 also switched from 1 to 0 If this signal is switched from 1 to 0 during a brake test the brake test is suspended upon completion of the test sequence currently under execution A brake test can be restarted from the be
60. lowest deceleration speed is selected External deceleration settings 2 and 3 can be disabled by the parameters EX2 and EX3 Since the Dual Check Safety function monitors the safe speed for both rapid traverse and cutting feed the external deceleration speed of the cutting feed must be set according to the axis having the lowest safe speed External deceleration signal JOG feed Manual handle feed For safety external deceleration is enabled when the external deceleration speed signal is 0 and disabled when the signal is 1 Two signals in the positive and negative directions are provided for each axis to select a deceleration direction For manual handle feed however when either the signal in the positive direction or the signal in the negative direction is 0 external decelerations in both directions are enabled it is impossible to select one direction For JOB feed the external deceleration speed of rapid traverse is enabled The maximum speed of manual handle freed is normally the manual rapid traverse rate but can be the maximum speed set in the parameter with the maximum speed switching signal However another speed can be selected by the external deceleration function depending on the external deceleration signal Relationships between signals and parameters External deceleration settings For cutting feed rapid traverse and JOG feed the relationships between external deceleration settings external signals and
61. parameters are shown in the table below Signal Parameter External deceleration External deceleration External valid Invalid speed deceleration Positive Negative Cutting apie signal traverse direction direction feed JOG feed Gn118 Gn120 No 1005 4 1 No 1005 5 1 No 1426 No 1427 Gn101 Gn103 No 1406 0 No 1440 1441 Gn107 Gn109 No 1406 1 No 1443 No 1444 189 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 External deceleration settings 1 To enable the external deceleration function in cutting feed both of bits 4 and 5 of parameter No 1005 need to be set to 1 In rapid traverse and JOG feed external deceleration is enabled regardless of this setting In manual handle feed the relationships between external deceleration settings external signals and parameters are shown in the table below Signal Parameter External Manual handle feed External External deceleration maximum speed deceleration deceleration signal switching signal valid Invalid speed 1 2 Gn023 3 2 No 1434 4 Gn101 Gn103 Gn023 3 3 No 1406 0 No 1442 4 Gn107 Gn109 Gn023 3 3 1406 1 No 1445 4 2 The external deceleration signal Gn118 Gn120 of external deceleration setting has no effect on the maximum speed of manual handle feed 3 In manual handle feed Gn023 3 and both of 101 and Gn103 need t
62. position control mode e Hysteresis Position switch sometimes turns on and off repeatedly near the boundary of position switch area by very small vibration of a servo motor According to this problem position switch is inconvenient to use So hysteresis described below is applied Minimum limit of Maximum limit of position switch position switch ME CIC Width of hysteresis Width of hysteresis Activated area of position switch Fig 3 9 a Measuring area of position switch in case state of switch is 0 Minimum limit of Maximum limit of position switch position switch Wet ae Activated area of position switch Fig 3 9 b Measuring area of position switch in case state of switch is 1 The position switch is checked at every sampling period When the minimum and maximum limit of position switch are given like above figure activated area is checked by the area shown in the figure 3 9 a considering hysteresis if the state of position switch measured at last time is 0 And activated area is checked by the area shown in the figure 3 9 b not considering hysteresis if the state of position switch measured at last time is 1 According to this it is possible to suppress frequent changing of position switch 38 B 64303EN 4 01 3 SAFETY FUNCTIONS 3 10 SAFETY RELATED PARAMETERS CHECK FUNCTION At every power on the CNC checks whether the safety related parameters are destroyed and are
63. protective bonding circuit is to be not less than 1 Q For further details please refer to Chapter 19 3 of IEC 60204 1 7 1 1 Acceptance Test and Report for Safety Functions Acceptance test for Safety function Acceptance report The machine tool builder is to conduct a Dual Check Safety function check test during machine start up operation In this test limits need to be exceeded to check that the Dual Check Safety function operates normally A qualified person is to check each Dual Check Safety function and record the test results in a check report NOTE When modifying Dual Check Safety function data conduct an additional check test on the modified Dual Check Safety function and record the test results in a check report Safety related I O monitoring test MCC off Test check Data cross check operation is tested with the I O device connector detached The test mode signal is used to check that a MCC off Test is conducted Negative test Conduct a MCC off Test by disconnecting the MCC contact signal input Check that an alarm is issued and the MCC remains to be shut off 148 B 64303EN 4 01 7 START UP Safety limitation speed monitoring test This test checks that when the actual speed exceeds a speed limit safety stop state is set by a stop response Safety machine position monitoring test Data modification A positional limit test is conducted by making many different movements A posit
64. remaining risks and must be documented 1 1 4 Certification Test Certification of the dual check safety function The German certification organization TUV PS has certified that the dual check safety function satisfies the safety standards 1 OVERVIEW B 64303EN 4 01 1 2 DEFINITION OF TERMS 1 2 1 General Definition of Terms Reliability and safety Reliability and safety are defined by EN292 1 as follows Reliability Capability of a machine machine component or equipment to perform its required function under a specified condition for a specified period Safety Capability of a machine to perform its function without injuring the health under a condition of use for an intended purpose specified in the operator s manual and allow its transportation installation adjustment maintenance disassembly and disposal 1 2 2 Definition of Terms Related to the Safety Function Safety related I O signal Safety related 1 signals are input output signals monitored by two systems These signals are valid for each feed axis and spindle with a built in safety function and are used with each monitoring system Example Protection door state signal Safety stop When a safety stop occurs power to the drive section is shut off The drive section can generate neither a torque nor dangerous operation The following are measures for incorporating the safety stop feature Contactor between the line and drive system line contactor Conta
65. servo ready signal SA is set to 0 If the input of the Emergency Stop signal is detected the CNC automatically specifies a command to zero the speed of a servo motor and reduces the speed to zero controlled stop See below caution After the servo motor slows down and stops the power is turned off and the servo motor is brought into the dynamic brake stop state The spindle motor is slowed down by the PMC command see below caution and the power is shut off 87 5 1 0 SIGNALS B 64303EN 4 01 N CAUTION 1 The Emergency Stop signal for DCS PMC is assigned to each machine group like the signal for PMC lt X0008 4 gt The related parameter must be set in order to perform the controlled stop of a servo motor If the parameter is not set a servo motor is stopped by dynamic brake control just after an emergency stop is detected A spindle motor is slowed down by the command PMC ladder program If the PMC does not command to slow down the spindle motor continues rotating at the speed prior to power down and runs by inertia and eventually stopping in the end When safety function is active protective door is open and abnormal speed is given due to the trouble of PMC the spindle is brought into safe stop state N WARNING A machine tool builder must make the ladder to control to open and shut protective door in emergency stop state For instance a machine tool builder must make the ladder program for procedure to inhib
66. set to 0 when Emergency Stop signal ESP 15 0 or MCC off Test 15 carried out machine tool builder makes a ladder program to output a signal to shut off MCC when this signal is turned to 0 Output signal This signal output to both PMC but is not monitored doubly When the Dual Check Safety Function is applied this signal allows turning on MCC When either MCC Off signal through PMC or that through DCS PMC is 0 MCC is turned off When both MCC Off signal through PMC and that through DCS PMC is 1 MCC is turned on 0 MCC off 1 on When Emergency Stop signal is input turns off this signal When off Test is carried out CNC turns off this signal too In the following case this signal turns to 0 not permit MCC on MCC off Test is carried out e n emergency stop state In other than the above case this signal turns to 1 permit MCC on NOTE When the spindle motor induction motor is powered off while rotating the motor performs free running at the speed before power off eventually stopping after a period of time In some cases however it is better to stop the motor as early as possible for safety When the spindle is decided to be controlled even if the MCC Off signal is set to 0 the rotation of the spindle can be stopped under control of the ladder program controlled stop To do this make a ladder program that interrupts power upon lapse of
67. signal is 0 In the Cs contour control mode this signal is 1 N CAUTION This signal is enabled only when bit 7 CSS of parameter No 3704 is 0 When bit 7 CSS of parameter No 3704 is 1 when Cs contour control by the individual spindles is used use the Cs contour change completion signals FCCS1 Fn274 0 to FCCS2 Fn274 1 of the individual spindles 213 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 Cs contour control change signals in each axis CONS1 to CONS2 lt Gn274 0 to Gn274 1 gt Classification Function Input signal When the Cs contour control function is used this signal specifies switching between the spindle rotation control mode and Cs axis control mode for the first and second spindles within the path When this signal is set to 1 the spindles are switched from the spindle rotation mode to the Cs contour control mode When this signal is set to 1 while the spindles are rotating the spindles stop immediately and then enter the Cs contour control mode When these signals are set to 0 the spindles are switched from the Cs contour control mode to the spindle rotation mode N CAUTION These signals are enabled only when bit 7 CSS of parameter No 3704 is 1 when Cs contour control by the individual spindles is used When bit 7 CSS of parameter No 3704 is 0 use the Cs contour change signal CON Gn027 7 Cs contour control change completion signals in each axis FCCS1 to FCCS2
68. the door lock state is changed as follows before the safety monitoring state is established Door lock state transition Protective OPIHB door lock 5 Locked A protective door open request is not made Normal and the door is locked operating state Locked A guard open request is made Locked The request is transferred to the CNC Locked The CNC receives the request Locked Reference point is established and a safe speed check a machine position check and a position error check prove that there is no failure and that the CNC can enter the safe state Unlocked The actual safety door is unlocked Safety function SGOPN 0 Operations can be performed with the door is enabled open Locked The door is closed and locked again Locked The guard open request is canceled Locked The CNC is notified of the release of the above request Locked The CNC receives the release of the above request NOTE The PMC ladder must be designed to monitor whether the protective door is open SGOPN is set to 0 while ORQ is set to O If the door open is detected the PMC ladder judges that an abnormal event has occurred and enters the safe stop state This can occur for instance when the door happens to open or to be unlocked while machining is in progress with the protective door closed 26 B 64303EN 4 01 3 SAFETY FUNCTIONS Timing diagram from door close sta
69. the spindle side Input type Parameter input Data type Word spindle Set the number of gear teeth on the spindle side in speed control such as feed per revolution and threading For spindle positioning set 1 204 B 64303EN 4 01 11 APPLICATION OF OTHER FUNCTIONS 7 6 5 4 3 2 1 0 des T 1 Input type Parameter input Data type Bit spindle 4000 4 RETSV The reference position return direction of the spindle in spindle positioning is 0 CCW counterclockwise 1 CW clockwise 4044 Proportional gain of the velocity loop in servo mode HIGH gear Proportional gain of the velocity loop in servo mode LOW gear Input type Parameter input Data type Word spindle Set a proportional gain for the velocity loop on spindle positioning Integral gain of the velocity loop in the servo mode HIGH gear Integral gain of the velocity loop in the servo mode LOW gear Input type Parameter input Data type Word spindle Unit of data Valid data range 0 to 32767 Set an integral gain of the velocity loop on spindle positioning Gear ratio HIGH gear 4057 Gear ratio MEDIUM HIGH gear 4058 Gear ratio MEDIUM LOW gear Gear ratio LOW gear Input type Parameter input Data type spindle Unit of data Motor speed per spindle rotation x 100 Valid data range 0 to 32767 These parameters set the gear ration between the spindle and spindle motor 205 11 APPLICATION OF OT
70. this alarm specify the safe machine position parameters before making a reference position return N CAUTION 1 The machine coordinate of the safety function is based on position feed back So it does not always indicate the same value as the machine coordinate based on the summation of the command value 2 This function is activated only in position control mode HE e 3 SAFETY FUNCTIONS B 64303EN 4 01 3 8 MCC OFF TEST A MCC off Test must be carried out in intervals of 24 hours so that the safety functions would not be damaged by a possible cause of failure A message telling that the MCC off Test must be carried out is displayed at power on or when 24 hours have elapsed after the previous MCC off Test The machine tool builder must set up the machine not to open the protective door before a MCC off Test is not completed The protective door can be opened only after the MCC off Test is carried out accordingly A MCC off Test performs the test to turn on and off MCC by controlling SMC signal in order to confirm whether the circuit to shut off MCC is normal The MCC off Test is performed both on PMC and DCS PMC If the MCC off Test is not completed within the time specified by the parameter No 1946 MCC off Test timer servo alarm SV0488 is generated It is necessary to carry out the MCC off Test before the protective door is open when power is on or 24 hours have elapsed after previous MCC off Test The PMC ladder progra
71. through the serial interface Then it is fed to two CPUs a CNC CPU and a CPU built into the spindle amplifier The safety related signal such as guard signal is sent via the independent I O unit and is applied to the CNC through the I O link interface Then it is fed to two CPUs a CNC CPU and a PMC CPU The safety function is monitored independently by a CNC CPU and servo CPU or by a CNC CPU and spindle CPU Each CPU cross checks data and results at certain intervals If the monitoring function detects an error the CNC CPU and the servo spindle CPU switch off the MCC via independent paths to shut off the power to the feed axis and spindle Compliance with the Safety Standard The Dual Check Safety function satisfies the requirements of the following safety standard e EN954 1 1997 Category 3 e EC62061 2005 SIL2 e EC61508 2000 SIL2 e 5013849 1 2006 These safety standards require following e The safety function of a safety related portion must not degrade when a single failure occurs e Single errors must be detected at all times when natural execution 15 possible To satisfy these requirements the Dual Check Safety function is implemented using the two channel configuration shown below 1 OVERVIEW B 64303EN 4 01 Motor detector Cross check ut off power Magnetic contactor Shut off power signal of data and results Door switch signal Monitoring of servo motor and spindle mo
72. transferred to the SV the SP and the PMC normally or not The SV the SP and the PMC also check whether the safety related parameters are transferred from the CNC normally or not If some problem is found in this check an alarm is generated and the MCC is shut off DCALM 0 3 11 PARAMETER LOCK FUNCTION Parameters related to the Dual Check Safety function safety parameters can be locked to protect against modification The parameter No 3225 and No 3226 unlock these parameters The following parameters are locked No 0980 No 0981 No 0982 No 1023 1240 No 1838 No 1839 No 1840 No 1841 1842 No 1902 6 No1904 No 1945 1946 No 1948 No 1950 No 3225 No 3717 No 3797 No 4372 4438 No 4440 No 4442 No 4448 No 4460 No 10500 to No 10596 No 11950 to No 11957 No 11960 to No 11967 No 11970 to No 11977 11980 to No 11987 13805 13810 No 13811 13821 to No 13829 13831 to 13838 No 13840 to No 13843 No 13880 to No 13911 No 13912 to No 13919 No 13920 to No 13951 No 13960 to No 13991 39 3 SAFETY FUNCTIONS 3 12 B 64303EN 4 01 SEFETY POSITION ERROR MONITORING FUNCTION Both the CNC and the SV check whether the servo following error of each axis exceeds the limit of deviation specified by the parameters If the servo following error exceeds an alarm is generated and MCC OFF signal MCFVx is output immediately The relation between the safety mon
73. used to check if the MCC Off signals MCF operates normally in MCC off Test mode When the MCC Contact State signals both SMC PMC and SMC DCS are 1 in the emergency stop state ESP 0 it is possible to design the ladder program to release the guard lock N CAUTION Input this signal according to the MCC state Safety Check Request signal input VLDVx lt PMC Gn750 0 to 4 gt lt DCS PMC G 002 m 0 to 4 gt for each axis VLDPs lt PMC Gn751 0 to 1 gt lt DCS 003 0 to 1 gt for each spindle If these signals are set to 0 when Guard State signal SGOPN machine side signal is 0 the alarm monitoring of safety speed limit safety machine position and safety position error is activated Classification Input signal Dual signal Function Safety Check Request signals request each CPU to carry out the safety check for the Dual Check Safety Function These signals select a servo axis and a spindle that must be checked when a protective door is open 0 Alarm by safety check is monitored as a protective door is open 1 Alarm by safety check is not monitored as a protective door is closed Operation Each CPU carries out the safety check of the servo axis and the spindle that are selected by these signals Safety speed limit for a spindle safety speed safety machine position and safety position error for a servo axis If each CPU finds out any problem it generates a safety related alarm a
74. 0 3 1 Rotating the Spindle Manually in the Emergency Stop State The Dual Check Safety function allows the spindle to rotate at a safe speed by using the safe speed limit monitoring function even when the protective door is open In some cases the operator rotates the spindle manually by entering the emergency stop state to interrupt excitation of the spindle with the protective door open Generally the safe speed limit with the protective door open is set to a much lower value Therefore if the spindle is rotated manually the rotation speed may exceed the safe speed limit To prevent a safe speed limit monitoring alarm from occurring even in the case above it is necessary to create a ladder program that implements the following circuitry 1 Method by the Safety Check Request signal VLDPs When the MCC is placed in the off state SMC 1 in the emergency stop state a safety monitoring alarm can be disabled by setting VLDPs to 1 even if the protective door is open 2 Method by the safe speed limit safe machine position selection signals SPAs and SPBs Switching between SPAs and SPBs is made depending on whether the MCC is placed in the off state SMC 1 in the emergency stop state As the safe speed setting parameter selected when the MCC is placed in the off state in the emergency stop state SMC 1 select a value that does not cause a safety monitoring alarm to occur even when the operator rotates the spindle manually
75. 06B 6164 H202 H580 SVSP 40 40 15 068 6164 223 580 pi SVSP 20 20 40 7 5 A06B 6164 H311 H580 pi SVSP 20 20 40 11 068 6164 312 580 pi SVSP 40 40 40 15 AO6B 6164 H333 H580 SVSP 40 40 80 15 AO6B 6164 H343 H580 235 APPENDIX A Directives Standards and Technical Conditions for 3rd Party Servo Spindle Motors amp Encoders when Applying FANUC B 64303EN 4 01 APPENDIX GE Fanuc Dual check Safety A Directives Standards and Technical Conditions for 3rd Party Servo Spindle Motors amp Encoders when Applying FANUC GE Fanuc Dual check Safety 239 A Directives Standards and Technical Conditions for 3rd Party Servo Spindle Motors amp Encoders when Applying FANUC GE Fanuc Dual check Safety APPENDIX B 64303EN 4 01 A 1 GENERAL Applying 3 party servo spindle motors and 3 party feedback devices with FANUC GE Fanuc Dual check Safety Function these 3 party devices must comply with specific mandatory standards and directives i e regulations regarding EMC and LVD IP classification Electrical safety and environmental testing Further details regarding standards and directives to comply with are described under chapter 2 Mandatory Standards and Directives Please refer to it The components also need to meet the technical requirements as specified in this document 240 B 64303EN 4 01 A Directives Standards and Te
76. 07 C171 AC digital output module AOA05E A03B 0819 C176 AC digital output module AOA08E A03B 0819 C177 AC digital output module AOA12F A03B 0819 C178 Relay output module AOR08G A03B 0819 C179 Relay output module AOR16G A03B 0819 C180 DC digital output module AOD16DP A03B 0819 C182 DC digital output module AOD08DP A03B 0819 C183 DC digital input output module AIO40A A03B 0807 C200 228 B 64303EN 4 01 12 COMPONENTS LIST Descripion Specification Number Remarks 80 Relay output module AOR16G2 A03B 0819 C184 ae 229 12 COMPONENTS LIST 12 2 SOFTWARE CNC CPU software Name FSOi TD Series Edition D6F1 06 B 64303EN 4 01 Remarks FSOi MD PMC CPU software D4F1 06 Name Series Edition Remarks PMC BASIC 40B0 01 Servo control software ________ Series Ediion Remarks Servo DSP 90C5 02 Servo DSP 90E5 02 Spindle software ________ _ Series Ediion Remarks Spindle Software aiSP series 9D80 01 Spindle Software BiSVSP series 9D80 11 FREE 230 B 64303EN 4 01 12 3 SERVO AMPLIFIER SERVO AMPLIFIER ai series 200V Common power supply Series Name Model Name al PS 5 5 Specification Number AO06B 6140 H006 12 COMPONENTS LIST Remarks al PS 11 068 6140 011 al PS 15 068 6140 015
77. 1 External deceleration rate setting 2 for each axis in rapid traverse TT Inputtype Parameter input Data type Real axis Unit of data mm min inch min degree min machine unit Minimum unit of data Depend on the increment system of the applied axis Valid data range Refer to the standard parameter setting table C When the increment system is IS B 0 0 to 999000 0 Set the external deceleration rate of rapid traverse for each axis 193 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 1434 Maximum manual handle feedrate setting 1 for each axis 1442 Maximum manual handle feedrate setting 2 for each axis 1445 Maximum manual handle feedrate setting 3 for each axis Input type Parameter input Data type Real axis Unit of data mm min inch min degree min machine unit Minimum unit of data Depend on the increment system of the applied axis Valid data range Refer to the standard parameter setting table C When the increment system is IS B 0 0 to 999000 0 Set a maximum manual handle feedrate for each axis 194 B 64303EN 4 01 11 APPLICATION OF OTHER FUNCTIONS 11 3 SPINDLE OUTPUT CONTROL BY THE PMC 11 3 1 Overview The Dual Check Safety function uses the CNC CPU and spindle DSP to separately monitor the spindle speed safe speed monitoring function When the safe speed is exceeded by some axes with the guard closed after a guard open request is input RSPs 0 the protective door needs to be locke
78. 10HV Specification Number 068 6127 102 Remarks B 64303EN 4 01 al SV 10HVL A06B 6127 H152 al SV 20HV 068 6127 103 al SV 20HVL A06B 6127 H153 al SV 40HV A06B 6127 H104 al SV 40HVL A06B 6127 H154 al SV 80HV AO6B 6127 H105 al SV 80HVL AO6B 6127 H155 al SV 180HV AO6B 6127 H106 al SV 360HV AO06B 6127 H109 al SV 10 10HV AO06B 6127 H202 al SV 10 10HVL AO06B 6127 H252 1 SV 20 20HV AO06B 6127 H205 al SV 20 20HVL 068 6127 255 al SV 20 40HV 068 6127 206 al SV 20 40HVL AO6B 6127 H256 al SV 40 40HV AO6B 6127 H207 al SV 40 40HVL 068 6127 257 al SV 40 80HV 068 6127 208 al SV 80 80HV Servo Amplifier Series Name Model Name pi SV 4 068 6127 209 Specification Number 068 6130 001 Remarks pi SV 20 A06B 6130 H002 pi SV 40 A06B 6130 H003 pi SV 80 A06B 6130 H004 SERVO AMPLIFIER i series 400V Servo Amplifier Series Name Model Name SV 10HV Specification Number AO6B 6131 H001 Remarks pi SV 20HV AO06B 6131 H002 pi SV 40HV AO06B 6131 H003 234 B 64303EN 4 01 Servo Amplifier Series Name pi SVSP series Model Name SVSP 20 20 7 5 Specification Number AO6B 6164 H201 H580 12 5 LIST Remarks 20 20 11 A
79. 1952 No 11972 No 11953 No 11973 No 11954 No 11974 No 11955 No 11975 No 11956 No 11976 No 11957 No 11977 3 SAFETY FUNCTIONS B 64303EN 4 01 Signaltype Combination No DCS PMC No 11960 No 11980 No 11961 No 11981 No 11962 No 11982 No 11963 No 11983 No 11964 No 11984 No 11965 No 11985 No 11966 No 11986 No 11967 No 11987 Signals other than safe related I O The following signals are not safe related signals are not checked in redundant mode but are important signals in the Dual Check Safety system The machine tool builder must create an appropriate Ladder program with these signals IMPORTANT The error of ladder program cannot be checked by safety function itself Please make sure to check safety function see Chapter 7 10 ORQ Guard Open Request signal input When this signal is input the CNC set the Guard Open Inhibit signal OPIHB to 1 Guard open accept The PMC ladder program of a machine tool builder confirms the safety machine position and the safety speed If both machine position and speed are judged within safe range according to the result of confirmation the guard unlock signal is set to 1 guard unlock enabled The machine tool builder must provide an output signal that opens the actual protective door through the PMC 11 OPT Test Mode signal input When the signal is input a MCC off Test is executed The MCC off Test checks w
80. 3 SAFETY FUNCTIONS B 64303EN 4 01 3 21 3 Details of Brake Test The following operations are performed in brake tests to 3 a b d e f The Safety Brake signal BRKx is output according to a test pattern The torque limit value of a brake test target axis is used as a torque limit value for brake test A torque limit value can be set in parameter No 13915 Time tl is awaited until the brake has been applied to enable a command to be issued Time tl is set in parameter No 13914 A position command from the NC is output according to the travel distance set in parameter No 13916 and the speed command set in parameter No 13917 A position deviation is checked to see if the brake has been applied normally when the issue of commands is completed If the brake has been applied normally no axis movement is made So the position deviation corresponding to a specified travel distance is accumulated The range of position deviation to be checked is the corresponding position deviation plus minus the tolerance value parameter No 13918 Parameter No 13919 is used to set time t2 for checking whether the brake has been applied normally If the position deviation is outside the range alarm DS0039 or DS0040 is issued assuming that the brake has not been applied normally Upon completion of checking a command is issued to return the accumulated position deviation to the original value Time tl parameter No 13914
81. 35 6 gt for 2nd spindle Classification Input signal Function This signal specifies that either the CNC or PMC is used to control the output polarity of the spindle motor speed command Operation When this signal is 0 the output polarity of the spindle motor speed command is controlled by the CNC When this signal is 1 the output polarity of the spindle motor speed command is controlled by the PMC Spindle motor command polarity command signals SGN lt Gn033 5 gt for 1st spindle SGN2 lt Gn035 5 gt for 2nd spindle Classification Input signal Function When the output polarity of the speed command for the spindle motor is controlled by the PMC set this signal Operation When this signal is 0 the output polarity of spindle is the positive direction When this signal is 1 the output polarity of spindle is the negative direction 197 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 11 3 3 2 Signal address 4 7 6 5 3 2 1 rosi roai 0 11 3 4 Parameters 7 6 5 4 3 2 1 0 Input type Parameter input Data type Bit path 2 MSI In multi spindle control the SIND signal is valid 0 Only when the first spindle is valid SIND signal for the 2nd 3rd spindle becomes ineffective TYPE A 1 For each spindle irrespective of whether the spindle is selected Each spindle has its own SIND signal TYPE B 198 B
82. 64303EN 4 01 11 APPLICATION OF OTHER FUNCTIONS 11 4 SPINDLE POSITIONING T SERIES 11 4 1 Overview The Dual Check Safety function uses the CNC CPU and spindle DSP to separately monitor the spindle speed safe speed monitoring function When monitoring the stop state of the spindle with the safe speed monitoring function set the safe speed parameter to a non zero value by considering a margin according to the machine This is because the actual speed cannot be assumed to be 0 In this case the spindle may rotate at a speed less than the set safe speed so it is necessary to position the spindle by forming a position control loop at the same time The spindle positioning function positions the spindle with the spindle motor and position coder or the like To use the spindle positioning function set bit 1 AXC of parameter No 8133 to 1 The Cs contour control function and the spindle positioning function cannot be used at the same time 199 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 11 4 2 Specifications Spindle positioning Spindle positioning is performed as follows e Cancel the spindle rotation mode which is used for turning with the spindle rotating and enter the spindle positioning mode Position the spindle in the spindle positioning mode Cancel the spindle positioning mode and enter the spindle rotation mode Selecting a spindle positioning axis Any axis address can be set with parameter No
83. 819 C001 45 l O unit base module ABUOBA A03B 0819 C002 46 l O unit base module ABU10B A03B 0819 C003 47 VO unit base module ABU05B A03B 0819 C004 48 l O unit interface module AIFO1A A03B 0819 C011 49 I O unit interface module AIFO1B A03B 0819 C012 DC digital input module AID32A1 A20B 9000 0970 0819 101 DC digital input module AID32B1 A20B 9000 0971 A03B 0819 C102 DC digital input module AID16D A03B 0819 C104 DC digital input module AID16L A03B 0819 C114 DC digital input module AID32E1 A03B 0819 C105 DC digital input module AID32F1 A03B 0819 C106 DC digital input module AIA16G A03B 0819 C107 DC digital input module AID32F2 A03B 0819 C109 DC digital input module AID32E2 A03B 0819 C110 DC digital input module AID32H1 A03B 0819 C111 DC digital input module AID16G A03B 0819 C115 DC digital output module AOD08D A03B 0819 C152 DC digital output module AOD16D A03B 0819 C154 DC digital output module AOD32D1 A03B 0819 C156 AC digital output module AOA05E A03B 0819 C157 AC digital output module AOA08E A03B 0819 C158 AC digital output module AOA12F A03B 0819 C159 Relay output module AOR08G A03B 0819 C160 Relay output module AOR16G A03B 0819 C161 Relay output module AOR16H2 A03B 0819 C165 DC digital output module AOD32D2 A03B 0819 C167 DC digital output module AOD16D2 A03B 08
84. 85 10 3 1 Rotating the Spindle Manually in the Emergency Stop State 185 11 APPLICATION OF OTHER FUNCTIONS 186 OVERVIEW Qu sau deca antes decus tape bein niet de ein 187 112 EXIERNALDEGEUERATIGON uuu uu uu EE E 188 11 2 1 OV erVISWu Lu gayana ies ette en ett ee CL Erbe ce 188 11 2 2 Sp cifications irn ete e Ere pes eerie te de He 189 11 2 3 uite eee EUER Dd oe 191 11 2 3 1 Detais on ette Du n Ra 191 11 2 3 2 Signal address i e p 192 TIZA ien eere tere ete 192 11 3 SPINDLE OUTPUT CONTROL BY THE 195 OVEryeW menearen e HR E E RH E tee IRL 195 T1 3 2 Specifications oe ee e hee tees 196 12337 ede een Re RS E 197 ALB SA D tails on Signals tpe E Ro qe qe Ia 197 11 3 3 2 Signal address u y a ote oe Rte 198 TS A Parameters ais sut uw aan ete o Hed fe 198 11 4 SPINDLE POSITIONING T SERIES 199 COV rVIeWw uae ee ted Beet heh 199 1142 Specifications dp e e ie 200 11433 Signals dot eterne ete nee e EE CE
85. 99999 9999 0 00000 to 9999 99999 6 PARAMETERS C Velocity and angular velocity parameters Unit of data mm min degree min Increment system Minimum data unit B 64303EN 4 01 Valid data range 999000 00 999000 000 to 99999 9999 inch min 0 00001 96000 000 9600 0000 to 4000 00000 If bit 7 IESP of parameter 1013 is set to 1 the valid data ranges for IS C are extended as follows Unit of data mm min degree min Increment system Minimum data unit Valid data range 0 000 to 999000 000 inch min D Acceleration and angular acceleration parameters Unit of data mm sec degree sec2 Increment system Minimum data unit 0 0000 10 9600 0000 Valid range to 999999 99 to 999999 999 to 99999 9999 inch sec 0 00001 to 99999 999 99999 9999 0 00000 to 9999 99999 If bit 7 IESP of parameter No 1013 is set to 1 the valid data ranges for IS C are extended as follows Unit of data mm sec degree sec Increment system Minimum data unit Valid data range 0 000 to 999999 999 inch sec Notes 1 2 3 0 0000 to 99999 9999 Values are rounded up or down to the nearest multiples of the minimum data unit A valid data range means data input limits and may differ from values representing actual performance For information on the r
86. B 64303EN 4 01 5 l O SIGNALS Safety Speed Safety Position Selection signal A input SVAx lt PMC Gn752 0 to 4 lt DCS PMC G 004 m 0 to 4 for each axis SPAs lt PMC Gn754 0 to 1 gt lt DCS PMC G 006 m 0 to 1 gt for each spindle Safety speed safety position selection signal B input SVBx PMC Gn753 0 to 4 lt DCS PMC G 005 m 0 to 4 gt for each axis SPBs lt 754 4 to 5 gt lt DCS PMC G 006 m 4 to 5 gt for each spindle Classification Input signal Dual signal Function When the Dual Check Safety Function is activated it is possible to select safety limit speed and safety machine position of each axis This signal is prepared for each axis and each spindle The final number in the signal name shows the number of the controlled axis and spindle SVAx SVBx x 1 Select safety speed safety machine position of the 1st axis Select safety speed safety machine position of the 2nd axis Select safety speed safety machine position of the 3rd axis Select safety speed safety machine position of the 4th axis Select safety speed safety machine position of the Sth axis SPAs SPBs s 1 Select safety speed of the 1st spindle 2 Select safety speed of the 2nd spindle Operation According to the combination of Safety Speed Safety Machine Position Selection signal safety speed and safety machine position are selected as the following table Safety Speed Safety Machine Position Safety limit spee
87. D1A gt Channel 2 When channels 1 and 2 are extended together Link branching adapter for three I O Link branching channels adapter A20B 1007 0680 Josia soste JD44a 1 JLHLIL Joia channel 1 JD1A 2 L E 9 channel 2 JD1A Channel 3 When channels 2 and 3 are extended together I O Link branching adapter for three channels Josia JL JD44A 1 gt channel 1 I O Link branching adapter A20B 1007 0680 JD44A 2 Jp44B JD1A 4 Channel 2 JD1A 2 9 channel 3775 4 INSTALLATION B 64303EN 4 01 Connection between the I O Link branching adapter for three channels and I O Link branching adapter for two channels Link branching adapter for three channels Link branching adapter for two channels JD44A 1 JD44B such as PCR E20MDK SL A PCR E20MDT 0 00 4 SOUTi 5 Sine re sna i6 SOUT2 17 9 10 20 5v 19 The 5V pin is provided to use the optical I O Link adapter for optical fiber transmission When not using the optical I O Link adapter leave the 5V pin unconnected Cable connection Link branching adapter Link branching adapter for three channels for two channels JD44B SOUT1 SOUT1 SIN1 Shield When not using the optical I O Link adapter leave the 5V pin unconnected Recommended cable connectors PCR E20FA Honda Ts
88. E ON 2 PATH CONTROL T SERIES This section describes cautions about safe related I O signals that should be taken in 2 path control 5 5 1 2 path Control T Series Two path control is used for example when one workpiece is machined using two tools simultaneously with independent programs An alarm is checked on a path by path basis If a servo alarm is issued on a path the MCC of all axes of the path are shut off If an alarm related to the safety check function is issued the MCC 15 also shut off on a path by path basis So basically a safety area needs to be set on a path by path basis If multiple safety areas are set within one path the MCC may be shut off for an alarm in another area If a safety area 1s configured using an axis that belongs to one of the paths selected by switching the MCC of another axis of the path may not be shut off when an alarm is issued If an axis that belongs to one of the paths selected by switching is used make connections so that the MCCs of both paths are shut off at the same time Two sets of cross check target safety input signals one set for the PMC and the other for the DCS PMC are used for each path Ensure that the two sets are exactly the same N CAUTION When Composite control or Path speed control of Multi path control is specified it is possible to give a command to control a servo axis or a spindle in another path But in this case the correspondence between a path and a belon
89. EFINITION OF WARNING CAUTION AND Important Items to Check Before Using the Safety NOTE eu itt sd ruth s 1 B lictioDs tA REAL tod 15 Details of Brake Test 66 Initial Start up i eee ere 150 Details on signals 191 197 202 213 219 INSTALELATION there tette 70 DIAGNOSIS RUD ne ERR ERR ga 161 lt L gt DIAGNOSIS SCREEN eere 172 Latent error detection and 7 Directives o ss 2 DIRECTIVES AND STANDARDS M MANDATORY STANDARDS AND DIRECTIVES 241 INDEX MCC Off Signal MCF MCFVx MCFPs DCALM MCC Contact State Signal SMC MCG TES y Ea lt N gt lt O gt lt P gt lt R gt MCC off Test of the Safe Stop Function 15 MCC OFF TEST STATUS SCREEN 162 Monitoring of the Excitation Off Signal 47 55 NOTE ON 2 PATH CONTROL T SERIES 108 OVERALL CONNECTION DIAGRAM 71 PARAMETER LOCK FUNCTION 39 Parameters 109 115 192 198 203 215 221 PREFACE MI 1 PROFIBUS DP PARAMETER SETTINGS 145 PROGRAMMABLE SAFETY I O SIGNAL 107 RAM CHECK eee 44 Related Safety Standards sss 2 Remaining risks eese 8 R
90. EPRESENTATION OF PARAMETERS 112 R strictioil ceo ie ro RR DEOR hee Risk Analysis and Evaluation Rotating the Spindle Manually in the Emergency Stop S Miri AE EE E IEEE 185 SAFE MACHINE POSITION MONITORING 32 SAFE MACHINE POSITIONING MONITORING SCREEN aseo unu Un ote eg 170 SAFE SERVO STOP FUNCTION 46 SAFE SPEED MONITORING ee 30 SAFE SPINDLE STOP 54 SAFE STOP MONITORING eee 45 SAFE RELATED I O SIGNAL MONITORING 19 SAFETY BRAKE SIGNAL OUTPUT FUNCTION 42 SAFETY FUNCTIONS 12 Safety monitoring cycle and cross check cycle 7 SAFETY POSITION ERROR MONITORING SCREEN cht nein tie tt a a ss Liber der 171 SAFETY POSITION SWITCH FUNCTION 37 SAFETY RELATED PARAMETERS CHECK FUNCTION 39 B 64303EN 4 01 lt T gt lt U gt SAMPLE CONFIGURATION SAMPLE CONNECTIONS SAMPLE SYSTEM CONFIGURATION 175 SEFETY POSITION ERROR MONITORING UNC TION Ee 40 SEQUENCE esiti ni PO UR ERES 224 Series 2nd and Subsequent Machines Startup 152 Series 01 ihres 226 SER VO i iie anette ds 244 SERVO AMPLIFIER cinesino 231 Servo Encoder Speed Position Feedback Sensor Embedded in Motor
91. F1758 49th to 64th position switch PMC F029 F030 49tht to 64th position switch DCS PMC NOTE 1 If all setting values are 0 the output address is regarded as follows Position switch 1 to 16 F755 F756 PMC F007 F008 DCS PMC Position switch 17 to 32 F757 F758 PMC F009 F010 DCS Position switch 33 to 48 F1755 F1756 PMO F027 F028 DCS PMC Position switch 49 to 64 F1757 F1758 PMC F029 F030 DCS PMC Do not assign two or more position switch to the same address 136 B 64303EN 4 01 6 PARAMETERS 13880 Axis corresponding to the 1st safe position switch 13911 Axis corresponding to the 32nd safe position switch Axis corresponding to the 33rd safe position switch Input type Data type Valid data range ose Axis corresponding to the 64th safe position switch NOTE When these parameters are set the power must be turned off before operation is continued Parameter input Byte 0 to Number of controlled axes These parameters specify the control axes numbers corresponding to the 1st thorough 64th safe position switch functions When one path is used up to 32 safety position switches can be set When two paths are used with the T series up to 64 safety position switches can be set corresponding position switch signal is output to I O Link 1 or 2 and I O Link 3 4 or PROFIBUS DP when the machine coordinate value of a corresponding axis is within the range that i
92. FANUC Series O MODEL D Dual Check Safety CONNECTION MANUAL B 64303EN 4 01 e No part of this manual may be reproduced in any form e All specifications and designs are subject to change without notice The products in this manual are controlled based on Japan s Foreign Exchange and Foreign Trade Law The export from Japan may be subject to an export license by the government of Japan Further re export to another country may be subject to the license of the government of the country from where the product is re exported Furthermore the product may also be controlled by re export regulations of the United States government Should you wish to export or re export these products please contact FANUC for advice In this manual we have tried as much as possible to describe all the various matters However we cannot describe all the matters which must not be done or which cannot be done because there are so many possibilities Therefore matters which are not especially described as possible in this manual should be regarded as impossible This manual contains the program names or device names of other companies some of which are registered trademarks of respective owners However these names are not followed by in the main body B 64303EN 4 01 DEFINITION OF WARNING CAUTION AND NOTE DEFINITION OF WARNING CAUTION AND NOTE This manual includes safety precautions for protect
93. FETY FUNCTIONS B 64303EN 4 01 3 SAFETY FUNCTIONS 3 SAFETY FUNCTIONS B 64303EN 4 01 3 1 APPLICATION RANGE Safety function The Dual Check Safety function assumes the following configuration A At least one protective door is provided B If protective door is closed safety is assured When the operator makes a request to open the protective door the safety functions are enabled and the protective door can be unlocked While the protective door is open the active safety functions assure safety When the request to open the protective door is canceled the protective door is locked and the safety functions are disabled The Dual Check Safety function provides these safety functions while the protective door is open as described above Some of the safety functions continue working while the protective door is closed N WARNING The machine tool builder is responsible for the followings To secure the safety by the sequence to make safety function effective according to the status of the protective door To secure the safety while the protective door is closed To secure the safety related to the other moving components and so on except FANUC servo motors and spindle motors controlled by the Dual Check Safety function while the protective door is open The Dual Check Safety function has the following safety functions e Safe related I O signal dual monitoring Emergency stop input protective door open close s
94. HER FUNCTIONS 4066 4067 4068 ect gt lt lt O Data type Unit of data Valid data range Data type Unit of data Valid data range Input type Data type 0 IORs 1 IDMs 2 ISZs B 64303EN 4 01 Position gain in servo mode HIGH gear Position gain in servo mode MEDIUM HIGH gear Position gain in servo mode MEDIUM LOW gear Position gain in servo mode LOW gear Parameter input Word spindle 0 01 sec 0 to 32767 These parameters set a servo loop gain on spindle positioning Grid shift amount on servo mode Parameter input Word spindle 1 pulse 360deg 4096 0 to 4095 The reference position is shifted counterclockwise by the set number of pulses Motor voltage in the servo mode Parameter input Word spindle 1 0 to 100 Set the motor voltage in the servo mode Parameter input Bit spindle Resetting the system in the spindle positioning mode 0 Does not release the mode 1 Releases the mode The direction of spindle positioning half fixed angle positioning based on M codes is 0 Plus direction 1 Minus direction When an M code for spindle orientation is specified in spindle positioning 0 The spindle is switched to the spindle positioning mode and spindle orientation operation is performed 1 Only the switching of the spindle to the spindle positioning mode is performed Spindle orientation operation is not performed
95. I DO DI DO ADDR to display the DI DO ADDRESS screen 2 Set the DI DO addresses DI ADDR and DO ADDR according to the following format S PMC address For R0500 of Dual Check Safety PMC for example S R0500 must be entered X and R address is available to DI ADDRess Y and R address is available to DO ADDRess If there 15 no key in your CNC unit it is substituted with the or key Broken wire detection enables slaves to monitor the communication interval detect the communication error when a slave cannot receive data from the Master and clear the DO data which is received from Master Broken wire detection and Watchdog time are configured with Slave parameters which are transferred from Master to Slaves during initialization 145 6 PARAMETERS B 64303EN 4 01 When PROFIBUS DP signal is used for Dual Check Safety function please activate Broken wire detection Watchdog time should be set to several times longer than the refresh time in consideration of re transmission The refresh time can be observed in STATUS INFORMATION screen of PROFIBUS setting screen Broken wire detection and Watchdog time can be configured in PROFIBUS setting screen When 1 is set into WD Broken wire detection becomes active Watchdog time is calculated with the following expression 10 x WD FACTI x WD FACT2 ms For example in the followin
96. I DO 48 32 module for connector panel Basic AOSB 0815 C001 DI DO 24 16 module for connector panel Extension A A03B 0815 C002 DI DO 24 16 With manual pulse generator module for connector panel Extension B A03B 0815 C003 DI DO 24 16 module for connector panel Extension C AOSB 0815 C004 DO 16 2A output module for connector panel Extension D module type 2 for connector panel B1 A03B 0815 C005 A03B 0815 C040 Analog input DI DO 48 32 With manual pulse generator I F module type 2 for connector panel B2 A03B 0815 C041 DI DO 48 32 Without manual pulse generator module type 2 for connector panel E1 A03B 0815 C042 DI DO 48 32 Terminal Type module Basic Module A03B 0823 C001 DI DO 24 16 With Link I F Terminal Type I O module Extension module A A03B 0823 C002 DI DO 24 16 With manual pulse generator Terminal Type I O module Extension module B A03B 0823 C003 DI DO 24 16 Without manual pulse generator Terminal Type I O module Extension module A03B 0823 C004 DO 16 2A output Terminal Type I O module Extension module D A03B 0823 C005 Analog input Machine operator s panel Main panel A A02B 0319 C242 Key with both symbol and English indicated With alphabetic MDI Three point pressing supported Machine operator s panel Main panel B A02B 0319
97. Input type Data type Unit of data Valid data range NOTE When this parameter is set the power must be turned off before operation is continued Parameter input Integer axis msec 0 to 999999999 To ensure correct timing relative to the BRKx signal until a move command is issued in a brake test on each axis this parameter sets a time after controlling of the BRKx signal until the brake is applied and a time after controlling of the BRKx signal until the brake is released If a time for applying the brake differs from a time for releasing the brake set a longer time When 0 is set in this parameter the setting of 400 ms is assumed 13915 Brake test current limit override value Input type Data type Unit of data Valid data range NOTE When this parameter is set the power must be turned off before operation is continued Parameter input Integer axis 100 255 0 to 255 This parameter sets a current limit override value applicable to a brake test The relationship between a set value and torque limit override value is as follows Torque limit override value Setting 255 x 100 When 0 is set in this parameter the setting of 12 is assumed 138 B 64303EN 4 01 6 PARAMETERS 13916 Travel distance to be specified for brake test NOTE When this parameter is set the power must be turned off before operation is continued Input type Parameter input Data type Real axi
98. K OFF VO UNIT DCS VOLINK 3 mon scorn STATUS MCC STATUS power amplifier amplifier supply 24V LINE CONTACTOR MAIN MCC SPINDLE Servo ervo Motor Motor Motor 176 B 64303EN 4 01 10 SAMPLE SYSTEM CONFIGURATION 10 1 2 Example of Configuration Using Multiple MCCs VO UNIT VOLINK 1 2 VLDVx VLDPs OPIHB L gt gep MCC e Spindle amplifier I I amplifier amplifier 177 10 SAMPLE SYSTEM CONFIGURATION B 64303EN 4 01 10 2 SAMPLE CONNECTIONS 10 2 1 Emergency Stop Signal ESP I O Link 1 UNIT C ESP X0008 4 1 O Link 3 Unit ESP X0008 4 Common power supply NOTE Use a two contact emergency stop button with a forced guided contact mechanism Connect the emergency stop button to the PSM common power supply as illustrated in the figure When the signal is input the spindle slows down and stops Input a power down factor to Gn008 4 other than the signal from the emergency stop button Create a Ladder program so that X0008 4 becomes a factor of Gn008 4 Machine side l O Link UNIT Emergency stop factor Ladder Emergency stop button Emergency stop factor program other than emergency ESPG stop button Gn008 4 IMPORTANT Emergency stop button must fulfill the Standard IEC60947 5 1 This is mandatory 178 B 64303EN 4 01 10 SAMPLE SYSTEM CONFIGU
99. L B 64393EN Network PROFIBUS DP Board CONNECTION MANUAL B 64403EN Fast Ethernet Fast Data Server OPERATOR S MANUAL B 64414EN DeviceNet Board CONNECTION MANUAL B 64443EN FL net Board CONNECTION MANUAL B 64453EN Dual Check Safety Dual Check Safety CONNECTION MANUAL B 64303EN 4 Operation guidance function MANUAL GUIDE i B 63874EN Common to Lathe System Machining Center System OPERATOR S MANUAL MANUAL GUIDE i For Machining Center System B 63874EN 2 OPERATOR S MANUAL MANUAL GUIDE i Set up Guidance Functions B 63874EN 1 OPERATOR S MANUAL MANUAL 0 OPERATOR S MANUAL B 64434EN TURN MATEi OPERATOR S MANUAL B 64254EN p 2 B 64303EN 4 01 PREFACE Related manuals of SERVO MOTOR The following table lists the manuals related to SERVO MOTOR 02061 series Table2 Related manuals Specification number FANUC AC SERVO MOTOR ai series DESCRIPTIONS FANUC AC SPINDLE MOTOR ai series DESCRIPTIONS FANUC AC SERVO MOTOR Bi series DESCRIPTIONS FANUC AC SPINDLE MOTOR Bi series DESCRIPTIONS FANUC SERVO AMPLIFIER ai series DESCRIPTIONS FANUC SERVO AMPLIFIER pi series DESCRIPTIONS FANUC SERVO MOTOR ais series FANUC SERVO MOTOR ai series FANUC AC SPINDLE MOTOR ai series B 65285EN FANUC SERVO AMPLIFIER ai series MAINTENANCE MANUAL FANUC SERVO MOTOR fis series FANUC AC SPINDLE MOTOR Bi series FANUC SERVO AMPLIFIER pi series MAINTENANCE MANUAL FANUC AC SERVO MOTOR ai
100. OM 64MB SRAM 1 A20B 3900 0242 FROM SRAM module 1 FROM 128MB SRAM 1MB A20B 3900 0240 FROM SRAM module B2 FROM 128 SRAM 2MB A20B 3900 0241 Power supply 0 slot A20B 8200 0560 Power supply 2 slot A20B 8200 0570 Inverter for 8 4 inch color LCD A20B 8002 0703 Inverter for 10 4 inch color LCD A20B 8002 0702 PROFIBUS DP master board A20B 8101 0050 PROFIBUS DP slave board NOTE A20B 8101 0100 Only the hardware for the Dual Check Safety function is indicated above 226 B 64303EN 4 01 12 COMPONENTS LIST 12 1 2 Hardware Components for Other Units Other unit for CNC Description Separate detector I F unit Basic 4 axes Specification Number A02B 0303 C205 Remarks Separate detector I F unit Additional 4 axes A02B 0236 C204 Analog input separate detector interface unit Basic 4 axes AO6B 6061 C201 Optical I O Link adapter A13B 0154 B001 Optical adapter A13B 0154 B003 Spindle connector adapter A13B 0180 B001 I O Unit for Oi A02B 0309 C001 DI DO 96 64 With manual pulse generator I F module for operator s panel A1 A03B 0815 K200 DI DO 72 56 DI General 16 Matrix 56 With manual pulse generator I F module for operator s panel B1 A03B 0815 K202 DI DO 48 32 With manual pulse generator I F module for operator s panel B2 A03B 0815 K203 D
101. P1976 SERIAL SPINDLE COMMUNICATION The amplifier No could not be set to the serial spindle amplifier ERROR SP1977 SERIAL SPINDLE COMMUNICATION An error occurred in the spindle control software ERROR 158 B 64303EN 4 01 8 ALARM MESSAGE Number Message O SP1978 SERIAL SPINDLE COMMUNICATION A time out was detected during communications with the serial ERROR spindle amplifier SP1979 SERIAL SPINDLE COMMUNICATION The communications sequence was no longer correct during ERROR communications with the serial spindle amplifier SP1980 SERIAL SPINDLE AMP ERROR Defective SIC LSI on serial spindle amplifier analog spindle amplifier side serial spindle amplifier side SP1983 SERIAL SPINDLE AMP ERROR Could not clear on the spindle amplifier side SP1987 SERIAL SPINDLE CONTROL ERROR Defective SIC LSI on the CNC Number Message Amplifier indication Faulty location and remedy Description 1 SP9073 MOTOR SENSOR 1 Replace the feedback cable The motor sensor feedback DISCONNECTED 2 Check the shield processing signal is not present connector 3 Check and correct the JYA2 connection 4 Adjust the sensor SP9081 1 ROT MOTOR 1 Check and correct the The one rotation signal of the SENSOR ERROR parameter motor sensor cannot be correctly 2 Replace the feedback cable detected connector JYA2 3 Adjust the sensor SP9082 NO 1 ROT MOTOR 1 Replace test feedback cable The o
102. PMC side Note that the signal on the DCS PMC side always indicates the brake release state The output signals other than the above are described below The following signals always indicate 1 on both the PMC and DCS PMC sides MCC Off signal DCALM one for each system MCC Off signals for each axis and MCFPs for each spindle Safety monitoring result signals RSVx for each axis and RSPs for each spindle 2 The following signals always indicate 0 on both the PMC and DCS sides Safe Position Switch signals SPS1 to SPS32 Guard Open Inhibit signal OPIHB MCC Off Test Execution Request signal RQT Position Information Effect signal POSEx 121 6 PARAMETERS B 64303EN 4 01 7 6 5 4 3 2 1 0 pp mer Input type Data type 6 DCNx NOTE When at least one of these parameters is set the power must be turned off before operation is continued Parameter input Bit axis The checks of the target axis by Dual Check Safety function are 0 carried out 1 not carried out NOTE 1 ltis not possible to inhibit each check of Dual Check Safety Function of all axes by the parameter DON Set the DCNx bit to 1 for the slave axis under tandem control or for the tool axis of an electronic gear box M series The checks by the Dual Check Safety function are not carried out on an axis for which the DCNXx bit is set to 1 Set the DCNx bit to 0 for normal axes 1945 Safety input si
103. R E20MDK SL A PCR E20MDT 0 00 F4 sourr 14 ov 6 SIN2 16 5 8 SOUT2 18 5V 9 i9 sours 20 5V The 5V pin is provided to use the optical I O Link adapter for optical fiber transmission When not using the optical I O Link adapter leave the 5V pin unconnected Cable connection Link branching adapter for three channels JD51B SOUT1 SOUT1 SIN1 SIN1 SOUT2 SOUT2 SIN2 SIN2 SOUTS Shield When not using the optical I O Link adapter leave the 5V pin unconnected Recommended cable connectors PCR E20FA Honda Tsushin Kogyo Co Ltd 73 4 INSTALLATION I O Link branching adapter for three channels JD44A 1 20 3 ISOUT1 13 OV 4 SOUT1 14 OV 5 SIN2 15 6 9N2 T SoUr 7 SOUT2 18 5 atem 9 _ 10 20 5V B 64303EN 4 01 FI30 20S Hirose Electric Co Ltd FCN 247J020 G E Fujitsu 52622 2011 Molex Japan Co Ltd Connector FI30 20S Hirose Electric Co Ltd cannot be used as connector JD51A for the stand alone type 307 series main CPU board Recommended cable A66L 0001 0284 10P Signal configuration of the I O Link branching adapter for three channels JD44A 2 JD1A PCR E20MDT 3 SOUT3 13 OV 4 SOUT3 14 0V 5 15 2 SOUT2 13 SOUT2 14 OV SIN3 5V 2 3 4 5 6
104. RATION 10 2 2 Guard Open Request Signal ORQ NOTE Create a Ladder program of conditions for making a guard open request and then input the program to the PMC side When the guard open request signal ORQ is input CNC will output the OPNIHB signal After the ladder program confirms the safety status the signal for the guard unlock enable signal should be outputted by the ladder program Also the ladder program should inform the status of guard open by the VLDVx and VLDPs signals If the input of ORQ is canceled while the guard is open the ladder program should enter a safely stopped status state in which the guard is open although the guard open request signal is not input Close the guard VLDVx and VLDPs are set to 1 then cancel this signal Test start button I O Link UNIT I I Ladder program NOTE When all the conditions for the MCC off test become ready this signal OPT should be set to 1 179 10 SAMPLE SYSTEM CONFIGURATION B 64303EN 4 01 10 2 4 Guard Open Inhibit Signal OPIHB Monitoring Result Signal RSVx RSPs Safety check Request Signal VLDVx VLDPs Guard closed Guard monitoring Safety relay limit switch SW3 RY1 RY3 RY2 RY3 lt wo Sample control components SW1 SW2 Guard state monitoring Ladder program VLDVx Guard state VEDPs switch with forced guided SGOPN OPIHB contact RSVx SW3 Guard Lock RSPs
105. SP If inconsistency is found alarm SP9070 Spindle alarm 70 is output MCC Off signal DCALM is turned to 0 41 3 SAFETY FUNCTIONS B 64303EN 4 01 3 14 SAFETY BRAKE SIGNAL OUTPUT FUNCTION The CNC and the SV output the Safety Brake signal BRKx to control the mechanical brake When this signal 15 0 mechanical brake must be activated When this signal 1s 1 mechanical brake is allowed to be released When the inconsistency between the break signal on PMC and that on DCS PMC is lasted for the time that is specified by the parameter No 1945 the safety function sets MCC Off signal DCALM to 0 and generates the alarm safe cross check error PW0010 PW0011 42 B 64303EN 4 01 3 SAFETY FUNCTIONS 3 15 SELF TEST FUNCTION The CNC the PMC the SV and the SP carry out the following self diagnosis If the error is detected the alarm is generated and sets MCC Off signal DCALM to 0 lt 1 gt CPU check It is checked whether each CPU runs normally or not It is checked whether the instructions related to safety function is executed normally or not PW0014 PWO0009 SV0484 SP9074 Spindle alarm 74 2 Program monitoring It is confirmed whether all safety related function run normally PW0017 SV0490 PW0008 DCS PMC PW0009 SV0484 SP9076 Spindle alarm 76 SP0755 3 Cross check It is checked whether the result of
106. ST is finished normally 128 is displayed Refer to the section of MCC OFF TEST for further detail When the MCC off Test has never been performed after power on 0 is displayed Message When the power is turned on or 24 hours passes from the last MCC OFF TEST this screen is selected and the message EXECUTE MCC TEST is displayed 162 B 64303EN 4 01 9 DIAGNOSIS 9 2 CROSS CHECK DATA SCREEN The CROSS CHECK DATA screen displays ALARM INFORMATION SCREEN Press the CROSS CHECK soft key then the screen shown below appears This screen shows the DI DO status when the cross check alarm occurs eee 163 9 DIAGNOSIS B 64303EN 4 01 DI SIGNAL STAUS SCREEN mu Press the page key Ls and select the second page The screen shown below appears This screen shows the current DI status If there is difference of DI state between PMC and DCS is displayed on the left side of the address ABSOLUTE DI SIGNALS ADDRESS PMC DCSPMC X00083 X8808 88118808 888018888 6580748C1 60808 88888808 88888888 650750c1 60002 8808008008 88088888 60751c15 60003 88888000 0808808088 650752c1 608004 88888808 88888888 60753 1 gt 600095 88888888 88888888 6580754c1 60006 88888808 8B8BBB88B 60008 1 gt 60019 800118001 8080818088 cease f DO SIGNAL STATUS SCREEN EN Press the page key 4 and select the third page The screen shown belo
107. Safety function ensures safety with the power turned on so that an operator can open the protection door to work without turning off the power A major feature of the Dual Check Safety function is that the required time is very short from the detection of an abnormality until the power is shut off A cost advantage of the Dual Check Safety function is that external detectors and safety relays can be eliminated or simplified If a position or speed mismatch is detected by a cross check using two CPUs the safety function of the Dual Check Safety works the power to be shut off MCC off to the motor drive circuit IMPORTANT The Dual Check Safety function cannot monitor the stop state of the motors 1 OVERVIEW B 64303EN 4 01 1 1 DIRECTIVES AND STANDARDS 1 1 1 Directives Machine tools and their components must satisfy the EC directives listed below The FANUC CNC systems with the Dual Check Safety function are compatible with all of these directives Directives Directive 98 37 EC 1998 Safety of machinery Directive 2004 108 EG 2004 Electromagnetic compatibility Directive 2006 95 EC 2006 Low Voltage Equipment 1 1 2 Related Safety Standards To be compatible with the directives especially the machine directive the international standards and European standards need to be observed Important safety standards ISO 12100 1 2003 Safety of machinery Basic concepts general principles for design Part 1 Ba
108. Software disconnection alarm of the o pulse coder Turn off the power to the CNC then remove and insert the pulse coder cable If this alarm is issued again replace the pulse coder SV0460 FSSB DISCONNECT The FSSB connection was discontinued Or the FSSB connection cable was disconnected or broken The amplifier was turned off In the amplifier the low voltage alarm occurred 157 8 ALARM MESSAGE B 64303EN 4 01 Number Descripion the FSSB communication error because of the FSSB communication error The Servo detected that the positional deviation during stopping exceeded the parameter No 1839 No 1842 setting value The Servo detected that the positional deviation during traveling exceeded the parameter No 1838 No 1841 setting value 1067 FSSB CONFIGURATION The FSSB configuration error occurred Detected in software ERROR SOFT Or there is a difference in the type of connected amplifier and FSSB setting The axis card is thought to be defective V5136 FSSB NUMBER OF AMP IS The number of amplifier identified by the FSSB is insufficient than INSUFFICIENT the number of control axes Or the setting of the number of axes or the amplifier connection is in error SV5137 FSSB CONFIGURATION ERROR An FSSB configuration error occurred The connecting amplifier type is incompatible with the FSSB setting value SV5139 FSSB ERROR Servo initialization did not terminate normally The optical
109. _____ ___ Parameter input Bit spindle The reference position return direction of the spindle in Cs contour control is 0 CCW counterclockwise 1 clockwise Speed loop proportional gain in Cs contour control HIGH gear Speed loop proportional gain in Cs contour control LOW gear Parameter input Word spindle 0 to 32767 Set the speed loop proportional gain in Cs contour control Speed loop integral gain in Cs contour control HIGH gear Speed loop integral gain in Cs contour control LOW gear Parameter input Word spindle 0 to 32767 Set the speed loop integral gain in Cs contour control 216 B 64303EN 4 01 11 APPLICATION OF OTHER FUNCTIONS Gear ratio HIGH gear 4057 Gear ratio MEDIUM HIGH gear 4058 Gear ratio MEDIUM LOW gear Gear ratio LOW gear Input type Parameter input Data type Word spindle Unit of data Motor speed per spindle rotation x 100 Valid data range 0 to 32767 These parameters set the gear ration between the spindle and spindle motor 4069 Position gain in Cs contour control HIGH gear 4070 Position gain in Cs contour control MEDIUM HIGH gear 4071 Position gain in Cs contour control MEDIUM LOW gear 4072 Position gain in Cs contour control LOW gear Inputtype Parameter input Data type spindle Unit of data 0 01 sec Valid data range 0 to 32767 Set the servo loop gain in Cs contour control 4086 Motor voltage in Cs c
110. a Least unit of data Valid data range NOTE When this parameter is set the power must be turned off before operation is continued Parameter input Real axis mm inch deg Machine unit According to the input increment of corresponding axis 0 or positive 9 digit of least Input increment of data Refer to standard parameter setting table B But in case that CMR21 data range becomes 1 CMR of 9 digits of least input increment of data When the increment system is IS B and CMR 1 0 to 999999 999 When the increment system is IS B and CMR 2 0 to 499999 999 NOTE Whether to specify this parameter by using a diameter value or radius value depends on whether the corresponding axis is based on diameter specification or radius specification Position switch sometimes turns on and off repeatedly near the boundary of position switch area by very small vibration of a servo motor According to this problem position switch is inconvenient to use So hysteresis described below is applied Minimum limit of Maximum limit of position switch position switch Width of hysteresis Width of hysteresis Activated area of position switch Measuring area of position switch in case state of switch is 0 Minimum limit of Maximum limit of position switch position switch SS eee Activated area of position switch Measuring area of position switch in case state of switch is 1 The position switch is checked
111. agnosis screen for the maintenance operation of the Dual Check Safety function is displayed in the group of SYSTEM screens To display the Dual Check Safety diagnosis screen press the function key then press the DUAL CHECK soft key displayed by pressing the continuous menu key several times The state of MCC OFF TEST the state of signals in case that the alarm related to safety occurs and the cause of alarm is displayed on the Dual Check Safety diagnosis screen If an alarm is issued during execution of the dual brake monitor function information about brake test is displayed on the diagnosis screen 161 9 DIAGNOSIS B 64303EN 4 01 9 1 MCC OFF TEST STATUS SCREEN By pressing MCC TEST soft key the following MCC OFF TEST STATUS screen is displayed ffs The following items are displayed Passing time from the last MCC OFF TEST Passing time hour minute second from the last MCC OFF TEST is displayed Count of time is stopped when reaching 24 00 00 24 hours 24 00 00 is displayed at power on MCC OFF TEST execution request The CNC system notifies that it is necessary to select MCC OFF TEST mode and check whether MCC off signal MCF works normally or not When the MCC OFF TEST execution request signal is turned to 1 select MCC OFF TEST mode and execute MCC OFF TEST as soon as possible Last number of test sequence The current sequence number of MCC OFF TEST is displayed If MCC OFF TE
112. ake signal output B 64303EN 4 01 BRKx lt PMC Fn754 0 to 4 gt lt DCS PMC F 006 m 0 to 4 gt for each axis Classification Function Operation Output condition This signal is used to control mechanical brake of each axis CNC and SV output Safety Brake signal BRKx to control mechanical brake When BRKx is 0 mechanical brake is active When BRKx is 1 mechanical brake is not active Output signal Dual signal When the Dual Check Safety Function is applied this signal notifies to activate a mechanical brake When MCC is off a brake should be activated In emergency stop state or alarm state a mechanical brake is activated by this signal A machine tool builder must connect this signal to a mechanical brake In the following case this signal is 1 e Releasing brake state In the following case this signal is 0 e Activating brake state N CAUTION During the MCC off Test the MCC is turned off and on several times The brake state of the signal may change depending on the state of the MCC For the control of the brake during the MCC off Test see MCC off Test a Incase BRKx signal is 0 Emergency Stop state ESP signal is 0 1 ESP 0 BRKx Servo alarm occurs 1 Alarm 0 BRKx 0 Power on 1 Power 0 1 BRKx 0 100 B 64303EN 4 01 SIGNALS b In case signal is 1
113. anges of commands to the CNC refer to Appendix D List of Command Ranges in the USER S MANUAL B 64304EN 114 B 64303EN 4 01 6 PARAMETERS 6 5 PARAMETERS NOTE When this parameter is set the power must be turned off before operation is continued Input type Parameter input Data type Byte path Valid data range 1 Set the machine group number which each path belongs When using the 07 D set 1 in this parameter at all times NOTE When 0 is set the setting of 1 is assumed 0981 Absolute path number of each axis NOTE When this parameter is set the power must be turned off before operation is continued Input type Parameter input Data type Byte axis Valid data range 1 2 Set the path to which each axis belongs NOTE 1 If Ois set for all axes the parameter is automatically set according to the setting of the number of controlled axes of each path 2 Ifa value not within the valid data range is set each axis is assumed to belong to the first path 115 6 PARAMETERS B 64303EN 4 01 0982 Absolute path number of each spindle NOTE When this parameter is set the power must be turned off before operation is continued Input type Parameter input Data type Byte spindle Valid datarange 1 2 Set the path to which each spindle belongs NOTE 1 If Ois set for all axes the parameter is automatically set according to the setting of the number of controlled axes of each path
114. applied wait for a timer 1 Move 12 Test1 Position deviation check 13 Test1 Move in reverse direction 14 Testl Brake released wait for a timer 20 Test2 Brake applied wait for a timer 21 Test2 Move 22 Test2 Position deviation check 23 Test2 Move in reverse direction 24 Test2 Brake released wait for a timer 30 Test3 Brake applied wait for a timer 31 Test3 Move 32 Test3 Position deviation check 33 Test3 Move in reverse direction 34 Test3 Brake released wait for a timer 2 Torque limit released 128 Normal termination The test sequence numbers correspond to the states indicated in the brake test timing chart below 172 B 64303EN 4 01 Brake test timing chart Valid Torque limit BRKx Invalid 1 PMC DCS PMC command Command POS No command command Monitored Error monitor Not monitored Sequence No Test 1 Test 2 Diagnosis 3701 Data type Valid data range 9 DIAGNOSIS Next test Command Distance speed I I released i lt p applied Cancel command Position deviation monitor 12 22 32 Cause for brake test suspension Word axis 0 to 128 When a brake test being conducted is suspended for a cause such as an alarm this item indicates the cause with one of the following numbers 0 Normal state no suspension performed 1 An alarm was issued at the start of a brake tes
115. ate or not When a machine is judged to be in safe state it is necessary to turn on the signal for releasing a guard lock and outputs a signal actually to open a protective door Classification Output signal Output to both PMC but not checked doubly Function These signals show the result of monitoring of the Dual Check Safety Function These signals notify that an abnormal condition is detected in safety monitoring function of the Dual Check Safety Function such as safety speed check safety machine position check and safety position error check In the following case these signals are turned to 0 0 In dangerous condition Abnormal condition is detected by safety function In the following case these signals are turned to 1 1 In safe condition Abnormal condition is not detected 94 B 64303EN 4 01 5 l O SIGNALS Operation Each CPU notifies PMC of the result of safety monitoring through these signal A machine tool builder can release a guard lock by his ladder program when Guard Open Inhibit signal OPIHB 1 these Monitoring Result signal RSVx RSPs 1 and the condition of machine side is confirmed to be safe MCC Off signal output DCALM lt PMC F0748 7 gt lt DCS PMC F000 7 gt for all system In case this signal is 0 MCC is shut off through 2 channels of I O line respectively This signal is set to 0 when a crosscheck alarm of safety related signals or a CPU self diagnosis ala
116. can be reset by reset operation if the abnormal condition is cleared However if the problem related with the system is found and an alarm is generated when unfit condition is found by double check function of signals or so on alarm cannot be cancelled by a reset In this case to cancel the alarms turn off the power Servo Alarms SV alarm No Message The Servo detected that the positional deviation during stopping exceeded the parameter No 1839 No 1842 setting value EXCESS ERROR MOVE SV The Servo detected that the positional deviation during traveling exceeded the parameter No 1838 No 1841 setting value Dual Check Safety s SV V0476 ILLEGAL SPEED CMD SV The Servo detected that the specified speed on the axis exceeded the safety speed parameter No 13821 to 13824 No 13826 to 13829 during safety monitoring the safety check request signal VLDVx is 0 When the guard is open confirm a proper value is set to parameter No 13821 to 13824 No 13826 to 13829 and the operation is done within the safety speed SV0477 ILLEGAL MACHINE POS SV The Servo detected that the machine position on the axis is not in the safety area parameter No 13831 to 13838 during safety monitoring the safety check request signal VLDVXx is 0 When the guard is open confirm a proper value is set to parameter No 13831 to 13838 and do an operation in the safety area The safe machine position monitoring is done aft
117. chnical Conditions for 3rd Party Servo Spindle Motors amp Encoders when Applying FANUC APPENDIX GE Fanuc Dual check Safety A 2 MANDATORY STANDARDS AND DIRECTIVES 1 The standards and directives to be followed in general are listed below 73 23 EEC 93 68 EEC 89 336 EEC 92 3 1 EEC 98 37 EEC DIN EN 60068 EN 60204 1 1998 EN 60529 1991 TEC 60034 1 1999 Low voltage directive LVD Council directive from 19 February 1973 on the approximation of the laws of the member states relating electrical equipment designed for use in certain voltage limits relating to electromagnetic compatibility Electromagnetic compatibility EMC Council directive 3 May 1989 on the approximation of the laws of the member states Machinery directive Environmental testing Safety of machinery electrical equipment of machines Degrees of protection provided by enclosures IP code applicable for encoders feedback devices General requirements for motors to considered for spindle servo motors 2 The standards and directives the 3 party spindle servo motors must comply with are listed below 60034 1 1999 TEC 60034 5 2000 IEC 60034 11 1978 EN 61000 6 2 1999 EN 55011 2 1998 241 Rotating electrical machines part 1 rating and performance Rotating electrical machines part 5 degrees of protection provided by the integral design of rotating electrical machines IP code classificatio
118. ction signal SPAx SPBx are displayed Current machine position NC side and Spindle side B 64303EN 4 01 9 DIAGNOSIS 9 6 SAFETY POSITION ERROR MONITORING SCREEN The data that are related to the safety position error monitoring of the Dual Check Safety function are displayed Press the POS ERR soft key the screen shown below appears ei ee The following items a to c are displayed for every servo axis a MNT O Not Monitoring 1 Monitoring The reference position is not established b LIMIT From the safety position error limits at stop time move time servo off time the pertinent safety position error limit is displayed by judging the current state c POS ERR Current positioning error NC side and Servo side 171 9 DIAGNOSIS B 64303EN 4 01 9 7 DIAGNOSIS SCREEN Display data If an alarm is issued during execution of the dual brake monitor function information about brake test is displayed on the diagnosis screen To display the diagnosis screen press the function key then press the DIAGNOSIS soft key Diagnosis 3700 Brake test sequence number Data type Valid data range Word axis 0 to 128 This item displays the current test sequence number for each axis when a Dual Check Safety brake test is being executed When a test is suspended the suspended sequence number is displayed 0 Test not started normal state 1 Torque limit change 10 Testl Brake
119. ctor between the power section and drive motor motor contactor If an external force is applied such as a force applied onto a vertical axis an additional measure such as a mechanical brake must be securely implemented to protect against such a force Safety limitation speed When the drive system has reached a specified limitation speed a transition is made to the safe stop state measure must be implemented to prevent a set limitation speed from being changed by an unauthorized person Safety machine position When the drive system has reached a specified positional limit a transition is made to the safety stop state When a positional limit is set a maximum move distance traveled until a stop occurs must be considered A measure must be implemented to prevent a set positional limit from being changed by an unauthorized person B 64303EN 4 01 1 3 1 3 1 Detection Evaluation Response 1 3 2 1 OVERVIEW BASIC PRINCIPLE OF DUAL CHECK SAFETY Features of Dual Check Safety Dual Check Safety function has the following features e Two channel configuration with two or more independent CPUs Cross check function for detecting latent errors A servo motor detector signal is sent via the servo amplifier and is applied to the CNC through the FSSB interface Then it is fed to two CPUs a CNC CPU and a Servo CPU A spindle motor detector signal is sent via the spindle amplifier and is applied to the CNC connected
120. d Safety machine position Selection signal SVAn SVBn Parameter for Parameter direction direction SPAn SPBn servo axis for spindle parameter parameter Safety limit speed 1 Safety machine position 1 13821 4372 13831 13832 Safety limit speed 2 Safety machine position 2 No 13822 No 4438 No 13833 No 13834 Safety limit speed 3 Safety machine position 3 No 13823 No 4440 No 13835 No 13836 Safety limit speed 4 Safety machine position 4 No 13824 No 4442 No 13837 No 13838 0 0 N CAUTION Safety Speed Safety Machine Position Selection signal is a safety signal This signal is input through both PMC and DCS PMC Both CNC and PMC check doubly inconsistency of this signal 103 5 SIGNALS B 64303EN 4 01 Position Information Effect signal output POSEx lt Fn766 0 to 4 gt lt DCS F 018 m 0 to 4 gt for each axis Classification Function Operation This signal is output when Dual Check Safety function is activated and the reference point is established When the reference point is not established the machine system is in danger state because Safety Machine Position Monitoring and Safety Position Error Monitoring are not active If this signal is O Machine Tool Builder has to control not to open the protective door Output signal This signal output to both PMC but is not monitored doubly This signal i
121. d by the ladder program to prevent it from opening When the safe speed is exceeded by some axes with the guard open VLDPs 0 alarm SP0757 or SP9069 occurs to stop the spindle in the free running or controlled stop state Spindle output control by PMC is a function of controlling the speed and polarity of spindle motor rotation of each spindle by using the PMC The Dual Check Safety function and spindle output control by PMC can be used to construct a machine that operates as shown below e Automatically reduces the speed of the spindle motor to the safe speed or lower after a guard open request is input to allow the guard to open e Prevents an alarm by the safe speed limit monitoring function from occurring by limiting the speed of the spindle motor to the safe speed limit or less with the guard open For speed control of the feed axis see Section 11 2 EXTERNAL DECELERATION 195 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 11 3 2 Specifications Switching control Spindle output control function by the PMC can be used to specify the following e Spindle motor speed number of rotations e Output polarity for each spindle motor direction of rotation Usually the CNC is used to control the speed and polarity of the first spindle motor If a multi spindle control function T series is added bit 3 MSP of parameter No 8133 1 the CNC can also control the second spindle motor Spindle output control by th
122. de can be performed as with normal servo axes Although interpolation is enabled for the spindle and servo axis in the Cs contour contro mode this subsection describes only spindle positioning not interpolation of the spindle and servo axis Setting the Cs contour control axis The axis targeted for Cs contour control is placed as one axis of CNC control axes Any of the control axes can be selected as the Cs contour control axis but one of 1 to 2 The Ist to 2nd logical spindle is used as the Cs axis must be set for specifying the servo axis number parameter No 1023 The Cs contour control axis must be set as a rotation axis bit 0 of parameter No 1006 is 1 and parameter No 1022 is 0 The axis name parameter No 1020 of the Cs contour control axis can be arbitrarily selected To use the second spindle within the path as a Cs axis set bit 7 CSS of parameter No 3704 to 1 Shifting to Cs contour control To shift from the spindle rotation control mode to the Cs contour control mode set the Cs contour control change signal CON or CONSI to CONS2 to 1 This immediately stops the spindle and then executes mode switching Shifting to spindle rotation control To shift from the Cs contour control mode to the spindle rotation control mode set the Cs contour control change signal CON or CONSI to CONS2 to 0 Before switching make sure that the move command for the spindle during automatic or manual operation
123. e 24 V power externally supplied can damage the internal circuitry of the ai SV Use special care when connecting the connector At the time of shipment from factory a dummy connector for connecting CN7 A1 with CN7 A2 is set When this function is not used use the servo amplifier without removing the dummy connector 3 Be careful not to short circuit 24V CN7 A1 52 B 64303EN 4 01 3 19 5 Restrictions System configuration 3 SAFETY FUNCTIONS To use this function the following of series servo amplifier supporting the function for doubly outputting the Servo Excitation Off signal needs to be used e Servo amplifier based on the drawing number A06B 6127 H1uv uv 02 03 04 05 Moreover the following Dual Check Safety function needs to be used e Programmable Safety I O signal Section 5 4 25912 FUNCTIONS 3 20 B 64303EN 4 01 SAFE SPINDLE STOP FUNCTION Guard State signal Protective door Spindle e Spindle Rotation rotation enable Enable Switch switch signal SPEN1 2 During machine tool setup the operator may attach or detach a workpiece in the machining area with the protective door opened Conventionally the following measures have been used to ensure safety in such work e The emergency stop state is set to turn off the power to the spindle and feed axes e A device such as a magnetic contactor is
124. e I O Unit I O Link 3 is required On a system that uses a servo axis rotation enable switch a connection from the switch is additionally required Indicated in heavy lines Sch I O Link adapter VO Link 41 42 C p DA JD44A 2 JD1A I O Unit Guard State signal SGOPN Servo Unit Excitation Servo Axis Rotation lIcPD1 Off signal 1 Enable Switch signal AS2 1 SVEN I O Link 3 JD1A L Servo Excitation Off signal 2 AS2 2 lcoPtoB i SV p Icopioa To 2 Servo Amp CN Servo Excitation Off Request signal DOFEXT 5 3 SAFETY FUNCTIONS B 64303EN 4 01 Connection from ai SV connector CN7 to I O Link 3 Unit Safety relay Contact open Excitation on Contact closed Excitation off D2100 series connector Tyco Electronics Unit DOFEXT DO X 9 9 Contact open Excitation off Contact closed Excitation on Safety relay D2100 series connector Tyco Electronics Coil and contact specification of the safety relay of connector CN7 Allowable voltage range for input to the coil 20 4 VDC to 26 4 VDC Rated contact load 30 VDC 6 A resistive load N CAUTION 1 If the connector is connected incorrectly th
125. e Name High resolution serial output 2048 1ch circuit Specification Number A860 0333 T201 12 COMPONENTS LIST Remarks 2048 1ch A860 0333 T301 2048 1ch A860 0333 T701 2048 1ch A860 0333 T801 SERVO AMPLIFIER ai series 400V Common power supply Series Name al PS series Model Name Specification Number Remarks al PS 11HV 068 6150 011 al PS 18HV 068 6150 018 al PS 068 6150 030 al PS 45HV 068 6150 045 al PS 75HV A06B 6150 H075 al PS 100HV A06B 6150 H100 Spindle Amplifier Series Name Model Name al SP 5 5HV TYPE Specification Number AO6B 6151 HOO6 Hxxx Remarks al SP 11HV TYPE AO6B 6151 H0O1 1 Hxxx al SP 15HV TYPE A A06B 6151 H015 Hxxx al SP TYPE A06B 6151 H030 Hxxx al SP 45HV TYPE A06B 6151 H045 Hxxx al SP 75HV TYPE A06B 6151 H075 Hxxx al SP 100HV TYPE AO6B 6151 H100 Hxxx al SP 5 5HV TYPE B AO6B 6152 HOO6 Hxxx al SP 11HV TYPE B AO6B 6152 H01 1 Hxxx al SP 15HV TYPE B AO6B 6152 H01 5 Hxxx al SP TYPE B AO6B 6152 HO30 Hxxx al SP 45HV TYPE B AO6B 6152 HO45 Hxxx al SP 75HV TYPE B AO6B 6152 HO75 Hxxx al SP 100HV TYPE B AO6B 6152 H100 Hxxx Note xxx 580 233 12 COMPONENTS LIST Servo Amplifier Series Name SERVO AMPLIFIER i series Model Name al SV
126. e PMC can be used to specify that either the CNC or the PMC is used to set each of the spindle motor speed and output polarity If TYPE A 15 specified bit 2 MSI of parameter No 3709 is 0 when multi spindle control 1s used signals for the second spindle cannot be used Specifying the spindle motor speed The PMC can be used to specify the spindle motor speed upon executing the following e Switching the controller from the CNC to the PMC by issuing SINDx signal e Setting the spindle motor speed data calculated by the PMC in spindle control signals RO1Ix to R12Ix When controlled by the PMC the spindle motor speed is not affected by any signal for example the spindle speed override signal or parameter settings for example the maximum speed clamp parameter related to the spindle speed command of the CNC spindle control function However the individual spindle stop signals SSTPx Gn027 3 and 4 gt during use of multi spindle control are enabled bit 3 MSP of parameter No 8133 1 The spindle motor speed data is obtained from the following expression Its value can range from 0 to 4095 Spindle motor speed data Spindle motor speed Maximum spindle motor speed x4095 Normally the speed of the spindle is actually controlled If a gear train is used to connect the spindle to the spindle motor first obtain the maximum spindle speed at the maximum spindle motor speed Spindle motor speed data Spindle s
127. e door 14 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 always output If this signal is output a MCC off Test must be executed 15 POSEx Position Information Effect signal output This signal is output when Dual Check Safety Function is effective and the reference point is established When the reference point is not established the machine system is in danger state because Safety Machine Position Monitoring and Safety Position Error Monitoring are not active If this signal is 0 Machine Tool Builder has to control not to open the protective door 16 STBT Brake Test Start signal input When this signal is input a brake test is executed When a brake test is executed the brake mechanism is checked by a combination of the Safety Brake signals BRKx PMC DSC PMC doubly monitored 17 RQBT Brake Test Execution Request signal output This signal 1s output when a brake test needs to be executed When the power is turned on this signal is always output When this signal is output execute a brake test 25 3 SAFETY FUNCTIONS B 64303EN 4 01 Guard Open Request signal and Guard Unlock signal CNC PMC Door open request 24V Protective door Ladder Protective door lock The figure shows a sample connection of the protective door open request switch and the guard unlock signal In the normal state
128. e door is open Guard monitoring limit switch Ladder Example of control parts program SW1 SW Guard state monitoring switch with the forced guided contact SW3 SW4 Guard lock Guard lock switch Guard open state SGOPN Link 3 UNIT DCS PMC X000m n Ladder VLDVx Guard open program AEDES state SGOPN Y000n n RSVx Guard lock RSPs 183 10 SAMPLE SYSTEM CONFIGURATION B 64303EN 4 01 10 2 5 MCC Off Signal MCF MCFVx MCFPs DCALM MCC Contact State Signal SMC Link 1 2 UNIT MCFVx MCFPs DCALM UNIT 3 DCS PMC UNIT SMC MCFVx MCFPs DCALM U V W Electromagnetic contactor MAIN NOTE Only in case that all the signals MCF MCFVx MCFPs DCALM of the PMC side are 1 the signal which turns on the MCC should be asserted by the ladder program Also in the DCS PMC side similar logic should be made Also connect the MCC control signal to common power supply as illustrated in the figure If an error occurs in the common power supply the common power supply turns off the MCC Any equipment should not be connected on the 3 phase AC line between the MAIN MCC and common power supply NOTE The MCC shall have forced guided contacts and must fulfill the standard IEC60204 and IEC 60255 This is mandatory 184 B 64303EN 4 01 10 SAMPLE SYSTEM CONFIGURATION 10 3 EXAMPLE OF APPLICATION 1
129. e last number indicates the control axis number EDnx II Feed in the positive direction Feed in the negative direction n External deceleration setting 1 External deceleration setting 2 External deceleration setting 3 x External deceleration for 1st axis External deceleration for 2nd axis External deceleration for 3rd axis External deceleration for 4th axis 5 External deceleration for 5th axis Q WW Operation When this signal is 0 the feedrate of the corresponding axis in the corresponding direction is decreased to the corresponding speed In manual handle feed however when the external deceleration signal in either the positive direction or the negative direction is 0 external decelerations in both directions are enabled it is impossible to select one direction The external deceleration signal Gn118 Gn120 of external deceleration setting 1 has no effect on the maximum speed of manual handle feed 191 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 11 2 3 2 Signal address 7 6 5 4 3 2 1 0 I I eos IT 7 6 5 4 3 2 1 0 epe sEp23 Deseess bas Ep23 Ep22 7 6 5 4 3 2 1 0 emor Q pss 00 sepas sgpa eps 7 6 5 4 3 2 1 0 sena sens 1 eos 11 2 4 Parameters 7 6 5 4 3 2 1 0
130. e plate 78 B 64303EN 4 01 5 l O SIGNALS 5 SIGNALS 5 SIGNALS 5 1 OVERVIEW B 64303EN 4 01 The Dual Check Safety Function provides two input paths and two output paths for safe related signals safety signals For input signals safety input signals two paths are used one path for input to the CNC via I O Link 3 or PROFIBUS DP Notel and another for input to the PMC I O Link 1 2 The CNC DCS PMO and the PMC exchange the safety input signals with each other at all times to check each other If a mismatch is found between a safety input signal via one path and the same signal via another path and such a state lasts for the period set in a parameter or more the CNC DCS and the PMC independently detect an alarm Dual check for safety input signals For output signals safety output signals two paths are also used one path for output from the CNC via the I O Link 3 or PROFIBUS DP and another for output from the PMC via the I O Link 1 2 The MCC Off signal MCF is output via these two paths When both a signal via one path and the same signal via another path are 1 the signal is assumed to be 1 If either is 0 the signal is assumed to be 0 That is if the signal MCF of DCS PMC Note2 via the I O Link 3 or PROFIBUS DP and the signal MCF of PMC Note2 the Link 1 2 are both 1 the MCC may be turned on If either is 0 the MCC must be turned off In Subsection 5 3 a s
131. e position ERROR could not be obtained SV0360 ABNORMAL CHECKSUM INT The checksum alarm occurred on the built in Pulsecoder pus nn m phase data abnormal alarm occurred on the built in Pulsecoder Pulsecoder SV0363 ABNORMAL CLOCK INT The clock alarm occurred on the built in Pulsecoder Pulsecoder The digital servo software detected abnormal data on the built in Pulsecoder SV0366 PULSE MISS INT A pulse error occurred on the built in Pulsecoder SV0368 SERIAL DATA ERROR INT The communications data could not be received from the built in Pulsecoder DATA TRANS ERROR INT A CRC error or stop bit error occurred in the communications data from the built in Pulsecoder SV0380 BROKEN LED EXT Separate detector error SV0381 ABNORMAL PHASE EXT An abnormal alarm in the position data occurred on the separate linear scale SV0382 COUNT MISS EXT A count error occurred on the separate detector SV0383 PULSE MISS EXT A pulse error occurred on the separate detector detector detector from the standalone detector S r ndn ENCODER EXT An abnormality occurred on a separate detector For more information contact the scale manufacturer The digital servo software detected a disconnected Pulsecoder SV0448 UNMATCHED FEEDBACK ALARM The sign of the feedback signal from the standalone detector is opposite to that from the feedback signal from the built on Pulsecoder SV0453 SPC SOFT DISCONNECT ALARM
132. ed in the ROM area are checked The CNC software the servo software the PMC software and the spindle software are checked If some error is found an alarm is generated After power on CNC software CRC CHECK ERROR NC BASIC Servo software SERVO ROM TEST CRC CHECK ERROR PMC management software LED 6 Spindle software Spindle alarm 75 After power on Error detected Software Alarm CNC software PW0018 CRC CHECK ERROR PMC management software SYS ALM199 NON MASK INTERRUPT OTHER CPU 44 B 64303EN 4 01 3 SAFETY FUNCTIONS 3 18 SAFE STOP MONITORING When a safety door is open safe stop monitoring for servo axis and spindle can be realized by the combination of several functions Safe stop monitoring for servo axis According to the safe speed monitoring for servo axis and the safe positing error monitoring CNC and Servo monitor actual feedrate and deviation of each axis When a safety door is open monitoring of stop condition of each axis can be performed by the combination of the following three functions a b the safety speed monitoring function check whether the actual feed rate is lower than the safety level If the feedrate exceeds the safety limit an alarm is generated Actual speed is calculated with the feedback of a position detector So even if command feedrate is 0 actual feedrate may be detected as not 0 when an axis 15 moved by external power Set the va
133. eeded in some axes with the protective door open VLDVx 0 alarm SV0476 or SV0494 occurs to stop the servo motor The external deceleration function decelerates the speed of the feed axis to the external deceleration speed specified in the parameter by inputting the external deceleration signal maximum of three external deceleration speeds can be set The Dual Check Safety function and external deceleration function can be used to construct a machine that operates as shown below e Automatically reduces the speed of the feed axis to the safe speed or lower after a guard open request 15 input to allow the guard to open e Prevents an alarm by the safe speed limit monitoring function from occurring by limiting the speed of the feed axis to the safe speed limit or less with the protective door open To use the external deceleration function set bit 2 EDC of parameter No 8131 to 1 For speed control of the spindle see Section 11 3 SPINDLE OUTPUT CONTROL BY THE PMC 188 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 11 2 2 Specifications External deceleration speed The external deceleration speed is set for each of rapid traverse and cutting feed Three sets of external deceleration speeds and external deceleration signals are provided as external deceleration settings 1 2 and 3 which can be selected depending on the operator s skill or machine condition When multiple cutting conditions are provided the
134. ent an exact motion may be executed incorrectly until the safety functions setup correctly and confirm test Is completely Before the reference point return is performed and the MCC off test is performed it may be dangerous because the correct operation does not be guaranteed So the careful operations are required when the machine is operated in the status that the protection door opens The delay timer is prepared for the cross checking of the safety related input output signals When the inconsistency exists between the signal from the 2 paths system will recognize this failure after this time is passed The system will start the sequence of MCC shut off when this time is passed after the inconsistency is detected Even if lt Signal State via PMC gt does not match lt Signal State via DCSPMC gt for the time specified by parameter No 13810 after the CNC starts no alarm occurs 1 OVERVIEW B 64303EN 4 01 1 4 GENERAL INFORMATION The following requirements must be fulfilled for the Dual Check System Allconditions of the certification report have to be respected e The machine manufacturer is asked to check for insulation and protection connections before shipping the machine e Theprocedures for the changes in the System either HW or SW should be referred to maintenance manual B 64305EN When safety related components are exchanged confirmation test regarding safety functions can be performed according to Chapter 7 e
135. er Servo axis being rotated Protective door open Protective door closed lt gt lt gt lt gt Spindle excitation on gt T T eee P xaT 2 Contact Closed X Contact Open i Error state he Sh a 1 1 1 1 1 ME SGOPN t ME ae Vii nm 1 i 1 i I 1 1 SPEN2 D 4 N v DNE 71 The issue of an alarm is suppressed with a timer points are monitored UR EOM 2 channel error lt gt Set to 0 if normal V pn 1 1 alarm condition is detected for the period until spindle excitation is turned off EXOF2 1 after the Spindle Rotation Enable Switch signal SPEN2 is switched from on to off However by setting a timer on the ladder side ensure that no alarm is detected during this period 58 B 64303EN 4 01 3 SAFETY FUNCTIONS 3 20 3 Assignment of Programmable Safety I O Signals Assign Rxxx of the PMC and Ryyy of the DCS PMC as Programmable Safety I O signals input for double monitoring Thus the CNC and PMC doubly check whether the Rxxx and Ryyy bits match each other at all times Rxxx a b c d EXOF1 SPEN1 1 channel error 0 Ryyy a b EXOF2 SPEN2 0 2 channel error The Ist channel error signal or 2nd channel error signal set to 1 indicates an error state So by monitoring for matching with the state of 0 an er
136. er not to release a guard lock Once a guard is closed when MCC Off Test Execution Request signal RQT is set to 1 while a guard is open by Guard Open Request signal ORQ it is necessary not to release a guard lock until MCC off Test request signal RQT turns to 0 When MCC Off Test Execution Request signal RQT is 1 the following screen is displayed and the warning EXECUTE MCC TEST is displayed 98 B 64303EN 4 01 5 l O SIGNALS MCHN GRP TIME FROM MCC TEST 1 24 88 88 MCC TEST REQUEST 1 1 LAST TEST NO 1 8 EXECUTE TEST MACHINE GRP1 MCC Off Test Execution Request signal RQT is not output via the DCS PMC Make a ladder program to lock a protective door when MCC Off Test Execution Request signal RQT 1 Output condition In the following case this signal is set to 1 e MCC off Test is not completed after power on when bit 3 STP of parameter No 10500 is 0 e Twenty four hours have elapsed since the completion of the last MCC off Test In the following case this signal sets to 0 e MCC off Test is completed N CAUTION Do not turn Test Mode signal OPT to 0 during MCC off Test N WARNING While the MCC off Test processing is in progress the MCC Off signal MCF goes high and low to turn on and off the MCC Carry out the MCC off Test in such a state that the turning on or off of the MCC will not cause a problem 99 5 SIGNALS Safety Br
137. er the machine reference position is established 0478 ILLEGAL AXIS DATA SV The Servo detected that an error occurred on the axis during axis data transfer If the alarm occurs after performing axis number setting for the servo amplifier set parameter No 2212 4 to 1 and reset the bit to 0 and then turn off the power to the entire system When a multiaxis amplifier is used the alarm may not be cleared even if the above operation is performed once this case repeat the operation on the axis for which the alarm persists until it is cleared In the other case replace the servo amplifier if the alarm occurred 0481 SAFETY PARAM ERROR SV Error detected for safety parameter check function by Servo SV0484 SAFETY FUNCTION ERROR An error occurred in safety functions of Servo 1 The Servo or CNC detected the inexecution of servo software safety functions 2 Amismatch between the servo software results of the safety functions and the CNC results of them occurred 3 An error occurred in a servo CPU test 4 An error occurred in a servo RAM test 153 8 ALARM MESSAGE B 64303EN 4 01 No Message Description O SV0488 SELF TEST OVER TIME off Test was not completed within the specified time parameter No 1946 Check the MCC contact SV0489 SAFETY PARAM ERROR CNO Error for safety parameter check function is detected on n th axis by CNC SV0490 SAFETY FUNCTION ERROR An error occurred in safety fu
138. era _____________ e T _ es I I l I bee e 7 6 5 4 3 2 1 0 oaa sa oras T se 220 B 64303EN 4 01 11 6 4 Parameters 11 APPLICATION OF OTHER FUNCTIONS 7 6 5 4 3 2 1 0 eme bmri Input type Data type 2 DIRCTI 3 DIRCT2 Parameter input Bit spindle Setting of rotation direction at spindle orientation DIRCT2 DIRCT1 Rotation direction at spindle orientation By rotation direction immediately before It is CCW at the power on By rotation direction immediately before It is CW at the power on CCW counterclockwise direction looking from shaft of motor CW clockwise direction looking from shaft of motor Position coder method orientation stop position Input type Data type Unit of data Valid data range Parameter input Word spindle 1 pulse unit 360 4096 0 to 4096 Set the position coder method orientation stop position 4038 Spindle orientation speed Input type Data type Unit of data Valid data range Parameter input Word spindle Imin 0 to 32767 This parameter sets the orientation speed at the end of the spindle Velocity loop proportional gain on orientation HIGH gear Velocity loop proportional gain on orientation LOW gear Input type Data type Unit of data
139. eration is continued Parameter input 2 word axis Detection unit 0 to 99999999 Set the positioning deviation limit in servo off state for each axis for Dual Check Safety function If the positioning deviation in servo off state exceeds the positioning deviation limit in servo off state which is set in this parameter a servo alarm SV1069 or SV1070 occurs In Dual Check Safety function position deviation is always checked by CNC and Servo If it is detected that the position deviation in servo Off state is exceeded a servo alarm SV1069 or SV1070 occurs 118 6 PARAMETERS B 64303EN 4 01 1841 Input type Data type Unit of data Valid data range Position deviation limit of each axis in moving state during other than Dual Check Safety monitoring for Dual Check Safety Function NOTE When this parameter is set the power must be turned off before operation is continued Parameter input 2 word axis Detection unit 0 to 99999999 Set the positioning deviation limit in moving state for each axis for Dual Check Safety function in case that Safety Check is not carried out Safety Monitoring Request 1 In case that Safety Check 15 not carried out Safety Monitoring Request VLDVx 1 servo alarm SV0475 SV1071 is generated and operation is stopped immediately as in emergency stop when each CPU finds out that the deviation exceeds position deviation limit in moving state I
140. error The absolute position detector cable or servo interface module is thought to be defective SV0302 APC ALARM OVER TIME ERROR Since the absolute position detector caused an overtime error the correct machine position could not be obtained data transfer error The absolute position detector cable or servo interface module is thought to be defective SV0303 APC ALARM FRAMING ERROR Since the absolute position detector caused a framing error the correct machine position could not be obtained data transfer error The absolute position detector cable or servo interface module is thought to be defective 156 B 64303EN 4 01 8 ALARM MESSAGE Number Description SV0304 APC ALARM PARITY ERROR Since the absolute position detector caused a parity error the correct machine position could not be obtained data transfer error The absolute position detector cable or servo interface module is thought to be defective SV0305 APC ALARM PULSE ERROR Since the absolute position detector caused a pulse error the correct machine position could not be obtained The absolute position detector or cable is thought to be defective SV0306 APC ALARM OVER FLOW ERROR Since the amount of positional deviation overflowed the correct machine position could not be obtained Check parameter No 2084 and No 2085 0307 APC ALARM MOVEMENT EXCESS the machine moved excessively the correct machin
141. ess Setting example X8 setting value 101000008 E8 setting value 104000008 11980 1st byte address of Safety output signal for PMC CPU 11987 8th byte address of Safety output signal for PMC CPU NOTE When these parameters are set the power must be turned off before operation is continued Input type Parameter input Data type 2 word Valid data range 0 to 104999999 Besides the standard safety I O signals 8 byte 64 bit Programmable Safety I O signals can be freely defined These parameters set the address of the 1st through 8th double checked output signals of PMC CPU Setting value TYPE ADRS ADRS Byte address 0 This signal is not checked 101000000 Y address 102000000 R address 103000000 D address 104000000 E address Setting example X8 setting value 101000008 E8 setting value 104000008 144 B 64303EN 4 01 6 6 6 PARAMETERS PROFIBUS DI DO signals can be assigned to Dual Check Safety PMC per each slot unit To configure PROFIBUS parameters please refer to Part SETTING of PROFIBUS DP board for Series 0i MODEL D Operator s manual B 64404EN The following is the additional information relating to Dual Check Safety function Assigning PROFIBUS DI DO signals to Dual Check Safety PMC Broken wire detection Assigning PROFIBUS DI DO signals to Dual Check Safety PMC can be set up as follows 1 Press soft key D
142. f the value of this parameter is 0 the parameter No 1828 is used for the value of deviation limit in moving state In case that Safety Check is carried out Safety Monitoring Request VLDVx 0 the parameter No 1838 is used for the value of deviation limit in moving state 119 6 PARAMETERS 1842 Input type Data type Unit of data Valid data range B 64303EN 4 01 Position deviation limit of each axis in stopped state during other than Dual Check Safety monitoring for Dual Check Safety Function NOTE When this parameter is set the power must be turned off before operation is continued Parameter input 2 word axis Detection unit 0 to 99999999 Set the positioning deviation limit in stopped state for each axis for Dual Check Safety function in case that Safety Check is not carried out Safety Monitoring Request VLDVx 1 In case that Safety Check is not carried out Safety Monitoring Request VLDVx 1 servo alarm SV0474 SV1072 is generated and operation is stopped immediately as in emergency stop when each CPU finds out that the deviation exceeds position deviation limit in stopped state If the value of this parameter is 0 the parameter No 1829 is used for the value of deviation limit in stopped state In case that Safety Check is carried out Safety Monitoring Request VLDVx 0 the parameter No 1839 is used for the value of deviation limit in stopped state
143. fety APPENDIX B 64303EN 4 01 A 4 A 4 1 A 4 2 A 4 2 1 A 4 2 2 SERVO Servo Motors Driven by FANUC GE Fanuc Servo Amplifier 3 phase AC synchronous motor compact type Input voltage 200 V AC or 400 V AC Number of pole pairs actually limited to 72 Applicable maximum speed of servomotors 60 pole pairs fmax fmax 266 Hz e Rated current must be equal or less than rated current of servo amplifier e Maximum current must be equal or less than maximum current of servo amplifier e Maximum peak current of servo amplifier must be less than demagnetization current of motor e Current at dynamic braking must not exceed the maximum DB current Maximum DB current depends on servo amplifier model DB resistor relay contacts e Regenerated energy at dynamic braking must not exceed the DB resistor capacity DB resistor capacity depends on servo amplifier model Servo Encoder Speed Position Feedback Sensor Embedded in Motor Encoder with FANUC GE Fanuc Serial Interface e Signal type Special FANUC serial interface e g aAI1000S RCN723F LC191F Number of pulses per revolution up to 27 ppr A B Phase Sine wave Interface Connected to FANUC GE Fanuc Interpolation Circuit e Signal type sine wave 1V peak to peak e g Heidenhain ERM 180 e Number of pulses per revolution up to 32768 ppr 32768 512 27 ppr e Signal specification see Attachment 2 e Maximum input frequency 200 kHz 244
144. fety position switch output destinations can be assigned to each path in units of 16 points For details see the descriptions of parameter No 13840 to No 13843 in Chapter 6 PARAMETERS In the following case this signal is set to 1 e machine position of the axis is within the specified range In the following case this signal is set to 0 e machine position of the axis is out of the specified range When the axis 15 just on the boundary of the range machine position is equal to parameter setting value it is regarded that the machine position is within the range If the state of two Safety Position Switch of the signal of DCS PMC side and the signal of PMC side is different more than the specified period each CPU shuts off MCC by DCS alarm A safety related I O cross check error PW0010 or PW0011 is output NOTE Position switch signal is activated when the reference point correspond to the axis is established after power on The state of position switch is kept to 0 till then Once activating position is always checked and state of signal is changed according to the result of checking Even if the reference point is lost the state of signal is changed according to the coordinate kept in both CNC and servo CPU So if the special procedure is required when the reference point is lost design the ladder program by combining with Position Information Effect signal POSEx 102
145. fic and medical ISM radio frequency equipment NOTE 1 All products should be considered that the electrical safety of the final products can be guaranteed Degrees of protection provided by enclosures should be guaranteed according mandatory regulations for the machine applications 242 A Directives Standards and Technical Conditions for 3rd Party Servo Spindle Motors amp Encoders when Applying FANUC B 64303EN 4 01 APPENDIX GE Fanuc Dual check Safety A 3 SPINDLES A 3 1 Spindle Motors Driven by FANUC GE Fanuc Spindle Amplifier 3 phase AC asynchronous motor compact type built in type e Input voltage 200 V AC or 400 V e Winding switching available e g start delta or 2 different windings like star star e Number of pole pairs 1 2 3 or 4 e Rated current must be equal or less than rated current of Spindle Amplifier e Maximum current must be equal or less than maximum current of Spindle Amplifier e Applicable maximum speed of spindle motors gt maximum speed 60 pole pairs max output freq A 3 2 Spindle Encoder Speed Position Feedback Sensor Embedded in Motor e Signal type A B phase sine wave for speed feedback Z phase one per rotation signal for position feedback e Signal specifications see Attachment 1 243 A Directives Standards and Technical Conditions for 3rd Party Servo Spindle Motors amp Encoders when Applying FANUC GE Fanuc Dual check Sa
146. for CNC CPU 11967 8th byte address of Safety output signal for CNC CPU NOTE When these parameters are set the power must be turned off before operation is continued Input type Parameter input Data type 2 word Valid datarange 0 to 3999999 Besides the standard safety I O signals 8 byte 64 bit Programmable Safety I O signals can be freely defined These parameters set the address of the 1st through 8th double checked output signals of CNC CPU DCS PMC Setting value TYPE ADRS ADRS Byte address 0 This signal is not checked 1000000 Y address 2000000 R address 3000000 D address Setting example Y8 setting value 1000008 R8 setting value 2000008 143 6 PARAMETERS B 64303EN 4 01 11970 1st byte address of Safety input signal for PMC CPU 11977 8th byte address of Safety input signal for PMC CPU NOTE When these parameters are set the power must be turned off before operation is continued Input type Parameter input Data type 2 word Valid data range 0 to 104999999 Besides the standard safety I O signals 8 byte 64 bit Programmable Safety I O signals can be freely defined These parameters set the address of the Ist through 8th double checked input signals of PMC CPU Setting value ADRS ADRS Byte address TYPE Meaning 0 This signal is not checked 101000000 X address 102000000 R address 103000000 D address 104000000 E addr
147. g 47 3 SAFETY FUNCTIONS Signal connection diagram example Guard Open Request signal Guard State signal SGOPN Servo Axis Rotation SVENI Enable Switch signal SVEN2 Guard Unlock signal Servo Excitation Off Request signal DOFEXT SV Output Contact signal AS2 I O Link X Y I O Link 5 GF User ladder Timing chart provided in the next section DCS PM User ladder Timing chart provided in the next section 48 B 64303EN 4 01 191 3_ ORQ Gn750 0 VLDVx 752 0_ 5 750 0 RSVx Safety I O Rxxx b SVEN1 _1 error gt lt _ AS2 1 G 002 m 0 VLDVx 004 0 SVAx Programmable Safety Ryyya _ 52 2 x Ryyyb SVEN2 xd Ryyyd 2 channel error B 64303EN 4 01 3 SAFETY FUNCTIONS 3 19 2 User Ladder Processing Processing on the PMC side e With the Guard Open Request signal ORQ motor excitation is turned off DOFEXT 0 then the excitation off state AS2 1 is confirmed Next the locking of the protective door guard lock signal is released e If AS2 1 0 or AS2 2 0 contact open servo excitation on for a certain time 1 when SGOPN is 0 door open and SVEN is 0 Servo Axis Rotation Enable Switch signal turned off an error is assumed to issue a 1st channel or 2nd channel alarm Timing chart 1 Error judgment processing by the PMC side ladder Serv
148. g axis Up to 4 safety machine position can be specified Safety machine position is selected by Safety Speed Safety Position Selection signal SVAx SVBx As for the detail of Safety Speed Safety Position Selection signal refer to the description about Safety Speed Safety Position Selection signal N CAUTION The safety machine position checks are made on the basis of the machine position to the detection unit Accordingly a calculation error may occur N WARNING 1 CNC and Servo check the machine position of only each axis whose reference position is established and not check it of each axis whose reference position is not established After safety machine position parameters No 13831 to No 13838 have been set the power must be turned off then back on for the setting to become effective 134 B 64303EN 4 01 6 PARAMETERS Address to which safety position switch 1 to 16 are assigned Address to which safety position switch 17 to 32 are assigned Address to which safety position switch 33 to 48 are assigned 13840 Address to which safety position switch 49 to 64 are assigned NOTE When these parameters are set the power must be turned off before operation is continued Input type Parameter input Data type Byte Valid data range 0 1 10 11 According to this parameter the address to output 64 points of position switch signals can be assigned for each 16 points When one path is used up t
149. g setting Broken wire detection will activate when a watchdog time of 250ms expires SLAVE PARAMETER SLAVE NO 3 IDENT NO SLAVE WD 1 25 WD FACT2 1 MIN TSDR 55 amp de 195 12 00 00 rv PRMMoDULE 51750 _____ SLAVE PARAMETER SLAVE 3 SLAVE FLAG ACT NPR RSV RSV RSV RSV RSV RSV 1 ff e p STATION STATUS LOC UNL SYN FRZ WD RSV RSV RSV i 1 e GROUP IDENT 67 G6 95 G4 G3 G2 Gi o e o Bey 5 MDI KKK 12 00 00 PRMMODULE 51750 _____ 146 B 64303EN 4 01 7 START UP 7 START UP 147 7 START UP B 64303EN 4 01 7 1 START UP OPERATION The machine tool builder has to do tests for insulation and protective bonding Testing must be performed according to Chapter 19 2 and 19 3 of the standard IEC 60204 1 by an appropriately authorized person and recorded Continuity of the protective bonding circuit Insulation resistance tests When the machine is installed and the electrical connections are complete including those to the power supply the continuity of the protective bonding circuit can be verified by a loop impedance test in accordance with 612 6 3 of IEC 60364 6 61 For further details please refer to Chapter 19 2 of IEC 60204 1 The insulation resistance measured at 500 V d c between the power circuit conductors and the
150. ging servo axis or spindle is not changed An alarm related to a servo axis or a spindle occurs in the path that the axis and the spindle originally belong to and MCC shut off signal correspond to the axis or spindle is output also in original path Then as the path that gives a command and the path that an axis and a spindle belongs to should be regarded as the same group it is necessary to wire MCC off signal MCFVx MCFPs to shut off the MCC of both path at the same time when Composite control or Path speed control of Multi path control is specified 108 B 64303EN 4 01 6 PARAMETERS 6 PARAMETERS 109 6 PARAMETERS 6 1 OVERVIEW B 64303EN 4 01 The parameters related to the Dual Check Safety function safety parameters are protected by a code No 3225 for the safety parameters The value of a safety parameter cannot be modified unless the same value as the code for the safety parameters is set as the key No 3226 for the safety parameters The safety parameters are stored in two locations on the CNC The CNC PMC servo and spindle software check the matching of the parameters stored at the two locations If a mismatch is found an alarm is issued If the setting of a safety parameter is modified the power must be turned off then back on The new setting of the parameter becomes effective after the power is turned back on 110 B 64303EN 4 01 6 PARAMETERS 6 2 DATA TYPE Parame
151. ginning by setting this signal to 1 again Brake Test Execution Request signal output RQBT lt PMC Fn191 3 gt for each machine group Classification Function Output signal Single signal Output signal for requesting a brake test When this signal is set to 1 execute a brake test Even if this signal is set to 1 operation can be continued until the current machining is completed To secure safety however a brake test should be conducted as soon as possible by setting the Brake Test Start signal STBT to 1 Upon normal completion of brake test this signal is set to 0 106 B 64303EN 4 01 5 l O SIGNALS 5 4 PROGRAMMABLE SAFETY SIGNAL The programmable safety 1 signal is a safety signal that can be defined by the machine tool builder The Dual Check Safety function monitors both the safety signal determined by the system and the programmable safety 1 signal defined by the machine tool builder redundantly The programmable safety I O signal is defined by parameters See also the description of the programmable safety I O signal in Section 5 3 How to turn off programmable safety signal When it is confirmed that DCALM MCF MCFVx and MCFPs Is 0 turn programmable safety I O signal off if necessary a Incase MCC off Test is carried out When 1 and OPT 1 ignore MCF 0 b Incase of emergency stop ESP 0 When ESP 0 ignore MCF 0 107 5 l O SIGNALS B 64303EN 4 01 5 5 NOT
152. gnal check timer Input type Data type Unit of data Valid data range NOTE When this parameter is set the power must be turned off before operation is continued Parameter input Word machine group msec 0 to 1000 Input output signals related to Dual Check Safety function safety double input output signals are transmitted through two paths I O Link 1 or 2 and I O Link 3 or PROFIBUS DP CNC CPU and PMC CPU exchange the input output signals with each other at all time to check each other If a mismatch between double input output signals through two paths lasts greater than the time set in this parameter alarm PW0010 PW0011 PWO0012 or PWO013 is generated If a value of less than 16 is specified it is assumed that 16 ms is specified If a value of more than 1000 is specified it is assumed that 1000 ms is specified NOTE All paths are checked using the setting of this parameter 122 B 64303EN 4 01 6 PARAMETERS 1946 MCC off Test timer NOTE When this parameter is set the power must be turned off before operation is continued Input type Parameter input Data type Word machine group Unit of data msec Valid data range 0 to 32767 When MCC off Test mode is selected with Dual Check Safety function CNC CPU carries out MCC off Test by the safety output signal MCF If MCC off Test is not completed within the time set in this parameter a servo alarm SV0488 is generated If
153. he key is opened to enable modifications to the safety parameters The value set in this parameter 15 not displayed When the value other than 0 is set to the code for safety parameters No 3225 and the value is different from this parameter the key 15 locked and the safety parameters can not be modified When the power is turned off the value set in this parameter is cleared to 0 Then the power off results in the locked state 3717 Motor number to each spindle Input type Data type Valid data range NOTE When this parameter is set the power must be turned off before operation is continued Parameter input Byte spindle 0 to Maximum number of controlled axes Set a spindle amplifier number to be assigned to each spindle 0 No spindle amplifier is connected 1 Spindle motor connected to amplifier number 1 is used 2 Spindle motor connected to amplifier number 2 is used 3 Spindle motor connected to amplifier number 3 is used NOTE When using an analog spindle set the analog spindle at the end of the spindle configuration Example When a system uses three spindles two serial spindles and one analog spindle in total set 3 as the spindle amplifier number this parameter of the analog spindle 126 6 PARAMETERS B 64303EN 4 01 Unit of data Valid data range 7 6 5 4 3 2 1 0 UTP k NOTE When this parameter is set the power must be turned off before operation is continued
154. he safety parameters can be set when the safety parameters are not locked that is when the code for safety parameters is 0 or when the code for safety parameters is the same as the key for safety parameters No 3226 The following safety parameters are protected by a code for safety parameters No 0980 No 0981 No 0982 No 1023 No 1240 No 1838 No 1839 No 1840 No 1841 No 1842 No 1902 6 No1904 No 1945 No 1946 No 1948 No 1950 No 3225 No 3717 No 3797 No 4372 No 4438 No 4440 No 4442 No 4448 No 4460 No 10500 to No 10596 No 11950 to No 11957 No 11960 to No 11967 No 11970 to 11977 No 11980 to No 11987 No 13805 13810 No 13811 13821 to 13829 13831 to 13838 No 13840 to No 13843 13880 to No 13911 No 13912 to No 13919 No 13920 to No 13951 No 13960 to No 13991 NOTE Once parameters are locked the lock must be released or memory must be cleared before the safety parameters can be modified Moreover the code for the safety parameters cannot be modified in locked condition Be careful when setting a code for safety parameters 125 6 PARAMETERS B 64303EN 4 01 Key for safety parameters Input type Data type Valid data range NOTE When this parameter is set the power must be turned off before operation is continued Parameter input 2 word 0 to 99999999 When the same value as the code for safety parameters No 3225 15 set in this parameter t
155. he settings as for the I O Link 3 or PROFIBUS Make a ladder program for the safe related I O PMC DCS PMC In case PROFIBUS is used please refer to the Section 6 6 Assignment of PROFIBUS DI DOs to Dual Check Safety PMC 150 B 64303EN 4 01 Step 3 7 START UP Safety parameter input Enable the Dual Check Safety function and enter the safety parameters Preparation 1 Enable the Dual Check Bit 6 DCE of parameter No Safety function 1902 1 Set safety parameters indicated the table below Parameter setting Meaning 980 Machine group number of each path 981 Absolute path number of each axis 982 Absolute path number of each spindle 1023 Servo axis number of each axis 1240 Coordinates value of the reference position in the machine coordinate system 1838 Position deviation limit for each axis in moving state 1839 Position deviation limit for each axis in stopped state 1840 Position deviation limit for each axis in servo off state 1841 Position deviation limit of each axis in moving state during other than Dual Check Safety monitoring for Dual Check Safety Function Position deviation limit of each axis in stopped state during other than Dual Check Safety monitoring for Dual Check Safety Function 1904 6 Enable safety function for each axis 1945 Timer for safety input signal check 1946 Timer for MCC off Test 1948 Timer for MCC off 1950
156. hether the contact of the MCC is abnormally closed When carrying out the MCC off Test manually input this signal after the preparation of a MCC off Test is completed by the PMC 24 B 64303EN 4 01 3 SAFETY FUNCTIONS 12 OPIHB Guard Open Inhibit signal output When the Guard Open Request signal ORQ is input the CNC sets this signal to 1 The machine tool builder must design the PMC ladder logic by this signal If this signal is set to 1 the PMC confirms safety machine position and safety speed If the result of confirmation is judged safe PMC turns on the signal to release guard lock and outputs the signal to open the actual protective door If the protective door is unlocked SGOPN becomes 0 while the signal is set to 0 PMC will notify alarm occurrence to an operator by lighting a lamp or so on and bring the motor into the safe stop state NOTE This signal is not output while MCC off Test is carried out 13 RSVx RSPs Monitoring Result signal output These signals show the result of monitoring safety machine position and safety speed of each axis and the result of monitoring safety speed of each spindle When Guard Open Inhibit signal OPIHB is set to 1 machine tool builder can judge whether the machine is in the safety state or not according to these signals If safety is confirmed as a result turn on the signal to unlock the guard lock and output the signal to open the actual protectiv
157. hich belong to the same path as the alarm spindle are turned to 0 when a spindle alarm occurs When the power is turned on a MCC off test is 0 Carried out The screen is changed to Dual Check Safety Diagnosis screen automatically and the warning EXECUTE MCC TEST is displayed at power on and MCC off Test execution request signal RQT is output 1 Not carried NOTE The STP parameter is used temporarily for example when a MCC off Test is not to be made at power on as in the case of machine adjustment After adjustment set STP 0 Even when STP 1 a MCC off Test is required if the power is turned 24 hours or more after the completion of the previous MCC off Test Set the same value for all paths The screen is changed to ALARM SCREEN when an alarm occurs at power on In this case Dual Check Safety Diagnosis screen is not displayed at power on automatically 13810 Timer to start safety I O signal after power on Input type Data type Unit of data Valid data range NOTE When this parameter is set the power must be turned off before operation is continued Parameter input Word msec 0 to 32767 In Dual Check Safety function the time from CNC start up to I O cross check error start is specified just after power on 129 6 PARAMETERS B 64303EN 4 01 13811 Hysteresis width of position switch Dual Check Safety Input type Data type Unit of dat
158. ial Spindle Alarms SP9016 SSPA 16 RAM Replace the Spindle amplifier An error in a spindle amplifier control circuit control printed circuit board component was detected Error in RAM for external data SP9069 SPEED 1 Check the speed command Safety speed exceeded 2 Check the parameter setting 3 Check the sequence A motor speed exceeding the safety speed was detected when the safety speed monitoring is enabled Alternatively an error was detected at free run stop time SP9070 ILLEGAL AXIS Match the setting on the spindle Axis data error amplifier side to the connection The connection state of the spindle state amplifier does not match the amplifier setting 155 8 ALARM MESSAGE B 64303EN 4 01 SP9071 SAFETY Reenter the safety Safety parameter error PARAMETER parameters An error wad detected in safety parameter ERROR 2 Replace the Spindle amplifier checking control printed circuit board SP9072 MISMATCH 1 Replace the Spindle amplifier Motor speed judgment mismatch RESULT OF control printed circuit board A motor speed judgment mismatch MOTOR SPEED 2 Replace the main board or occurred between the CNC and spindle CHECK sub CPU board on the amplifier ERROR control printed board NE por control printed circuit board SP9076 INEXECUTION OF Replace the Spindle amplifier Safety function not executed SAFETY control printed circuit board Any safety function was no
159. ication Function Operation This signal 15 Input when an operator intends to release the guard lock and open the protective door Input signal Single signal In order to open the protective door this signal requests CNC to unlock the guard lock with the Dual Check Safety Function Guard Open Request signal ORQ is not input via the DCS PMC 0 Not request to open guard lock 1 Request to open guard lock When CNC detects that the Guard Open Request signal ORQ is 1 CNC returns Guard Open Inhibit signal A machine tool builder must design the PMC ladder program so that the guard lock is released after judging the result of safety machine position check safety speed check safety position error check to be safe or other safety condition such as Dual Check alarm status signal to be safe This signal is not a safety signal that is checked doubly But this is an important signal to make up the safety system Then a machine tool builder must design the proper ladder program to deal with this signal IMPORTANT The mistake of the ladder program cannot be checked So be sure to perform the confirmation of the safety function refer to the chapter 7 Guard State signal Machine side input signal SGOPN PMC X machine side signal gt lt DCS PMC X machine side signal for each safety door Classification Function Operation Input the guard state of the protective door to this signal When the pr
160. ignal name is followed by its symbol and addresses via Link 1 4 2 gt and lt via I O Link 3 or PROFIBUS DP gt Then for an input signal its classification function and operation are described in this order For an output signal its classification function and output condition are described in this order For information about the emergency stop mode and MCC off Test mode described in Subsection 5 3 see Subsection 5 3 NOTE 1 I O Link and PROFIBUS DP can not be used for the safety X Y signals at the same time 2 DCS Dual Check Safety PMC PMC For the PMC refer to PMC PROGRAMMING MANUAL B 64393EN 80 B 64303EN 4 01 5 l O SIGNALS 5 2 SIGNAL ADDRESS Via Link 1 2 PMC n 0 or 1 NC path number 1 7 6 5 4 3 2 1 0 xo St ese 7 6 5 4 3 2 1 0 l 7 6 5 4 3 2 1 0 PT omj or 7 6 5 4 3 2 1 0 pp ee ee eee 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 Gn749 7 6 5 4 3 2 1 0 Gn750 VLDVS VLDVA VLDV3 VLDV2 vtpvi 7 6 5 4 3 2 1 0 ovs 7 6 5 4 3 2 1 0 ovs vas sva svas svaz 7 6 5 4 3 2 1 0 ovss sves svea sves svez sver 7 6 5 4 3 2 1 0 ovs _________ sper saz spat 81 5 l O
161. indicated upon detection Bit Symbol Set to 1 when a safety parameter failure is detected Set to 1 when an axis data failure is detected Set to 1 when the speed exceeds Safety Limit Speed for each Spindle set by the parameter 165 9 DIAGNOSIS B 64303EN 4 01 SERVO STATUS SCREEN mu Press the page key 4 and select the fifth page The screen shown below appears When the judging result of safety function of CNC is not the same as other CPU the cross check alarm occurs This screen shows the cause of cross check alarm related to a servo motor ABSOLUTE 0 000 O 000 RUN TIME 25 CYCLE TIME 85 NHLKJ 88888888 HOOOHOO J EXCESS ERR 88888888 88888888 K SPEED ERR 88888888 688888888 L POS ERR 88808888 08888888 M AXIS NO ERR 888808888 G888BBBB N SAFE PRM ERR 88888888 88888868 MEM 18 33 84 lt LU RELATI ALL HANDLE MCC ROSS gt VE TEST HECK Cross check data about the following items for the servo CPU and CNC CPU is displayed When no alarm is detected in a cross check the results of the current check are indicated When an alarm is detected in a cross check the held data is indicated upon detection Set to 1 when the amount of positional deviation exceeds Positional Deviation Limit during Safety Monitoring set by the parameter Set to 1 when the speed exceeds Safety Limit Speed for each Axis se
162. ine groups is 1 at all times In this case those signals that are set for each machine group are always assigned to the first path So use the signal area for the first path to input output those signals 20 B 64303EN 4 01 3 SAFETY FUNCTIONS related with Dual Check Safety Function n NC path number 1 for m NC path number 1 x 20 for DCS Symbol 40008 4 bos PMC monitoring HOn l Said State one lt G 002 m 0 to nos PMC monitoring lt G 003 m 0 to 5 nee PMC monitoring SVAn Safety Speed lt Gn752 0 to 4 Gn753 0 to 4 gt PMC Dual input Safety Position Selection signal Servo lt G 004 m 0 to 4 monitoring G 005 m 0 to 4 gt DCS o SPBn lt G 006 m to 1 4 to 5 gt ee PMC monitoring B lt G 000 m d DCS PMC monitoring for all system lt F000 7 gt pos PMC for each machine group lt F 000 m s DCS PMC CR Fn752 0 to 4 PMC Dual output for each servo axis lt F 004 m 0 to DCS PMC for each spindle F 005m 0 to DCS PMC WK signal Servo lt Fn754 0 to 4 gt PMC Dual output i 006 m 0 to mE PMC G lt F 007 m to DCS PMC Programmable Safety I O signals Dual input Pic Dual w 10 Guard Open Request signal 3 gt PMC 11 OPT TestModesgna X Test Mode Signal Gn191 22 PMC lt F 019 m 0 gt 7 lt F 002 010 ed
163. ing servo motor The cross check cycle represents a cycle at which all I O data subject to cross checking is compared Cross check cycle 8 ms 1 OVERVIEW B 64303EN 4 01 1 3 2 3 Error analysis The table below indicates the results of system error analysis controlled by the Dual Check Safety function Error analysis when the protection door is open Excessive speed Amplifier or control unit failure Safety limitation speed monitoring function for Spindle axis operation error etc EN60204 1 Category 1 0 stop Excessive speed Amplifier or control unit failure Safety limitation speed monitoring function for feed axis operation error etc EN60204 1 Category 1 0 stop Feed axis safety Amplifier or control unit failure Safety machine position monitoring machine position operation error etc function error EN60204 1 Category 1 0 stop Input output signal Wiring error control unit failure etc Safe related I O signal monitoring function error EN60204 1 Category 1 0 stop Error analysis when the protection door is closed Input output signal Wiring error control unit failure etc Safe related I O signal monitoring function error EN60204 1 Category 1 0 stop 1 3 2 4 Remaining risks The machine tool builder is to make a failure analysis in connection with the control system and determine the remaining risks of the machine The Dual Check Safety system has the following remaining risks a The safety function
164. ing the user and preventing damage to the machine Precautions are classified into Warning and Caution according to their bearing on safety Also supplementary information is described as a Note Read the Warning Caution and Note thoroughly before attempting to use the machine N WARNING Applied when there is a danger of the user being injured or when there is a danger of both the user being injured and the equipment being damaged if the approved procedure is not observed N CAUTION Applied when there is a danger of the equipment being damaged if the approved procedure is not observed NOTE The Note is used to indicate supplementary information other than Warning and Caution e Read this manual carefully and store it in a safe place 5 1 B 64303EN 4 01 PREFACE PREFACE Description of this manual Applicable models The manual consists of the following chapters Chapter 1 OVERVIEW Chapter 2 SYSTEM CONFIGURATION Chapter 3 SAFETY FUNCTIONS Chapter 4 INSTALLATION Chapter 5 I O SIGNALS Chapter 6 PARAMETERS Chapter 7 START UP Chapter 8 ALARM MESSAGE Chapter 9 DIAGNOSIS Chapter 10 SAMPLE SYSTEM CONFIGURATION Chapter 11 APPLICATION OF OTHER FUNCTIONS Chapter 12 COMPONENTS LIST Appendix A DIRECTIVES STANDARDS AND TECHNICAL CONDITIONS FOR 3RD PARTY SERVO SPINDLE MOTORS amp ENCODERS WHEN APPLYING FANUC GE FANUC DUAL CHECK SAFETY This manual can be u
165. installed between the servo amplifier and servo motor and between the spindle amplifier and spindle motor This function turns off the power to the spindle in a safe manner based on the dual monitoring function For this purpose this function outputs the state signal excitation off signal of the power output circuit built into the spindle amplifier as two independent signals from the spindle amplifier and assigns them as Programmable Safety I O signals Section 5 4 By using this function safety can be secured in turning off the power to the spindle only without using an emergency stop or magnetic contactor So machine usability can be enhanced A function for rotating the spindle by power with the door open can be additionally used by setting a spindle rotation enable switch Spindle Excitation Off signal 1 EXOF1 ai SP Spindle Motor ai SV State Cross a Servo monitor ladder check Motor ai PS PMC CPU Safety yo Safety CNC CPU Contact output State monitor adder AC reactor Magnetic Cut command and check signal contactor Spindle Excitation Off signal 2 EXOF2 54 B 64303EN 4 01 Safety function 3 SAFETY FUNCTIONS When the protective door is open the safety function monitors whether the power to the spindle motor is turned off without turning off the magnetic contactor connected to the power supply or the input
166. ion Function Power interruption signal Input signal This signal specifies an emergency stop When the signal is set to 1 the spindle motor and spindle amplifier become ready to operate When the signal is set to 0 the spindle motor immediately decelerates and then stops By monitoring the orientation completion signal ORARx set the signal to 0 if there is a deviation from the stop position Since the spindle motor becomes ready to rotate when the signal is set to 1 the spindle motor immediately rotates upon receiving the rotation command Therefore immediately after setting this signal to 0 reset the command signals velocity command forward command and reverse command for the spindle amplifier MPOFA lt Gn073 2 gt for 1st spindle MPOFB lt Gn077 2 gt for 2nd spindle Classification Function Input signal This signal turns off the excitation of the motor By setting the signal to 1 the excitation of the spindle motor can be turned off to enable free running By monitoring the orientation completion signal ORARx set the signal to 1 if there is a deviation from the stop position The excitation of the motor can be turned on again after the motor stops zero speed signal SSTx 1 Even if this signal is set to 0 excitation cannot be turned on while the motor is rotating SSTx 0 After turning off the excitation of the motor reset the command signals velocity command forward command and reverse c
167. ional limit is placed at the center of an axis and the position is moved at many different speeds in a rapid traverse mode Thus the distance traveled on the axis until stop state 1s set by a stop response is measured The machine tool builder is to determine a safety limit stop position including a safety margin The user needs to enter the correct password before setting safety parameters with the system After a safety parameter is modified a check test needs to be conducted on the related safety function and the test results need to be recorded in a report 149 7 START UP B 64303EN 4 01 7 2 START UP OF THE SAFETY FUNCTION 7 2 1 Initial Start up Disable dual check Safety related Safety parameter Machine start up Initial state First check that the machine starts up normally when the Dual Check Safety function is disabled Main flow Step 1 Preparation 1 Disable the Dual Bit 6 DCE of parameter No Check Safety function 1902 0 Preparation 2 Wire to control the Connect the relay to control MCC MCC with I O output NOTE When the Dual Check Safety function is disabled the MCC Off signal DCALM MCFVx MCFPs is set to 1 The MCC Off signal changes according to the state of the emergency stop signal on the PMC side So make a ladder program to output DO signal to control the relay for the MCC control according to the MCC Off signal Step 2 DCS PMC side setting Make t
168. is always checked by CNC and Servo In case that Safety Check is carried out Safety Monitoring Request VLDVx 0 servo alarm SV0475 SV1071 is generated when each CPU finds out that the deviation exceeds position deviation limit in moving state 117 6 PARAMETERS Input type Data type Unit of data Valid data range Input type Data type Unit of data Valid data range B 64303EN 4 01 Position deviation limit for each axis in stopped state during safety check NOTE When this parameter is set the power must be turned off before operation is continued Parameter input 2 word axis Detection unit 0 to 99999999 Set the positioning deviation limit stopped state for each axis for Dual Check Safety function If the position deviation at halt time exceeds the position deviation limit at halt time set in this parameter during safety monitoring when the Safety Check Request signal VLDVx is set to 0 servo alarm SV0474 or SV1072 is issued In Dual Check Safety function position deviation is always checked by CNC and Servo In case that Safety Check is carried out Safety Monitoring Request VLDVx 0 servo alarm SV0474 SV1072 is generated when each CPU finds out that the deviation exceeds position deviation limit in stopped state Position deviation limit for each axis in servo off state during safety check NOTE When this parameter is set the power must be turned off before op
169. is fully completed If the switching is made while the spindle is rotating the interlock state is entered or an alarm indicating a too large positional deviation occurs 212 B 64303EN 4 01 11 APPLICATION OF OTHER FUNCTIONS 11 5 3 Signals 11 5 3 1 Details on signals Cs contour control change signal CON lt Gn027 7 gt Classification Input signal Function When the Cs contour control function is used this signal specifies switching between the spindle rotation control mode and Cs contour control mode for the first spindle within the path When this signal is set to 1 the spindle is switched from the spindle rotation mode to the Cs contour control mode When this signal is set to 1 while the spindle is rotating the spindle stops immediately and then enters the Cs contour control mode When this signal is set to 0 the spindle is switched from the Cs contour control mode to the spindle rotation mode N CAUTION This signal is enabled only when bit 7 CSS of parameter No 3704 is 0 When bit 7 CSS of parameter No 3704 is 1 when Cs axis contour control by the individual spindles is used use the Cs contour change signals CONS1 Gn274 0 to CONS2 Gn274 1 of the individual spindles Cs contour control change completion signal FSCSL lt Fn044 1 gt Classification Output signal Function This signal indicates that the Cs contour control mode is entered Output condition In the spindle rotation control mode this
170. is not active until the control system and drive system have fully powered up The safety function cannot be activated if any one of the components of the control or drive is not powered on b Interchanged phases of motor connections reversal in the signal of encoder and reversal mounting of encoder can cause an increase in the spindle speed or acceleration of axis motion If abnormal speed detected system controlled to brake to zero speed but no effective for above error MCC off is not activated until the delay time set by parameter has expired Electrical faults component failure etc may also result in the response described above c Faults in the absolute encoder can cause incorrect operation of the safety machine position monitoring function d With a 1 encoder system encoder faults are detected in a single channel but by various HW and SW monitoring functions The parameter related to encoder must be set carefully Depending on the error type a category 0 or category 1 stop function according to EN60204 1 is activated e The simultaneous failure of two power transistors in the inverter may cause the axis to briefly motion depend on number of pole pairs of motor 8 B 64303EN 4 01 g h i j k D n 1 OVERVIEW Example An 8 pole synchronous motor can cause the axis to move by a maximum of 45 degrees With a lead screw that is directly driven by e g 16mm per revolution this corresponds to a ma
171. it to open the protective door in emergency stop state IMPORTANT 1 Emergency stop button must fulfill the Standard IEC60947 5 1 This is mandatory 2 signal for emergency stop is available for each path However ensure that the G signals are controlled from the viewpoint of all paths 8 B 64303EN 4 01 SIGNALS Example of protective door open shut sequence The following figure shows the sequence in case of emergency stop EMG P ESP SMC RSVx RSPs Actual door lock releasing signal SGOPN Safety related I O Door closed Door closed Actual door open close signal Door opened A machine tool builder must design the ladder program as follows 1 In case Emergency Stop signal ESP is input the guard lock signal is turned off after confirming safety machine position safety speed and safety position error by the Monitoring Result signals RS Vx RSPs 2 In this example it is assumed that a protective door with an electronic door lock is applied When a door is opened door lock releasing signal must be turned off At the same time Guard State signal SGOPN machine side signal is changed to show guard releasing state 3 This is door open state 4 Protective door is shut and locked Then Emergency Stop signal ESP is released 1 Pay attention the time t 5 After Emergency Stop signal is released CNC turns MCC Off signal
172. itoring state and the parameter of limit of deviation is shown in the following table Moving Safety monitoring is activated In case VLDVx 0 No 1838 Safety monitoring is not activated In case VLDVx 1 No 1841 Stopping No 1839 No 1842 Servo off No 1840 No 1840 Error detected CPU Alarm CNG SV1069 SV1071 SV1072 SV SV0474 SV0475 8V1070 When position deviation exceeds the limit given by the parameter No 1839 in stop state No 1838 in moving state and No 1840 in servo off state during safety monitoring Monitoring result signal RSVx is set to 0 regardless of the state of Safety check request signal VLDVx This function is valid after the reference position return is finished or the follow up of absolute position is finished in case an absolute position coder N CAUTION This function is activated only in position control mode 40 B 64303EN 4 01 3 SAFETY FUNCTIONS 3 13 AMPLIFIER CIRCUIT MONITORING FUNCTION The SV and the SP transmit the data of plural axes to amplifiers through one electronic circuit LSI The CNC the SV and the SP check whether this transmission is performed normally without placing data on wrong address In case of servo amplifier the CNC axis numbers kept by the CNC are compared with the CNC axis numbers kept by the SV In case of spindle amplifier the spindle numbers kept by the CNC are compared with the spindle number kept by the
173. k target signals The Emergency Stop signals in X address are double checking signals Position switch signals as many as indicated below are provided depending on the number of paths 1 When one path is used 32 points maximum 2 When two paths are used with the T series 64 points maximum The following signals are provided for each machine group Emergency Stop ESP X0008 Test Mode signal OPT Guard Open Request signal ORQ Guard Open Inhibit signal OPIHB MCC Off signal MCC Contact State signal 5 MCC Test Execution Request signal RQT With the FSO D the number of machine groups is 1 at all times With the FSO D the signals Fxxxx Gxxxx prepared for each machine group are located in the signal area for the first path at all times 85 5 l O SIGNALS B 64303EN 4 01 Interface Signals between the CNC and the PMC The addresses for the interface signals F and G signal addresses viewed from the CNC between the CNC and the PMC are shown below For 1 path CNC PMG F0000 G0000 DCSPMC When two paths are used with a CNC of the T series path 1 CNC path 2 x Foooo G0000 F1000 G1000 x DCSPMC x DCSPMC G000 Fozo 6020 x The signal for the x th axis of the k th path is placed in the x 1 th bit in the address G or F for the k th path in the above figure n k 1 7 6 5 4 3 2
174. l axis 1023 Number of the servo axis for each axis Input type Parameter input Data type Byte axis Set relationships between the individual axes and the servo axis numbers Set one of 1 to 2 1 to 2 logical spindle number for the Cs contour control axis Setting value 1 Cs contour control axis by the first logical spindle 2 Cs contour control axis by the second logical spindle N CAUTION 1 When Cs contour control is to be exercised on the second spindle within the path bit 7 CCS of parameter No 3704 needs to be set to 1 2 One spindle cannot be set as multiple Cs contour control axes 1260 The shift amount per one rotation of a rotation axis Input type Parameter input Data type Real axis Set the amount of a shift per one rotation of a rotation axis Set 360 0 for the Cs contour control axis 215 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 1820 Command multiplier for each axis CMR Input type Data type 3704 Input type Data type 7 CSS Unit of data Valid data range Unit of data Valid data range Parameter input Byte axis Set 2 for the Cs contour control axis 7 6 5 4 3 2 1 0 SS pes T qj Parameter input Bit path On the second spindle in the path Cs contour control 15 0 Not performed l Performed To exercise Cs contour control on the second spindle in the path set this bit to 1 7 6 5 4 3 2 1 0 ______
175. larm is suppressed with a timer 2 d channel error lt gt 1 1 1 1 1 1 1 1 1 1 1 i 1 L I I l I 1 I Set to 0 if normal lt 1 An alarm condition is detected for the period until servo excitation 15 turned off 2 2 1 after the Servo Axis Rotation Enable Switch signal SVEN2 is switched from on to off However by setting a timer on the ladder side ensure that no alarm is detected during this period 3 19 3 Assignment of Programmable Safety I O Signals Assign Rxxx of the PMC and Ryyy of the DCS PMC as Programmable Safety I O signals input for double monitoring Thus the CNC and PMC doubly check whether the Rxxx and Ryyy bits match each other at all times Rxxx a b C d AS2 1 SVEN1 1 channel error 0 b C d AS2 2 SVEN2 0 2 d channel error The Ist channel error signal or 2nd channel error signal set to 1 indicates an error state So by monitoring for matching with the state of 0 an error state 15 detected If a mismatch occurs due to an error state safety is secured by turning off the magnetic contactor of the ai PS to turn off the power to the main circuit 50 B 64303EN 4 01 3 SAFETY FUNCTIONS 3 19 4 Connections CNC l O LINK JD51A FSSB COP10A In addition to Dual Check Safety connections a connection from connector CN7 on the ai SV to th
176. lease the guard lock by his ladder program when the following conditions are met OPIHB 1 RSVx and RSPs to be refered 1 and the safety conditions of the machine The safety monitor signals RSVx and RSPs are redundant output signals Each set of RSVx and RSPs monitors the speed or other data items with a separate circuit Therefore a temporary mismatch may occur between both sets when for example one set of RSVx and RSPs has been shifted to the safe state while the other set is not yet shifted to the safe state for example situations where the spindle is in a deceleration state In such a case if a circuit that releases a guard lock based on the state of one set of RSVx and RSPs is created an alarm such as speed limit monitoring may occur depending on the state of the other set of RSVx and RSPs 181 10 SAMPLE SYSTEM CONFIGURATION B 64303EN 4 01 e Toprevent this create a circuit that releases a guard lock when both sets of RSVx and RSPs have shifted to the safe state as shown by NOTE in the figure e Ora circuit that releases a guard lock after a while from when RSVx and RSPs shift to the safe state When using a guard lock switch of two contact type the safety relay can be omitted as shown in the following figure 182 B 64303EN 4 01 10 SAMPLE SYSTEM CONFIGURATION Example of connection when both the guard state monitoring switch and the guard lock switch are of two contact type 24V When the protectiv
177. ll have forced guided contacts and must fulfill the standard IEC60204 and IEC 60255 This is mandatory Before performing the MCC off Test stop the spindle and feed axis For axes such as the vertical axis that move when the MCC is turned off apply a brake in advance regardless of the state of the brake signal BRKx to place the axes in the servo off state N WARNING While the MCC off Test processing is in progress the MCC Off signal MCF goes high and low to turn on and off the MCC Carry out the MCC off Test in such a state that the turning on or off of the MCC will not cause a problem NOTE If MCC off Test is executed when is forced to shut off in emergency stop state servo alarm state or spindle alarm state the test cannot be executed normally MCC off Test should be executed only when the test can be executed normally 90 B 64303EN 4 01 5 SIGNALS Test No 1 2 3 4 5 128 MCF DCS PMC w M UM 3333 MCF PMC l SMC DCS PMC j l Timer limit Timer Test start Test completion Example 1 Timing chart 1 of MCC off test normal state Test No 1 2 3 4 MCF DCS PMC Tl a vt PMC us Oo SMC DCS r SMC PMC Timer limit Timer Test start Example 2 Timing chart 2 of MCC off test abnormal state 91 5 SIGNALS B 64303EN 4 01 Guard Open Request signal input ORQ lt PMC Gn191 3 gt for each machine group Classif
178. llowing describes notes and a timing chart during the MCC off Test lt 1 gt Before performing the MCC off Test stop the feed axis and spindle lt 2 gt When the MCC off Test ends the MCC Off Test Execution Request signal goes off After the MCC Off Test Execution Request signal goes off set the test mode signal to off lt 3 gt When the vertical axis is present take measures such as preparing a brake circuit for drop prevention Take 500 ms or more from when the brake is driven until test start signal OPT is activated in the ladder lt 4 gt Do not connect a peripheral device or noise filter between the MCC and the common power supply Otherwise the test may not terminate normally lt 5 gt Enable the servo off signals SVF1 5 after applying a brake to the servo axis connected to the common power supply to be tested If the servo off signals are not input an alarm may occur during the test lt 6 gt When the power failure backup module is connected the ready signal contact output signal RDY of the power failure backup module goes off during the MCC off Test Therefore make considerations to eliminate a problem in the ladder A possible measure is to mask the ready signal by the test mode signal 23522 3 SAFETY FUNCTIONS B 64303EN 4 01 Timing chart of the MCC off Test During a test MCC off Test start Signal from the user Brake on Vertical axis brake Signal from the user Test mode signal OPT Gn191
179. lt Fn274 0 to Fn274 1 gt Classification Function Output condition 11 5 3 2 Signal address Output signal This signal indicates that the first and second spindles within the path are switched to the Cs contour control mode In the spindle rotation control mode these signals are 0 In the Cs contour control mode these signals are 1 N CAUTION These signals are enabled only when bit 7 CSS of parameter No 3704 is 1 when Cs contour control by the individual spindles is used When bit 7 CSS of parameter No 3704 is 0 use the Cs contour change completion signal FSCSL Fn044 1 7 6 5 4 3 2 1 0 _ om I I Leon consi 7 6 5 4 3 2 1 0 a emm DL Dese ees 214 B 64303EN 4 01 11 APPLICATION OF OTHER FUNCTIONS 11 5 4 Parameters 7 6 5 4 3 2 1 0 Lo paj j ee Input type Parameter input Data type Bit axis 0 ROTx Setting linear or rotation axis 0 Linear axis 1 Rotation axis Set 1 for the Cs contour control axis 3 DIAx The move command for each axis is based 0 Radius specification 1 Diameter specification Set 0 for the Cs contour control axis 1022 Setting of each axis in the basic coordinate system Input type Parameter input Data type Byte axis Specify whether each axis is one of the three basic axes X Y Z or one of their parallel axes Set 0 for the Cs contour contro
180. lue of safety limit that does not cause an alarm when feedrate command is 0 By the safe positioning error monitoring function check whether position deviation is within a safety limit If an axis is moved unexpectedly an alarm is generated According to Axis moving signal MVx Fn102 check whether axis motion command 15 not given Axis moving signal Is prepared for PMC and is not double check signal Safe stop monitoring for spindle In monitoring of the safe speed limit of the spindle the actual speed of the spindle motor is monitored at the CNC and spindle When a safety door is open monitoring of stop condition of each spindle can be performed by the combination of the following two functions a b By the safety speed monitoring function check whether the actual speed is lower than the safety level If the feedrate exceeds the safety limit an alarm is generated Actual speed is calculated with the feedback of a position detector So even if command speed is 0 actual speed may be detected as not 0 when a spindle is moved by external power Set the value of safety limit that does not cause an alarm when speed command is 0 There is a possibility that spindle rotate at speed lower than safety speed limit Then it is necessary to select the function to make position control loop such as spindle positioning T series Cs contouring control or spindle orientation 45 3 SAFETY FUNCTIONS 3 19 Guard State sig
181. m must be designed to carry out the following control lt 1 gt When MCC off Test request signal is set to 1 at power on or in case 24 hours are elapsed after the previous MCC off Test the protective door is locked till the MCC off Test is performed But the operator can operate the machine while the protective door is closed lt 2 gt When the MCC off Test request signal RQT is turned to 0 the protective door can be unlocked Example DO state during MCC off Test Test No 1 2 3 4 5 128 MCF DCS PMC T L MCF PMC SMC DCS PMC SMC PMC RQT Timer limit Timer Test start Test completion 34 B 64303EN 4 01 3 SAFETY FUNCTIONS When the MCF signals on both the PMC and DCSPMC sides are 1 confirm that the MCC is on SMC 0 Confirm that the MCC turns off when the MCF signal on the DCSPMC side is set to 0 5 1 Confirm that the MCC turns on when the MCF signal on the DCSPMC side is returned to 1 SMC 0 Confirm that the MCC turns off when the MCF signal on the PMC side is set to 0 SMC 1 Confirm that the MCC turns on when the MCF signal on the PMC side is returned to 1 SMC 0 This state is entered when tests 1 to 5 end successfully IMPORTANT Carry out the MCC off Test with the protective door closed As the test shuts off the MCC prepare the system for mechanical MCC shut off before starting the MCC off Test The fo
182. mpletion 222 B 64303EN 4 01 11 APPLICATION OF OTHER FUNCTIONS 4075 Orientation completion signal detection level limits of in position Input type Parameter input Data type Word spindle Unit of data 1 pulse unit 360 4096 Valid data range 0 to 100 This data is used to set the detecting level of orientation completion signal ORARx When the spindle position is located within the setting data on orientation completion the bit of orientation completion signal ORARx in the spindle control signals is set to 1 4076 Motor speed limit ratio on orientation Input type Parameter input Data type Word spindle Unit of data 1 Valid data range 0 to 100 This data is used to set motor speed limit ratio on orientation 4077 Orientation stop position shift value Input type Parameter input Data type Word spindle Unit of data 1 pulse unit 360 4096 Valid data range 4095 to 4095 In the position coder method orientation set this data to shift stop position 4084 Motor voltage setting on orientation Input type Parameter input Data type Word spindle Unit of data 1 Valid data range 0 to 100 This parameter sets the motor voltage for orientation 223 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 11 6 5 Sequence The following is a sample sequence in which orientation is specified during rotation of the spindle and work is conducted with the spindle stopped Motor speed
183. n applicable for motors Rotating electrical machines part 11 built in thermal protection chapter 1 rules for protection of rotating electrical machines Electromagnetic compatibility EMC generic immunity standard Part 2 industrial environment Limits and methods of measurement of radio disturbance characteristics of industrial scientific and medical ISM radio frequency equipment A Directives Standards and Technical Conditions for 3rd Party Servo Spindle Motors amp Encoders when Applying FANUC GE Fanuc Dual check Safety APPENDIX B 64303EN 4 01 3 The standards and directives the linear motors and 3 party feedback devices must comply with are listed below EN 60335 1 1995 Safety of household and similar electrical appliances part 1 General requirements EN 61000 6 2 1999 Electromagnetic compatibility EMC generic immunity standard Part 2 industrial environment EN 55011 2 1998 Limits and methods of measurement of radio disturbance characteristics of industrial scientific and medical ISM radio frequency equipment 4 The standards and directives the 3 party feedback devices must comply with are listed below EN 50178 1997 Electronic equipment for use in power installations EN 61000 6 2 1999 Electromagnetic compatibility EMC generic immunity standard Part 2 industrial environment EN 55011 2 1998 Limits and methods of measurement of radio disturbance characteristics of industrial scienti
184. nal Signal Amplitude of PS1 from JY2 B 64303EN 4 01 Value 205 kHz in Spec A 256 kHz in Spec B 0 50 Vpp min 1 2 Vppmax incl tolerances 0 60 Vpp min 1 2 Vppmax incl tolerances 100 mV max 1 00 0 10 V max 4 usec min 90 3 deg SPM type 1 2 N4005 4 1 PS2 from JY5 Reference Signal MZ MZ x 2 4 Pulse Width MZ MZ 0 25 V min Check Terminal Signal Amplitude of Reference Signal MZ MZ x 2 4 0 25 V min 4 usec min SPM type 4 JY5 N4004 4 1 SPM type 1 JY2 PS1 from JY2 PS2 from JY5 Signal Offset Z 2 0 25 V N4005 4 0 SPM type 4 5 246 3 5 V max 2 V N4004 4 0 A Directives Standards and Technical Conditions for 3rd Party Servo Spindle Motors amp Encoders when Applying FANUC B 64303EN 4 01 APPENDIX GE Fanuc Dual check Safety Attachment 2 Specification of 3rd Party Servo Encoders 4 Input specifications and examples of available linear encoders 4 1 Input specifications A B type I c 2 Usable component c peperere Min Amplitude typel aof A B phase A B phase typell bof A phase b of XA phase b of B phase b of XB phase pf Z pahse of XZ phaseZ Level type I Voa Vxa VoB VxB DC Level VoA VoxA VoB VoxB Voz Voxz an 2 8 pran typeI VoA Voxa a
185. nal Protective door Servo axis rotation enable switch SVEN1 2 Servo Axis Rotation Enable Switch signal B 64303EN 4 01 SAFE SERVO STOP FUNCTION During machine tool setup the operator may attach or detach a workpiece in the machining area with the protective door opened Conventionally the following measures have been used to ensure safety in such work e The emergency stop state is set to turn off the power to the spindle and feed axes e device such as a magnetic contactor is installed between the servo amplifier and servo motor and between the spindle amplifier and spindle motor This function turns off the power to the servo axis in a safe manner based on the dual monitoring function For this purpose this function outputs the state signal excitation off signal of the power output circuit built into the servo amplifier as two independent signals from the servo amplifier and assigns them as Programmable Safety I O signals Section 5 4 By using this function safety can be secured in turning off the power to the servo axis only without using an emergency stop or magnetic contactor So machine usability can be enhanced A function for rotating the servo axis by power with the door open can be additionally used by setting a servo axis rotation enable switch Servo Excitation Off signal 1 AS2 1 Servo Excitation Off Request signal DOFEXT PMC CPU
186. nction enters the safety stop state For each feed axis and spindle up to four safe speed ranges can be specified in safety parameters Both the CNC and the SV SP monitor whether a safe speed is kept on each feed axis and spindle Limit speed can be changed by the Safety Speed Safety Position Selection signals SVAn SVBn for feed axis SPAn SPBn for spindle Safety Speed Safety Position Selection signal SVAn SVBn SPAn SPBn Safety speed 1 0 0 No 13821 No 4372 Safety speed 2 1 0 No 13822 No 4438 Safety speed 3 0 1 No 13823 No 4440 Safety speed4 1 1 No 13824 No 4442 Safety speed parameter Name Feed axis Spindle When excess limit error is detected Monitoring Result signal RSVx RSPs is set to 0 In this situation if Safety Check Request signal VLDVx VLDPs is 0 and safety monitor is executed an alarm is generated CNC SV0494 SP0757 SV SV0476 SP SP9069 SPINDLE ALARM 69 N CAUTION 1 Whenan illegal speed is detected for the servo axis if the axis is not stopped after the time specified in the parameter the MCC Off signal is turned to 0 When an illegal speed is detected for the spindle axis CNC checks whether the spindle speed decelerates continuously or not If acceleration is detected the MCC Off signal MCFPs is turned to 0 For the spindle bit 1 CTLSTP of parameter No 4399 can be used to select a stop method free run st
187. nctions of CNC 1 The Servo detected the inexecution of CNC safety functions 2 A mismatch between the CNC results of the safety functions and the Servo results of them occurred 5 0494 SPEED CMD CNC The CNC detected that the specified speed exceeded the setting parameter No 13821 to 13824 in case of position control No 13826 to 13829 in case of velocity control during safety monitoring the safety check request signal VLDVx is 0 When the guard is open confirm a proper value is set to parameter No 13821 to 13824 No 13826 to 13829 and the operation is done within the safety speed SV0495 ILLEGAL MACHINE POS CNC The CNC detected that the machine position is not in the safety area parameter No 13831 to 13838 during safety monitoring the safety check request signal VLDVx is 0 When the guard is open confirm proper values is set to parameter No No 13831 to 13838 and operation is done in the safety area The safe machine position monitoring is done for the axis whose machine reference position is established SV0496 ILLEGAL AXIS DATA CNC The CNC detected that an error occurred during axis data transfer If the alarm occurs after performing axis number setting for the servo amplifier set parameter 2212 4 to 1 and reset the bit to 0 and then turn off the power to the entire system When a multiaxis amplifier is used the alarm may not be cleared even if the above operation is performed once this
188. nd stops motors 93 5 l O SIGNALS B 64303EN 4 01 Guard Open Inhibit signal output OPIHB lt PMC Fn191 0 gt lt DCS PMC F 019 m 0 gt for each machine group CNC returns these signals as answer when CNC detects that Guard Open Request signal is set to 1 Classification Output signal Not checked doubly Function When CNC receives Guard Open Request signal ORQ 1 CNC returns these signal as answer CNC outputs Guard Open Inhibit signal OPIHB through both PMC and DCS PMC 0 Inhibit guard open 1 Permit guard open Operation A machine tool builder can release a guard lock by his ladder program when Guard Open Inhibit signal 1 Monitoring Result signal RSVx RSPs 1 and the condition of machine side is confirmed to be safe NOTE During the MCC off Test this signal is set to 0 regardless of the state of the guard open request signal ORQ IMPORTANT The mistake of the ladder program cannot be checked So be sure to perform the confirmation of the safety function refer to the chapter 7 Monitoring Result signal output RSVx lt PMC Fn750 0 to 4 gt lt DCS PMC F 002 m 0 to 4 gt for each axis RSPs lt PMC Fn751 0 to 1 gt lt DCS PMC F 003 m 0 to 1 gt for each spindle These signals show the result of monitoring safety speed safety machine position and safety position error By checking these signals a machine tool builder can judge whether a machine is in safe st
189. ne rotation signal of the SENSOR 2 Adjust the sensor motor sensor is not generated connector JYA2 SP9083 MOTOR SENSOR 1 Replace the feedback An irregularity was detected in a SIGNAL ERROR 2 Adjust the sensor motor sensor feedback signal connector JYA2 Reference of Dual Check Alarm message Dual Check Alarm by Servo CPU and CNC CPU Servo CNC Dual Check Alarm by Spindle CPU and CNC CPU No Message Spindle No Message CNC SP9069 SAFETY SPEED OVER SP0757 SAFETY SPEED OVER 69 SP9070 ILLEGAL AXIS DATA SP0756 ILLEGAL AXIS DATA 70 159 8 ALARM MESSAGE B 64303EN 4 01 No Message Spindle No Message CNC SP9071 SAFETY PARAMETER ERROR SP1700 SAFETY PARAM ERROR 71 SP9072 MISMATCH RESULT OF MOTOR SPEED SP0755 SAFETY FUNCTION ERROR 72 CHECK SP9076 INEXECUTION OF SAFETY FUNCTIONS 76 SP9077 MISMATCH RESULT OF AXIS NUMBER 77 CHECK SP9078 MISMATCH RESULT OF SAFETY 78 PARAMETER CHECK Dual Check Alarm by PMC CPU and CNC CPU Power must be off Message PMC CPU SELF TEST ERROR PMC PWO0008 CPU SELF TEST ERROR DCS PMC SAFE I O CROSS CHECK ERROR PMC PW0010 SAFE I O CROSS CHECK ERROR DCS PMC USER I O CROSS CHECK ERROR PMC PW0012 USER I O CROSS CHECK ERROR DCS 160 B 64303EN 4 01 9 DIAGNOSIS DIAGNOSIS The di
190. nents for Other eee 2277 122 230 123 SERVOJOMEPEIEIEU ce Mae e ed 231 APPENDIX A Directives Standards and Technical Conditions for 3rd Party Servo Spindle Motors amp Encoders when Applying FANUC GE Fanuc Dual check Safety 239 A 1 QENERAL una bestes aaa buio Lour 240 A 2 MANDATORY STANDARDS AND DIRECTIVES sss 241 SPINDLES Su L 243 A 3 Spindle Motors Driven by FANUC GE Fanuc Spindle Amplifier 243 A 3 2 Spindle Encoder Speed Position Feedback Sensor Embedded in Motor 243 SGERVO a OESTE NUR 244 4 1 Servo Motors Driven by FANUC GE Fanuc Servo Amplifier 244 4 2 Servo Encoder Speed Position Feedback Sensor Embedded in Motor 244 A 4 2 1 Encoder with FANUC GE Fanuc Serial Interface 244 A 4 2 2 AJB Phase Sine wave Interface Connected to FANUC GE Fanuc Interpolation Circuit n p S Sun ia ee aaa rr treu 244 c 4 B 64303EN 4 01 1 OVERVIEW OVERVIEW Setup for machining which includes attaching and detaching a workpiece to be machined and moving it to the machining start point while viewing it is performed with the protection door opened The Dual Check Safety func
191. nforms whether the reference point is established or not 0 The reference point is not established 1 The reference point is established Each CPU informs whether the reference point is established or not In the following case this signal is turned to 1 e After the reference point is established e When the follow up operation of absolute pulse coder is finished after power on In the following case this signal is turned to 0 e When the reference point is lost NOTE In case that the reference point is re established this signal is turned to 0 till the reference point is re established from the dog signal is turned off 104 B 64303EN 4 01 5 l O SIGNALS Programmable Safety I O signals input output Classification Input Output signal Dual signal Function The 8 bytes 64 bit programmable safe I Os can be freely defined as the different address from the above basic safe signals Each byte of 8 byte programmable safe I Os can be assigned on either address of X Y or R or D by parameter Each byte of the programmable safe I O between the PMC and DCS PMC is cross checked by the CNC and PMC CNC CPU DCS PMC PMC CPU PMC Input Signal 1 K Input Signal 2 Input Signal 8 E lt Input Signal 1 Input Signal 2 CNC and monitor each Input Signal 8 Output Signal 1 Output Signal 1 Output Signal 2 Output Signal 8
192. o 32 safety position switches can be set When two paths are used with the T series up to 64 safety position switches can be set The assigning addresses are Fn755 to Fn756 PMC F 007 m to F 008 m DCS PMC and Fn757 to Fn758 PMC F 009 m to F 010 m DCS PMC in each path n 0 to 1 m 0 to 1 x 20 The units of this parameter value specifies which address the signal of each path should be output to Fn755 to Fn756 PMC F 007 m to F 008 m DCS PMC or Fn757 to Fn758 PMC F 009 m to F 010 m DCS PMC Setting value Assigned address Fn755 to Fn756 PMC F 007 m to F 008 m DCS PMC Fn757 to Fn758 PMC F 009 m to F 010 m DCS PMC The tens of this parameter value specify which path the signal should be output to 0 Path 1 1 Path 2 The relationship between parameter settings and assigned addresses is shown below Assigned address Setting value Assigned address PMC DCS PMC 135 6 PARAMETERS B 64303EN 4 01 Example Parameter Ser ng Output address of position switch signal No value 13840 00 F755 F756 1st to 16th position switch PMC F007 F008 1st to 16th position switch DCS PMC 13841 10 F1755 F1756 17th to 32nd position switch PMC F027 F028 17th to 32nd position switch DCS PMC 13842 01 F757 F758 33rd to 48th position switch PMC F009 F010 33rd to 48th position switch DCS PMC 13843 11 F1757
193. o axis being rotated Protective door open Protective door closed Servo axis excitation on b aj DOFEXT N 2 1 Error state We Guard Unlock signal LN Protective Door MU Open State signal SVEN1 71 The issue of an alarm is suppressed with a timer O points are monitored 0 lt 1 channel error Set to 0 if normal 1 An alarm condition is detected for the period until servo excitation is turned off AS2 1 1 after the Servo Axis Rotation Enable Switch signal SVEN1 is switched from on to off However by setting a timer on the ladder side ensure that no alarm is detected during this period 49 3 SAFETY FUNCTIONS B 64303EN 4 01 Processing on the DCS PMC side If AS2 1 0 or AS2 2 0 contact open servo excitation on for a certain time 1 when SGOPN is 0 door open and SVEN is 0 Servo Axis Rotation Enable Switch signal turned off an error is assumed to issue 1st channel or 2nd channel alarm Timing chart 2 Error judgment processing by the DCS PMC side ladder Servo axis being rotated lt gt lt Protective door open Protective door closed Servo axis excitation on lt gt D z 4 4 p d AS2 2 Contact Closed T I 1 1 ea Contact Open Error state SGOPN s SVEN2 O points are monitored 1 The issue of an a
194. o be operated to enable external deceleration setting 2 and Gn023 3 and both of Gn107 and Gn109 need to be operated to enable external deceleration setting 3 4 The maximum speed for manual handle feed is usually the manual handle feedrate When the manual handle feed maximum feedrate change signal HNDLF Gn023 3 is set to 1 the speed set in these parameters 1s applied 190 B 64303EN 4 01 11 APPLICATION OF OTHER FUNCTIONS 11 2 3 Signals 11 2 3 1 Details on signals Manual handle feed maximum feedrate change signal HNDLF lt Gn023 3 gt Classification Input signal Function This signal switches to or from the maximum manual handle feedrate Operation When this signal is 1 the speed set in parameter 1434 is assumed as the manual handle feed maximum speed When external deceleration setting 2 or 3 is used the speed set in parameter No 1442 or 1445 can also be enabled External deceleration signals ED1 to 05 Gn118 0 to 4 gt ED1 to ED5 Gn120 0 to 4 gt 2021 to ED25 lt Gn101 0 to 4 gt ED21 to ED25 Gn103 0 to 4 gt ED31 to ED35 lt Gn107 0 to 4 gt ED31 to ED35 Gn109 0 to 4 gt Classification Input signal Function This signal selects which external deceleration to apply for each direction of the control axes with the external deceleration function In a signal name and indicate a direction the second number from the end indicates the target setting and th
195. om the spindle positioning mode to the spindle rotation mode is specified by the M code set in parameter No 4961 201 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 11 4 3 Signals 11 4 3 1 Details on signals Spindle stop complete signal SPSTPA lt Gn028 6 gt for 1st spindle SPSTPB lt Gn402 1 gt for 2nd spindle Classification Input signal Function The CNC checks that this signal turns 1 and then performs orientation before spindle positioning spindle positioning or spindle positioning cancellation Spindle unclamp signal SUCLPA lt 038 1 gt for 1st spindle SUCLPB lt 400 1 gt for spindle Classification Output signal Function This signal specifies that spindle mechanical clamping be released in a spindle positioning sequence When the signal turns 1 release spindle clamping on the machine side release the brake or draw the pin Output condition For details refer to the sequence time chart in the Connection Manual Function B 64303EN 1 Spindle unclamp completion signal SUCPFA lt Gn028 4 gt for 1st spindle SUCPFB lt Gn400 1 gt for 2nd spindle Classification Input signal Function This signal indicates that unclamping the spindle is complete in response to the spindle unclamp signal SUCLPs Spindle clamp signal SCLPA lt Fn038 0 gt for 1st spindle SCLPB lt Fn401 1 gt for 2nd spindle Classification Output signal Function This signal specifies that the
196. ommand for the spindle amplifier 219 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 Orientation completion signal ORARA lt Fn045 7 gt for 1st spindle ORARB lt Fn049 7 gt for 2nd spindle Classification Output signal Function This signal is set to 1 when the orientation command is entered and the spindle stops near the specified fixed position Output condition This signal is set to 1 when all conditions below are satisfied e ORCMx orientation command 1 e SSTx zero speed detection signal 1 e Thespindle is present near the fixed position The conditions of proximity to the fixed position are set by the parameter orientation completion signal detection level No 4075 This signal is set to 0 when the spindle deviates from the fixed position due to application of an external force or other causes To monitor the stop status of the spindle by setting a spindle positioning loop with the spindle orientation function set a sequence that interrupts the power of the spindle motor if there is deviation from the stop position by monitoring the signal Zero speed detection signal SSTA lt Fn045 1 gt for 1st spindle SSTB lt Fn049 1 gt for 2nd spindle Classification Output signal Function This signal is set to 1 when the rotation speed of the actual spindle motor becomes equal to or less than the zero speed detection level 11 6 3 2 Signal address 7 6 5 4 3 2 1 0 wova onwa s
197. on function can detect latent software and hardware errors in a system that has a two channel configuration So the safety related portions of the two channels need to be tested at least once within an allowable period of time for latent errors An error in one monitoring channel causes a mismatch of results so that a cross check detects the error N CAUTION Forced detection of a latent error on the MCC shutoff path must be performed by the user through a MCC off Test after power on and at intervals of a specified time within normally 24 hours When the system is operating in the automatic mode when the protection door is closed this detection processing is not requested as mandatory But before the protection door opens after the specified time the detection processing is required mandatory If this has not been performed lock for the protection door should not be released A latent safety related error associated with two channel monitoring can be detected as a result of cross checking NOTE An error detected as the result of forced latent error detection or cross checking leads to a safety See Subsec 3 3 3 1 3 2 2 Safety monitoring cycle and cross check cycle The safety function is subject to periodical monitoring in a monitoring cycle The following functions are monitored at every 8ms e Safe speed monitoring servo motor e Safe machine position monitoring servo motor e Safe position error monitor
198. ontour control Inputtype Parameter input Data type Word spindle Unit of data 1 Valid data range 010100 Set the motor voltage in Cs contour control Amount of grid shift in Cs contour control Inputtype Parameter input Data type 2 word spindle Unit of data 1 pulse 0 001deg Valid data range 360000 to 360000 The reference position of the spindle shifts counterclockwise by the specified number of pluses 217 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 11 6 SPINDLE ORIENTATION 11 6 1 Overview 11 6 2 Specifications Orientation The Dual Check Safety function uses the CNC CPU and spindle DSP to separately monitor the spindle motor speed safe speed monitoring function When the stop status of the spindle is monitored by the safe speed monitoring function set the safe speed parameter to a value including a margin appropriate for the machine instead of 0 because the actual speed cannot be assumed to be 0 Since the spindle may rotate at a speed less than the set safe speed in this case it is necessary to position the spindle with a position control loop formed at the same time The spindle orientation function stops the spindle at a fixed position using the position coder mounted on the spindle For details refer to the FANUC AC SPINDLE MOTOR ai series Parameter Manual B 65280EN or other documents To use the spindle orientation function set bit 4 NOR of parameter No 8135 to 0 The orien
199. op or controlled stop on occurrence of a safe Speed excess alarm 30 B 64303EN 4 01 3 SAFETY FUNCTIONS IMPORTANT 1 A gear ratio ball screw and the like must be carefully selected so that a safe speed can be kept on the feed axis Before inputting the Guard Open Request signal ORQ reduce each axial speed and spindle speed to a safe speed range or below If a speed exceeds the limit do not unlock the protective door The PMC ladder must be designed that the power to the driving circuit is shut off safe stop state if the door is forced open N WARNING The safe speed monitoring function monitors whether the traveling speed exceeds a specified limit The function cannot monitor the stop state zero speed If an error causes a movement on the feed axis at a speed lower than the safe speed range while the protective door is open for instance the function cannot detect this state The machine must be designed so that this state does not affect the safety of the machine system 31 3 SAFETY FUNCTIONS B 64303EN 4 01 3 7 SAFE MACHINE POSITION MONITORING While the door is open the Dual Check Safety function checks whether the position on each feed axis is within the safe machine position range defined by safety parameters If it detects a machine position beyond the safety range the Dual Check Safety function immediately enters the stop state If each axis is not stopped the Dual Check Safety function en
200. osition Servo in i Servo power monitoring redundant mode I supply Safe position error Dual monitoring monitoring I Power down of MCC I direction I Protective door PMC ____ ___ lt Power down Protective door lock signal Dual monitoring of MCC Dual power down Door lock Dual monitoring of Doa open close protective door state monitoring of error by MCC off test 14 B 64303EN 4 01 3 SAFETY FUNCTIONS 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 assembly of the machine replacing a part or changing a safety parameter such as a safe speed limit or safe range as described in Chapter 6 the user must check that all safety parameters are correct and that all safety functions are working normally A return reference position must be made on each axis The user must also check the absolute position of the machine For details see Chapter 7 START UP 3 2 2 MCC off Test of the Safe Stop Function An MCC off Test of the safe stop function monitors the contact state of the electromagnetic contactor MCC compares the state with a command to the electromagnetic contactor and checks that the safe stop function works normally The user of the machine must carry out the test This test must be carried out when the CNC is turned on or when 24 hours have elapsed af
201. otective door is open Guard State signal SGOPN 0 set Safety Check Request signal VLDVx VLDPs to 0 in order to activate the alarm monitoring of safety functions Input signal Dual signal Guard State signal informs CNC of the guard open closed state for the Dual Check Safety Function 0 Guard open state 1 Guard closed state When Guard State signal SGOPN is 0 the ladder program turn Safety Check Request signal VLDVx VLDPs to 0 in order to activate the alarm monitoring of safety speed safety machine position and safety position error If the ladder program detects abnormal condition in each CPU it generates a safety related alarm and stops motors IMPORTANT As for the contacts for Guard State signal it is recommended to fulfill the Standard IEC60947 5 1 92 B 64303EN 4 01 5 l O SIGNALS MCC Contact State input SMC lt PMC Gn748 6 gt lt DCS PMC G 000 m 6 gt for each machine group The state of MCC contact is checked doubly It is not possible to check whether the contact of MCC is melted and adhered abnormally because MCC contact is closed during normal operation The state of contact be checked by performing MCC off Test Classification Input signal Dual signal Function Contact State signals SMC inform CNC of the MCC state for the Dual Check Safety Function 0 MCC on state 1 MCC off state Operation Contact State signals SMC is
202. p are always assigned to the first path MCFVx is to allow turning on MCC of each axis according to monitor safety speed of servo axis or so on MCFPs is to allow turning on MCC of each spindle according to the result of monitoring safety speed of spindle These signals are assigned on both PMC and DCS PMC Machine tool builder must output the signal to shut off MCC when either one of these signal is 0 7T BRKx Safety Brake signal output These signals are output to control the brake of each servo axis 8 SPS1 to SPS32 SPS1 to SPS64 in case of T series with 2 path system Safety Position Switch output These signals show whether the machine position of each axis is stayed within the range specified by the parameters or not When a one path system is used up to 32 points can be set When a two path system is used with the T series up to 64 points can be set 9 Programmable Safety I O signals input output The 8 bytes 64 bit programmable safe I Os can be freely defined as the different address from the above basic safe signals Each byte of 8 byte programmable safe I Os can be assigned on either address of X Y or R or D by parameter Each byte of the programmable safe I O between the PMC and DCS PMC is cross checked by the CNC and PMC The combinations of cross checking these signals are defined by using Safety parameters as follows Signal type Combination No DCS PMC No 11950 No 11970 No 11951 No 11971 No 1
203. peed Maximum spindle speed x4095 By using this expression the spindle motor speed data can easily be obtained Specifying the output polarity for the spindle motor The PMC can specify the spindle motor output polarity when the following are executed e Switching the controller from the CNC to the PMC by issuing an SSINx signal e Specifying the output polarity to the SGNx signal 196 B 64303EN 4 01 11 APPLICATION OF OTHER FUNCTIONS 11 3 3 Signals 11 3 3 1 Details on signals Spindle motor speed command selection signal SIND lt Gn033 7 gt for 1st spindle SIND2 lt Gn035 7 gt for 2nd spindle Classification Input signal Function This signal specifies that either the CNC or PMC is used to control the spindle motor speed command Operation When this signal is 0 the spindle motor speed command is controlled by the CNC When this signal is 1 the spindle motor speed command is controlled by the PMC Spindle motor speed command signals R011 to R121 Gn032 0 to Gn033 3 gt for 1st spindle R0112 to R1212 Gn034 0 to Gn035 3 gt for 2nd spindle Classification Input signal Function When the spindle motor speed command is controlled by the PMC set the value obtained from the following expression for this signal in binary Spindle motor speed data Spindle motor speed Maximum spindle motor speed x4095 Spindle motor command polarity selection signals SSIN lt Gn033 6 gt for 1st spindle SSIN2 lt Gn0
204. peration is continued Parameter input Word machine group msec 0 to 32767 Set a time period from when CNC CPU and Servo CPU in Dual Check Safety function detects that the servo amplifier is ready MCC on state until Safety Brake signal BRKx goes 1 brake release enabled NOTE All paths are checked using the setting of this parameter 124 B 64303EN 4 01 6 PARAMETERS 3225 Code for safety parameters Input type Data type Valid data range NOTE When this parameter is set the power must be turned off before operation is continued Parameter input 2 word 0 to 99999999 Set a code password for protecting against modifications to parameters related to Dual Check Safety function safety parameters When a code for safety parameters is set other than the value 0 the parameters are locked In this state the setting code is not displayed but is blank and safety parameter input is disabled If an attempt is made to input data in a locked safety parameter the result indicated in the table below is produced depending on the method of input No attempt is successful Input method o Resut O U O MDI input Warning WRITE PROTECT Input via reader puncher interface No alarm is generated But parameter input is disabled Input through window function Completion code 7 WRITE PROTECT If the value other than 0 is set to this parameter the safety parameter cannot be modified T
205. power supply of the main circuit of the spindle amplifier If an error is detected during monitoring the magnetic contactor of the power supply is turned off to turn off the power to the main circuit 3 20 1 Monitoring of the Excitation Off Signal Assign the two Excitation Off signals EXOF1 and EXOF2 output from the aiSP or BiSVSP as Programmable Safety I O signals to check signal matching Moreover monitor whether the excitation on and excitation off states are normal by using two types of ladders namely PMC ladder and DCS PMC ladder If an error is detected secure safety by turning off the magnetic contactor of aiPS or BiSVSP to turn off the power to the main circuit The Excitation Off signal EXOF1 is the Excitation Off signal EXOFA that is actually output from the aiSP or BiSVSP it is forcibly masked to 1 at power on time For the difference between and EXOFA see timing chart 2 shown in the next subsection When additionally using a function for rotating the spindle by power with the door open assign the two switch signals SPEN1 and SPEN2 output from the spindle rotation enable switch as Programmable Safety I O signals to check signal matching 55 3 SAFETY FUNCTIONS Signal connection diagram example Link X Y Guard Open Request signal Guard State signal SGOPN Spindle Rotation Enable SPEN1 Switch signal SPEN2 Guard Unlock signal I O Link X Y SP Output Contact signal
206. provides additional braking Unlike an induction motor the servo motor does not coast because of this function If the input of the Emergency Stop signal or an error of a safe related signal or speed monitoring is detected the CNC automatically specifies a command to zero the speed and reduces the speed to zero controlled stop After the motor slows down and stops the power is turned off and the motor is brought into the dynamic brake stop state To slow down and stop the motor some parameters must be specified in the CNC If those parameters are not specified the motor is immediately brought into the dynamic brake stop state When abnormal state is detected in monitoring safety speed or so on a dynamic brake stop is made The following stop states are possible The power to the motor is shut off MCC off state in this state If the spindle motor can be controlled the ladder program must shut off the power after the spindle motor is slowed down to a stop If the spindle motor cannot be controlled the power is immediately shut off If the servo motor can be controlled the motor is slowed down to a stop and then brought into the dynamic brake stop state If the motor cannot be controlled the motor is immediately brought into the dynamic brake stop state If the power is shut off immediately the spindle motor continues at the same speed prior to the abnormal event and eventually comes to a stop If the spindle motor can be slowed do
207. r enters free run state The spindle motor can also enter the controlled stop state when the safe speed range 15 exceeded depending on the parameter setting If the spindle motor is not decelerated the system enters the safe stop state 4 SVAx SVBx SPAs SPBs Safety Speed Safety Position Selection signal input These signals are monitored in redundant mode SVA SVB are the signals to select safety speed safety position for each servo axis SPA SPB are the signals to select safety speed for each spindle The values of safety speed safety position are given by the parameters 5 SMC MCC Contact State signal input The MCC contact state is monitored in redundant mode In normal operation the MCC is closed therefore whether the contact of a relay is in an abnormally closed state cannot be detected In the test mode it can be detected whether the contact of relay is abnormally closed 22 B 64303EN 4 01 3 SAFETY FUNCTIONS 6 MCF MCFVx MCFPs signal output With these signals the MCC is shut off by 2 channels I O when either one of these signals state is 0 DCALM is to allow turning off MCC of all system when I O cross check alarm or some problems of safety check function are found MCF is to allow turning on MCC of each machine group according to emergency stop or MCC off Test With the FS0i D the number of machine groups is 1 at all times So the signals set for each machine grou
208. r speed safe speed monitoring function When the stop status of the spindle 1s monitored by the safe speed monitoring function set the safe speed parameter to a value including a margin appropriate for the machine instead of 0 because the actual speed cannot be assumed to be 0 Since the spindle may rotate at a speed less than the set safe speed in this case it is necessary to position the spindle with a position control loop formed at the same time The Cs contour control function makes spindle positioning control spindle contour control When Cs contour control is performed the configuration of the spindle detector is restricted For details refer to the FANUC AC SPINDLE MOTOR ai series Parameter Manual B 65280EN other documents To use Cs contour control set bit 2 SCS of parameter No 8133 to 1 The Cs contour control function and the spindle positioning function cannot be used at the same time 211 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 11 5 2 Specifications Cs contour control mode The Cs contour control change signal is used to switch between spindle rotation control method of controlling the rotation of the spindle with the velocity command and spindle contour control method of controlling the rotation of the spindle with the move command The mode for spindle contour control is called the Cs contour control mode The manual and automatic operation of the spindle in the Cs contour control mo
209. rameter No 1904 1 is not applied to Safety Position switch can be assigned up to 16 points per 1 group to the output signal F area and totally up to 4 groups can be used in the CNC system Two areas per a path are provided to assign It 1s possible to assign the signal to an appropriate area Safe position switch signals can be assigned to arbitrary controlled axes All points can be also assigned to one axis The assignment of controlled axes is set by the safety parameters No 13880 to No 13911 No 10501 to No 10532 And the signals can be also assigned to the rotary axes When inconsistency between the position switch on PMC and that on DCS PMC is lasted for the time that is specified by the parameter No 1945 the safety function sets MCC Off signal DCALM to 0 and generates the alarm safe I O cross check error PW0010 PW0011 E om 3 SAFETY FUNCTIONS B 64303EN 4 01 NOTE The machine coordinate of the safety function is based on position feed back So it does not always indicate the same value as the machine coordinate based on the summation of the command value Two machine coordinates that are calculated by two CPU independently are not always the same because the position feedback is continuously changed a little As there is a possibility that the condition of two signals is different from each other near the boundary do not stop an axis near the boundary N CAUTION This function is activated only in
210. rm occurs A machine tool builder makes a ladder program to output a signal to shut off MCC when this signal is turned to 0 If necessary control DO signal for peripheral devices Classification Output signal This signal output to both PMC but is not monitored doubly Function This is a signal to turn on MCC when both a crosscheck alarm and a CPU self diagnosis alarm are not caused 0 MCC off 1 MCC on Operation When each CPU finds out any abnormal condition it generates an alarm and turns off this signal at the same time NOTE When the spindle motor induction motor is powered off while rotating the motor performs free running at the speed before power off eventually stopping after a period of time In some cases however it is better to stop the motor as early as possible for safety When the spindle is decided to be controlled even if the MCC Off signal is set to 0 the rotation of the spindle can be stopped under control of the ladder program controlled stop To do this make a ladder program that interrupts power upon lapse of the timer set time after the MCC Off signal is set to 0 95 5 SIGNALS MCC signal output B 64303EN 4 01 MCF lt PMC Fn748 1 DCS PMC F 000 m 1 gt for each machine group Classification Function Operation Output condition In case this signal is 0 MCC is shut off through 2 channels of I O Link line respectively This signal is
211. rned on and when time t has elapsed after the previous test Set the value of t in parameter No 13913 3 21 2 Brake Test Procedure Starting a brake test lt 1 gt The Brake Test Execution Request signal RQBT is set to 1 when the power is turned on and when time t has elapsed after the previous brake test the value of t is set in parameter No 13913 When the Brake Test Execution Request signal is set to 1 conduct a brake test Even 1f RQBT is set to 1 operation can be continued until the current machining 1s completed To secure safety however a brake test should be conducted as soon as possible lt 2 gt Clear all NC alarms and set the JOG mode then retract the brake test target axis to a safe position lt 3 gt The execution of a brake test is started by setting the Brake Test Start signal STBT to 1 63 3 SAFETY FUNCTIONS Brake test execution Ending a brake test B 64303EN 4 01 NOTE lt 4 gt lt 5 gt lt 6 gt In a brake test move command is issued to the servo motor So ensure that the position control mode and servo on state are set No brake test is conducted when the test target axis is in a mode speed control or torque control mode other than the position control mode in the servo off state or in torque limit control When the test start condition is not satisfied alarm DS0039 or DS0040 is issued The cause of alarm DS0039 or DS0040 is indicated in diagnosis No 3701
212. ror state is detected If a mismatch occurs due to an error state safety is secured by turning off the magnetic contactor of the ai PS to turn off the power to the main circuit 59 FUNCTIONS 3 20 4 Connections al Series In addition to Dual Check Safety connections a connection from connector JX4 on the aiSP or connector JX6 on the BiSVSP to the I O Unit Link 3 is required On a system that uses a spindle rotation enable switch a connection from the switch is additionally required Indicated in heavy lines CNC Sch I O Link adapter l O LINK JD44A 1 JD51A T1 ps1B JD44A 2 JD1A I O Link 1 2 H I O Link 3 Unit Unit 1 1 y COP10A To 2 Spindle Amp 10 To 2 Servo Amp SPDL JA41 h 7 al SP 60 Jx4 2 TB2 B 64303EN 4 01 Guard State signal SGOPN Sh Spindle Rotation Enable Switch signal SPEN _ x Spindle Excitation Off signal 2 EXOF2 B 64303EN 4 01 BISVSP Series CNG 3ch I O Link adapter I O LINK Link 1 2 JD44A 1 JD51A D51B FSSB COP10A SPDL JA41
213. rs set the minimum operation range of the Ist through 64th safe position switches When one path is used up to 32 safety position switches can be set When two paths are used with the T series up to 64 safety position switches can be set N CAUTION 1 When machine position parameter setting the safety position switch operation range is assumed to be satisfied When the setting of operation range is maximum operation range minimum operation range the safe position switch is not output If parameter No 13960 to No 13991 No 10565 to No 10596 are changed please turn the power of the machine off once 142 B 64303EN 4 01 6 PARAMETERS 11950 1st byte address of Safety input signal for CNC CPU 11957 8th byte address of Safety input signal for CNC CPU NOTE When these parameters are set the power must be turned off before operation is continued Input type Parameter input Data type 2 word Valid data range 0 to 3999999 Besides the standard safety I O signals 8 byte 64 bit Programmable Safety I O signals can be freely defined These parameters set the address of the Ist through 8th double checked input signals of CNC CPU DCS PMC Setting value ADRS ADRS Byte address 0 This signal is not checked 1000000 X address 2000000 R address 3000000 D address Setting example X8 setting value 1000008 R8 setting value 2000008 11960 1st byte address of Safety output signal
214. s Unit of data mm inch degree machine unit Minimum unit of data Depend on the increment system of the applied axis Valid data range 9 digit of minimum unit of data refer to standard parameter setting table A When the increment system is IS B 999999 999 to 999999 999 This parameter sets a travel distance on each axis to be specified for brake test When 0 is set in this parameter the setting of 1 000 mm or value equivalent to 1 000 mm on an inch machine or 1 000 degree is assumed N CAUTION If a value smaller than the tolerance value parameter No 13918 for position deviation to be monitored in a brake test is set in this parameter the brake test may not be conducted normally NOTE For an axis based on diameter specification set a diameter value 13917 Speed command to be specified for brake test NOTE When this parameter is set the power must be turned off before operation is continued Inputtype Parameter input Data type Real axis Unit of data mm min inch min degree min machine unit Minimum unit of data Depend on the increment system of the applied axis Valid data range Refer to the standard parameter setting table C When the increment system is IS B 0 0 to 240000 0 This parameter sets a speed to be specified for each axis in a brake test When 0 is set in this parameter the setting of 10 mm min value equivalent to 10 mm min on an inch machine or 10 degrees min is assumed
215. s 49 3 19 3 Assignment of Programmable Safety Signals 50 SADA lt edi re ceca EP e N beastie to ce Co add 51 3 1925 Ree alee Rights t ese ke 53 3 20 SAFE SPINDLE STOP FUNGTION 54 3 20 1 Monitoring of the Excitation Off Signal eese 55 3 20 2 User Ladder Processing auem ee tee etie te 57 3 20 3 Assignment of Programmable Safety Signals 59 3204 eicere erii eee eset dee rio lee P pen RE PEL De 60 3 20 57 A GS Stay eee ee dele vette Fee 62 3 21 DUAL BRAKE MONITOR FUNCTION a 63 Test u seni eie ea 63 3 21 22 Brake Procedure cadena re teretes eiie ba 63 3 21 3 Details BrakefTestu u anie eee pt dete nied 66 3 21 4 Suspension and Restart of Brake Test 67 3 21 5 Brake ConbgUtatlon uu a ette Lon pre reete an ua Q reete 68 4 INSTALLATION iu aaa aaa rra 70 4 1 OVERALL CONNECTION DIAGRAM eene 71 5 JO SSIGNAES i i 79 5 1 OVERVIEW ate oett o mE Susa Shu Sun RR SO Sa 80 5 2 SIGNALE ADDRESS eiectus iex RE pum a pe Dime REL saywa qaqa ee
216. s set using a parameter NOTE 1 Set 0 for those position switch numbers that are not to be used The safe position switch signal of that number is not output The safe position switch signal for the axis whose parameter No 1904 6 is 1 Dual Check Safety function is disabled is not output After safety position switch parameters No 13880 to No 13911 No 10501 to No 10532 have been set the power must be turned off then back on for the setting to become effective 13912 Enable disable brake test Input type Data type Valid data range NOTE When this parameter is set the power must be turned off before operation is continued Parameter input Integer axis 0 1 This parameter enables or disables brake test To disable brake test set this parameter to 0 To enable brake test set this parameter to 1 137 6 PARAMETERS B 64303EN 4 01 13913 Brake test interval Input type Data type Unit of data Valid data range NOTE When this parameter is set the power must be turned off before operation is continued Parameter input Word Time 0 to 168 This parameter sets a time interval between two successive brake tests When the time set in this parameter has elapsed after a brake test the Brake Test Execution Request signal RQBT is set to 1 When 0 is set in this parameter the setting of 8 hours is assumed 13914 Time t1 after output of the brake signal until the brake operates
217. sed with the following models The abbreviated names may be used Series 01 D 01 D NOTE 1 The FANUC Series 0 Mate MODEL D does not support this function 2 For explanatory purposes these models may be classified as shown below T series 01 M series 0i MD Some functions described in this manual may not be applied to some products For details refer to the Descriptions B 64302EN For the 0i D parameters need to be set to enable or disable some basic functions For these parameters refer to Section 4 51 PARAMETERS OF 07 D 0i Mate D BASIC FUNCTIONS in the PARAMETER MANUAL B 64310EN 1 PREFACE B 64304EN 4 01 Related manuals of Series 0 D The following table lists manuals related to Series 0i D This manual is indicated by an asterisk Table 1 Related manuals Specification Manual name number DESCRIPTIONS B 64302EN CONNECTION MANUAL HARDWARE B 64303EN CONNECTION MANUAL FUNCTION B 64303EN 1 USER S MANUAL B 64304EN Common to Lathe System Machining Center System USER S MANUAL For Lathe System B 64304EN 1 USER S MANUAL For Machining Center System B 64304EN 2 MAINTENANCE MANUAL B 64305EN PARAMETER MANUAL B 64310EN START UP MANUAL B 64304EN 3 Programming Macro Executor PROGRAMMING MANUAL B 64303EN 2 Macro Compiler PROGRAMMING MANUAL B 64303EN 5 C Language Executor PROGRAMMING MANUAL B 64303EN 3 PMC PMC PROGRAMMING MANUA
218. series FANUC AC SERVO MOTOR Bi series FANUC LINEAR MOTOR LiS series B 65270EN FANUC SYNCHRONOUS BUILT IN SERVO MOTOR DiS series PARAMETER MANUAL FANUC AC SPINDLE MOTOR ai fi series BUILT IN SPINDLE MOTOR Bi series B 65280EN PARAMETER MANUAL B 65262EN B 65272EN B 65302EN B 65312EN B 65282EN B 65322EN B 65325EN This manual mainly assumes that the FANUC SERVO MOTOR ai series of servo motor is used For servo motor and spindle information refer to the manuals for the servo motor and spindle that are actually connected p 3 B 64303EN 4 01 TABLE OF CONTENTS TABLE OF CONTENTS DEFINITION OF WARNING CAUTION AND NOIE s 1 u iS ai AS Pa au Masa p 1 1 OVERVIEW 1 1 1 DIRECTIVES AND STANDARDS 2 1 1 1 u DD 2 1 1 2 Standards n re rte intere te qe 2 1 1 3 Risk Analysis and 3 1 1 4 Certification est ues uha OR EER EIS 3 1 2 DEFINITION OF TERMS 4 1 2 1 General Definition of Terms ankapa E NEE A E i 4 1 2 2 Definition of Terms Related to the Safety Function seen 4 1 3 BASIC PRINCIPLE OF DUAL CHECK SAFETY
219. set a value obtained by adding 1 to the value set for the slave axis 116 B 64303EN 4 01 6 PARAMETERS 1240 Coordinates value of the reference position in the machine coordinate system Input type Data type Unit of data Minimum unit of data Valid data range Input type Data type Unit of data Valid data range NOTE When this parameter is set the power must be turned off before operation is continued Parameter input Real axis mm inch degree machine unit Depend on the increment system of the applied axis 9 digit of minimum unit of data Refer to standard parameter setting table A When the increment system is IS B 999999 999 to 999999 999 Set the coordinate values of the reference position in the machine coordinate system Position deviation limit for each axis in moving state during safety check NOTE When this parameter is set the power must be turned off before operation is continued Parameter input 2 word axis Detection unit 0 to 99999999 Position deviation limit for each axis in moving state for safety check of Dual Check Safety function is specified If position deviation of a moving axis exceeds position deviation limit while Safety Check is carried out Safety Monitoring Request VLDVx 0 a servo alarm SV0475 SV1071 is generated and axes are stopped immediately like emergency stop state In Dual Check Safety function position deviation
220. set in this parameter the setting of 1000 ms is assumed 140 B 64303EN 4 01 6 PARAMETERS Maximum operation range of the 1st safe position switch Maximum operation range of the 32nd safe position switch Maximum operation range of the 33rd safe position switch Input type Data type Unit of data Minimum unit of data Valid data range es Maximum operation range of the 64th safe position switch NOTE When these parameters are set the power must be turned off before operation is continued Parameter input Real mm inch degree machine unit Depend on the increment system of the reference axis 9 digits of minimum unit of data Refer to standard parameter setting table A But in case that CMR21 data range becomes 1 CMR of 9 digits of minimum unit of data When the increment system is IS B and CMR 1 999999 999 to 999999 999 When increment system is IS B CMR 2 499999 999 to 499999 999 Whether to specify this parameter by using diameter value or radius value depends on whether the corresponding axis is based on diameter specification or radius specification These parameters set the maximum operation range of the 1st through 64th safe position switches When one path is used up to 32 safety position switches can be set When two paths are used with the T series up to 64 safety position switches can be set N CAUTION 1 When the machine position is on the
221. sic terminology methodology ISO 12100 2 2003 Safety of machinery Basic concepts general principles for design Part 2 Technical principles and specifications EN954 1 1996 Safety of machinery Safety related parts of control systems Part 1 General principles for design ISO 14121 1 2007 Safety of machinery Principles for risk assessment IEC 60204 1 2005 Safety of machinery Electrical equipment of machines Part 1 General requirements ISO 13849 1 2006 Safety of machinery Safety related parts of control systems Part 1 General principles for design ISO 13849 2 2006 Safety of machinery Safety related parts of control systems Part 2 Validation IEC 61508 2000 Functional safety of electrical electronic programmable electronic safety related systems part 1 part 7 IEC 62061 2005 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems B 64303EN 4 01 1 OVERVIEW 1 1 3 Risk Analysis and Evaluation According to the machine directive the manufacturer of a machine or machine components and a responsible person who supplies a machine or machine components to the market must conduct risk evaluation to identify all risks that can arise in connection with the machine or machine components Based on such risk analysis and evaluation a machine and machine components must be designed and manufactured Risk evaluation must reveal all
222. speed can be specified Safety speed is selected by Safety Speed Safety Position Selection signal SVAx SVBx As for the detail of Safety Speed Safety Position Selection signal refer to the description about Safety Speed Safety Position Selection signal NOTE 1 The safety speed checks are made on the basis of the speed converted to the detection unit Accordingly a calculation error may occur After safety speed parameters No 13821 to No 13824 have been set the power must be turned off then back on for the setting to become effective For diameter specification set the speed by the diameter use changes in diameter rev or in diameter min 131 6 PARAMETERS B 64303EN 4 01 Speed regarded as axis stop for Dual Check Safety NOTE When this parameter is set the power must be turned off before operation is continued Input type Parameter input Data type Real axis Unit of data mm min inch min degree min machine unit Minimum unit of data Depend on the increment system of the applied axis Valid data range 0 to 10000 This parameter sets the speed regarded as axis stop in case that an abnormal condition is found in safety speed check or safety machine position check of Dual Check Safety function When an abnormal condition is found in safety speed check or safety machine position check a servo alarm occurs And whether MCC off signal MCFVx is turned off or not is decided by judging if an axis is
223. spindle be clamped mechanically in a spindle positioning sequence When the signal turns 1 perform spindle clamping on the machine side insert the brake or pin Output condition For details refer to the sequence time chart in the Connection Manual Function B 64303EN 1 Spindle clamp completion signal SCPFA lt Gn028 5 gt for 1st spindle SCPFB lt Gn401 1 gt for 2nd spindle Classification Input signal Function This signal indicates that clamping the spindle is complete in response to the spindle clamp signal SCLPs 202 B 64303EN 4 01 11 APPLICATION OF OTHER FUNCTIONS Spindle orientation completion signal ZP1 to ZP5 lt Fn094 0 to 4 gt Classification Output signal Function This signal indicates that spindle orientation of the spindle positioning axis is completed Output condition When the orientation of spindle positioning is completed this signal is 1 When spindle positioning is performed or released this signal is 0 11 4 3 2 Signal address N f Gn401 A N 11 4 d Parameters 7 6 5 4 3 2 1 0 _ Ir ra Input type Parameter input Data type axis For an axis to be subject to spindle positioning set ISAx to ISCx to 0 1020 Program axis name for each axis Input type Parameter input Data type Byte axis Set the axis name of an axis to be subject to
224. spindle positioning 1023 Number of the servo axis for each axis Input type Parameter input Data type Byte axis This parameter sets the relationships between the individual axes and the servo axis numbers For an axis to be subject to spindle positioning set the number of the spindle to be subject to spindle positioning preceded by a minus sign 203 11 APPLICATION OF OTHER FUNCTIONS B 64303EN 4 01 1260 The shift amount per one rotation of a rotation axis Input type Parameter input Data type Real axis For the rotation axis set the amount of movement for one turn For the spindle positioning axis set 360 0 1820 Command multiplier for each axis CMR Input type Parameter input Data type Byte axis Set a value of 2 targeted for spindle positioning 1821 Reference counter size for each axis Input type Parameter input Data type 2 word axis Set a value of 10000 targeted for spindle positioning 3720 Number of position coder pulses Input type Parameter input Data type 2 word spindle Set the number of position coder pulses For spindle positioning set 4096 3721 Number of gear teeth on the position coder side Input type Parameter input Data type Word spindle Set the number of gear teeth on the position coder side in speed control such as feed per revolution and threading For spindle positioning set 2 where n is an integer greater than or equal to 0 3722 Number of gear teeth on
225. stopped after the decided time elapse At that time this parameter gives the speed to judge axis stop In case an abnormal condition is detected and an axis is stopped within the given time an MCC is not turned off Then the system can be recovered by reset operation without power off NOTE 1 2 For diameter specification set the speed by the diameter use changes in diameter rev or in diameter min In case of velocity control set the value calculated by the following formula to this parameter when R min is the velocity at which the axis is regarded as stopped Setting value R x PLS x Minimum data unit Machine unit x N CMR PLS Pulse per one revolution of motor Detection unit CMR Command multiplier N In case of diameter specification N22 In case of radius specification N21 Minimum data unit Refer to STANDARD PARAMETER SETTING TABLE 132 B 64303EN 4 01 6 PARAMETERS Safety limit speed 1 in velocity control for each axis 13827 Safety limit speed 2 in velocity control for each axis 13828 Safety limit speed 3 in velocity control for each axis Safety limit speed 4 in velocity control for each axis NOTE When these parameters are set the power must be turned off before operation is continued Input type Parameter input Data type 2 word axis Unit of data 0 to maximum motor speed This parameter sets the safety speed to 4 for each axis in velocity control mode in Dual Check Safety
226. t 2 PMC axis control was exercised at the start of a brake test 3 A mode other than the JOG mode was set at the start of a brake test 4 axis movement was being made at the start of a brake test 6 The servo off or emergency stop state was set at the start of a brake test 7 Areset was being made at the start of a brake test 8 A torque limit was applied at the start of a brake test 9 Torque control or speed control was exercised at the start of a brake test 10 Automatic operation was being performed at the start of a brake test 20 A brake test was suspended for an alarm detected by position deviation checking during brake test A brake error was detected 2 During brake test the D READY signal or V READY signal of the amplifier was turned off 22 A brake test being conducted was suspended by a reset or mode switching Restart operation is needed 173 9 DIAGNOSIS B 64303EN 4 01 23 A brake test being conducted was suspended for another cause 24 The mode of control was switched to torque control or speed control during brake test 25 A brake test being conducted was suspended by an emergency stop 174 B 64303EN 4 01 10 SAMPLE SYSTEM CONFIGURATION 1 0 SAMPLE SYSTEM CONFIGURATION 175 10 SAMPLE SYSTEM CONFIGURATION B 64303EN 4 01 10 1 SAMPLE CONFIGURATION 10 1 1 Example of Configuration Using a Single MCC VO UNIT VOLINK 1 2 DOOR SGOPN STATUS gt LOC
227. t by the parameter Set to 1 when the machine position falls outside the range of Safety Machine Position for each Axis set by the parameter Set to 1 when an axis data failure is detected Set to 1 when a safety parameter failure is detected 166 B 64303EN 4 01 9 DIAGNOSIS 9 3 FLOW MONITORING SCREEN The FLOW MONITORING screen displays Press the continuous menu soft key And press the FLOW MONIT soft key The screen shown below appears This screen shows the counter for program flow monitoring al a If each safety function works normally the present value shows the same value as the default 167 9 DIAGNOSIS B 64303EN 4 01 9 4 FEED LIMIT MONITORING SCREEN SERVO The data that are related to the safety limitation feed of the servo and the Dual Check Safety function are displayed Press the FEED LMT soft key The screen shown below appears ones ET The following items to d displayed every axis 0 Not Monitoring 1 Monitoring b FEED LMT In the safety limitation feed 1 to 4 Set by the parameter No 13821 to No 13829 the safety limit feed that is selected by the Safety speed Safety Position Selection signal A B SVAx SVBx is displayed c UNIT Unit of feed Position control D sec Velocity control min d ACT FEED Current actual feed rate NC side and Servo side 168 B 64303EN
228. t executed FUNCTIONS SP9077 MISMATCH 1 Replace the Spindle amplifier Axis number judgment mismatch RESULT OF AXIS control printed circuit board An axis number check result mismatch NUMBER CHECK 2 Replace the main board or occurred between the CNC and spindle sub CPU board on the CNC amplifier SP9078 MISMATCH 1 Replace the Spindle amplifier Safety parameter judgment mismatch RESULT OF control printed circuit board A safety parameter check result mismatch SAFETY 2 Replace the main board or occurred between the CNC and spindle PARAMETER sub CPU board on the CNC amplifier CHECK SP9079 INITIAL TEST 79 Replace the Spindle amplifier The safety functions at power up for ERROR control printed circuit board spindle were not executed Boot System Alarms Description CRC CHECK ERROR NC BASIC CRC error occurs CNC BASIC ROM Please install CNC BASIC ROM in flash memory again Servo Alarms to turn MCC off Signal MCFVx to 0 In case that the parameter No 10500 0 AVM is set to 0 the MCC off Signal of an alarm axis is turned to 0 immediately when the alarm related to data communication or detector occurs The following table shows this kind of servo alarm Number _______ Description O 0301 APC ALARM COMMUNICATION Since the absolute position detector caused a communication error ERROR the correct machine position could not be obtained data transfer
229. t in parameter No 13916 parameter No 13917 and parameter No 13918 respectively beforehand Be sure to close the protective door when conducting a brake test To secure safety specify a ladder so that if the Brake Test Execution Request signal RQBT is set to 1 the protective door is not opened until completion of a brake test even when a protective door open request is issued Do not conduct a brake test when the protective door is open Specify a ladder so that when the protective door is open the Brake Test Start signal STBT is not set to 1 When a brake test target axis is under synchronization control composite control or superposition control T series no brake test can be conducted Cancel synchronization control composite control or superposition control beforehand If alarm DS0039 or 050040 is issued in a brake test axis movements can be made by manual operation However automatic operation is enabled only after clearing the alarm by a reset When performing an automatic operation ensure that safety is secured If a brake test is suspended for a cause such as an alarm the target axis may not return to the original position A fixed override value of 100 is applied to a speed command Dry run is also disabled During a brake test interlock machine lock is enabled N CAUTION During a brake test an axis movement can occur So make an axis movement beforehand to a safe position that causes no interference 65
230. t signal This signal output to both PMC but is not monitored doubly Function When the Dual Check Safety Function is applied this signal allows turning on MCC 0 MCC off 1 MCC on Operation When the safe speed limit monitoring alarm is detected because the Safety Check Request signal VLDPs of each spindle is 0 each CPU first sets the spindle to the free running state or the controlled stop state After that if the spindle is not decelerated each CPU turns this signal to 0 In case of an alarm other than described above and related to data communication or position detector each CPU turns this signal corresponding to the alarm spindle to 0 immediately But according to the parameter setting No 10500 1 1 it is possible to turn to 0 this signals of all the spindles belonged to the path that involves the alarm spindle in case of any spindle alarms MCC Off Test Execution Request signal output lt PMC Fn191 2 gt for each machine group Classification Output signal Single signal Function This signal notifies that MCC off Test mode is required and a check should be made to determine whether the safety output signals MCC Off signal MCF operate normally When MCC Off Test Execution Request signal RQT is set to 1 set MCC off Test mode and carry out a safety output signal MCC off Test as soon as possible When MCC Off Test Execution Request signal RQT is 1 a machine tool builder must make ladd
231. t signal STBT to 1 again 691 3 SAFETY FUNCTIONS B 64303EN 4 01 3 21 5 Brake Configuration This function assumes the following two brake configurations Brake configuration 1 CNC Module 1 Link Channel 1 Link branching adapter 0V Built in motor brake I O Link Channel 3 68 B 64303EN 4 01 3 SAFETY FUNCTIONS Brake configuration 2 CNC O Link Module 1 24V 24V Channel 1 Link branching adapter 4 deum Built in motor External L brake brake BEL Vase OV Link Channel 3 69 4 INSTALLATION B 64303EN 4 01 INSTALLATION The hardware installation such as field wiring power supply etc should be referred to connection manual for CNC units and for servo amplifier EMC problem should be referred to EMC guideline manual Degree of IP protection Servo Motors IP55 Spindle Motors IP54 with oil seal IP40 without oil seal Servo and Spindle amplifiers IP1x CNC and other accessories IPxx NOTE Servo Spindle amplifiers CNC are to be installed in IP54 protected cabinets The peripheral units and the control unit have been designed on the assumption that they are housed in closed cabinets As for the environmental conditions for each unit such as CNC controller servo amplifier and etc please refer to each connection manual 70 B 64303EN 4 01 4 INSTALLATION
232. t states of the results may not match temporarily when for example the spindle speed is close to the safe speed Therefore keep the following in mind when only RSVx and RSPs are used as conditions for releasing a guard lock Confirm that RSVx and RSPs of the PMCs PMG and 5 are both placed in the safe state before releasing a guard lock When RSVx and RSPs of one PMC are used as conditions for releasing a guard lock keep in mind that before releasing a guard lock wait until the speed becomes low enough after RSVx and RSPs enter the safe state When the protective door is assumed to be open if RSVx and RSPs of only one PMC enter the safe state a safe speed limit monitoring alarm may occur depending on the result of the other monitoring state Ensure a time of 100 ms or longer in the figure from when the door is closed locked until the Guard Open Request signal ORQ goes off If this time requirement is not satisfied an alarm may be raised when the door is closed locked Design an operator panel to inform an operator that Guard Open Request signal ORQ is turned on by lighting a lamp 28 B 64303EN 4 01 3 SAFETY FUNCTIONS 3 5 EMERGENCY STOP The Emergency Stop signal is monitored in redundant mode When the emergency stop is input the servo motor slows down to a stop Caution and enters the dynamic brake stop The spindle slows down to a stop as instructed by the PMC Ladder program
233. tate relay state for turning off the MCC Output signal for shutting off the power turning the MCC off To detect the latent cause of an abnormal state of this output a MCC off Test must be made e Spindle motor Safe speed monitoring Servo motor Safe speed monitoring Safe machine position monitoring Safe position error monitoring 13 3 SAFETY FUNCTIONS B 64303EN 4 01 N CAUTION This safety function is enabled while the protective door is open after a request to open the protective door is made If the request to open the protective door is canceled and if the protective door is closed this safety function is disabled The dual input check of the safe related I O signal monitoring function and the emergency stop function are always active regardless of whether the protective door is opened or closed The CNC and the spindle check the safe speed of the spindle motor in redundant Dual monitoring of CNC mode emergency stop signal foc I Res i stop l CNC Cross software i check Spindle motor Spindle Safety related I amplifier signal is checked CNC DCS EU and dc Safe speed monitoring PMC in redundant Dos q I PMC j NH Servo amplifier Safe speed of p servo motor and I Cross I machine position check I are checked by i l Safe speed monitoring the CNC and the I Common Safe machine p
234. tation command ORCMx can be used to stop the spindle at a fixed position When the orientation command is entered while the spindle is rotating the spindle decelerates immediately and stops at the fixed position Switching to the orientation mode When the orientation command signal ORCMx is set to 1 spindle rotation control mode method of controlling the rotation of the spindle with the velocity command is switched to the orientation mode Switching to spindle rotation control When the orientation command signal ORCMx is set to 0 the orientation mode is switched to the spindle rotation control mode As soon as the orientation command signal is set to 0 the velocity command for spindle rotation control becomes valid and the spindle rotates For safety set the forward reverse spindle rotation commands SFRx SRVx and the velocity command to 0 218 B 64303EN 4 01 11 6 3 Signals 11 APPLICATION OF OTHER FUNCTIONS 11 6 3 1 Details on signals Orientation command signal ORCMA lt Gn070 6 gt for 1st spindle ORCMB lt Gn074 6 gt for 2nd spindle Classification Function Emergency stop signal Input signal This signal specifies spindle orientation When this signal is set to 1 the spindle immediately decelerates during rotation and stops at a fixed position Be sure to set the signal to 0 before power on ESPA lt Gn071 1 gt for 1st spindle ESPB lt Gn075 1 gt for 2nd spindle Classificat
235. te to door open state The following diagram shows the timings at which the door is opened and closed again ORQ P ORQ OPIHB RSVx RSPs POSEx Actual door unlock signal SGOPN Safety related VO signal Door closed Door opened Actual door unlock signal 1 6 lt P Door opened f 1 1 1 1 1 1 1 l 1 1 When the Guard Open Request signal is input the CNC returns the answer signal OPIHB to PMC 2 The PMC ladder program checks that the machine position speed and position error are within safe ranges by the Monitoring Result signal RSVx RSPs and the reference point is established by the Position Information Effect signal POSEx Then it turns on the guard unlock signal This example assumes that the protective door has an electromagnetic lock mechanism While the door is open the unlock signal is turned off 3 The door is open 4 The protective door is closed and locked After this the Guard Open Request signal ORQ must be turned off 5 When the Guard Open Request signal ORQ is turned off the CNC turned off the answer signal OPIHB Vu 3 SAFETY FUNCTIONS B 64303EN 4 01 A CAUTION 1 The RSVx and RSPs are redundant and output to both PMCs PMC and DCSPMO Since the RSVx and RSPs signals the monitoring results of two independent circuits are output to two PMCs the outpu
236. ter the MCC Off signal MCFVx is turned to 0 32 B 64303EN 4 01 3 SAFETY FUNCTIONS The user of the machine must first carry out a reference position return in order to obtain the initial position If the reference position return 15 not carried out the check function is disabled This check function is enabled after the reference position is established The function cannot be disabled by any means after the reference position is established A safe machine position limit on each feed axis 15 specified in a safety parameter N CAUTION A machine operator must confirm whether the machine reference position is established correctly by checking the actual machine position and position display of the CNC At power on the safety function does not work After power on the CNC checks whether a reference position return is completed If the reference position return is completed and if the protective door is open safe machine position monitoring safe speed monitoring and safety position error monitoring are performed Then the safety functions start working If the reference position return is not completed safe machine position monitoring cannot be performed because the coordinates are not established In this state the machine position monitoring function is disabled After a reference position return is made this function is enabled Depending on the safety parameter setting however an alarm may be raised To avoid
237. ter the previous test is completed If the CNC is turned on or if 24 hours have elapsed after the previous test 1s completed a guard open request protective door open request should not be accepted until the test is performed A machine tool builder must make the ladder program to realize this sequence 15 3 SAFETY FUNCTIONS B 64303EN 4 01 3 3 STOP 3 3 1 Stopping the Spindle Motor Because the spindle motor is an induction type motor power down during rotation causes the motor to continue rotating for a certain amount of time From a safety standpoint the motor may have to be stopped immediately If an error is detected and the spindle is judged to be controlled it is possible to stop spindle motor by the ladder program In case of emergency stop and abnormal condition of safety related I O it is necessary to design the ladder program to shut off the power after waiting the specified time elapses To speed down and stop the spindle the PMC must input the spindle Emergency Stop signals ESPA lt Gn071 1 gt and ESPB lt Gn075 1 gt When this signal is input the spindle slows down and stops A Ladder program for inputting this signal in case of alarm must be created The input of EMG emergency stop input connector of the common power supply or BiSVSP also has the same effect If the Emergency Stop signal is connected to emergency stop input connector CX4 of common power supply or BiSVSP the spindle slows down and s
238. ters are classified by data type as follows Data type Valid data range Remarks Bit Bit machine group Bit path Bit axis Bit spindle Byte Byte machine group Byte path Byte axis Byte spindle Word Word machine group Word path Word axis Word spindle 2 word 2 word machine group 2 word path 0 to 999999999 2 word axis 2 word spindle Real Real machine group Real path Real axis Real spindle Some parameters 128 to 127 handle these types of 0 to 225 data as unsigned data Some parameters 32768 to 32767 handle these types of 0 to 65535 data as unsigned data Some parameters handle these types of data as unsigned data See the Standard Parameter Setting Tables NOTE 1 Each of the parameters of the bit bit machine group bit path bit axis and bit spindle types consists of 8 bits for one data number parameters with eight different meanings Machine group type indicates that parameters are available for the maximum number of machine groups and independent data can be set for each machine group With the 0 D the maximum number of machine groups is 1 at all times Path type indicates that parameters are available for the maximum number of paths and independent data can be set for each path Axis type indicates that parameters are available for the maximum number of controlled axes and independent data can be set for
239. ters the safety stop state For each feed axis up to four safe positions can be specified in safety parameters Both the CNC and the Servo monitor whether each axis is within the safety position The range of the safety machine position can be changed by the Safety Speed Safety Position Selection signals SVAn SVBn for feed axis Safety Speed Safety Safety machine position Name Position Selection signal parameter SVAn SVBn direction direction Safety machine position 1 Safety machine position 2 Safety machine position 3 Safety machine position 4 0 0 No 13831 No 13832 1 0 No 13833 No 13834 No 13835 No 13836 No 13837 No 13838 When out of position error is detected Monitoring Result signal RSVx is set to 0 In this situation if Safety Check Request signal VLDVx is 0 and safety monitor is executed an alarm is generated Error detected CPU 50495 SV SV0477 N CAUTION 1 The safe machine position monitoring function does not keep monitoring the specified range Only after the function detects that a position on a feed axis exceeds the range the system enters the stop state Accordingly in the stop state an over travel has occurred on the feed axis The travel distance depends on the traveling speed and other conditions When an out of position error is detected if the axis is not stopped after the time specified in the parame
240. th spindle If an alarm occurs because of the configuration change of the spindle amplifier set the spindle amplifier correctly 154 B 64303EN 4 01 8 ALARM MESSAGE No Message SP0757 SAFETY SPEED OVER The CNC CPU detected that during safety monitoring the safety check request signal VLDPs is 0 the spindle motor speed was greater than the safety speed parameter No 4372 4438 4440 or 4442 on the n th spindle Operate within the safety speed SP1700 SAFETY PARAM ERROR The CNC CPU detected error in safety parameter check function Alarms requiring power to be turned off PW alarm No Message Desciptin ERROR DCS PMC check function ERROR PMC function ERROR DCS PMC check function ERROR PMC check function ERROR DCS PMC check function ERROR PMC function PW0014 CPU TEST ALARM CNC An error occurred in a CNC CPU test PW0015 SAFETY PARAM ERROR The CNC detected error for safety parameter check function PW0016 CHECK ERROR The CNC detected error in RAM check function PW0017 INEXECUTION OF SAFETY The CNC detected abnormal condition in the execution of CNC safety FUNCTIONS functions PW0018 CRC CHECK ERROR The CNC detected the CRC check error in the CNC ROM Other alarms DS alarm No Message _ DS0022 DUAL CHECK SAFETY IS NOT Dual Check Safety function is unavailable by setting a parameter WORKED 1902 6 to 0 Ser
241. than described above and related to data communication or position detector each CPU turns this signal corresponding to the alarm axis to 0 immediately But according to the parameter setting it is possible to turn to 0 this signals of all the axes belonged to the path that involves the alarm axis in case of any servo alarms NOTE When the spindle motor induction motor is powered off while rotating the motor performs free running at the speed before power off eventually stopping after a period of time In some cases however it is better to stop the motor as early as possible for safety When the spindle is decided to be controlled even if the MCC Off signal is set to 0 the rotation of the spindle can be stopped under control of the ladder program controlled stop To do this make a ladder program that interrupts power upon lapse of the timer set time after the MCC Off signal is set to 0 97 5 l O SIGNALS B 64303EN 4 01 MCC signal output MCFPs lt Fn753 0 to 1 gt lt DCS F 005 m 0 to 1 gt for each spindle In case this signal is 0 MCC is shut off through 2 channels of I O Link line respectively This signal is set to 0 when an alarm occurs in safety speed check for each spindle A machine tool builder makes a ladder program to output a signal to shut off the MCC of the path that the spindle belongs when this signal is turned to 0 Classification Outpu
242. the judgment about the safety related function of a CPU is consistent with that of another CPU If some error is found an alarm is output SV relation V0490 SV0484 SP relation SP9072 Spindle alarm 72 SP9077 Spindle alarm 77 SP9078 Spindle alarm 78 SP0755 PMC relation PW0008 DCS PMC PW0009 PMC 43 3 SAFETY FUNCTIONS B 64303EN 4 01 3 16 CHECK FUNCTION ECC Error Check and Correct function is applied to the battery back upped file memory Then a single bit error is corrected And when an error that cannot be corrected occurs memory parity error is generated Other memory for Dual Check Safety is checked as follows If the error is detected the alarm is generated and sets MCC Off signal DCALM to 707 1 Testat power on The several test patterns are written to the RAM area It 15 checked whether the written test data are read correctly If read error occurs an alarm is generated 2 Test during normal operation RAM area is checked in turn at constant interval during normal operation The several test patterns are written to the RAM It is checked whether the written test data are read correctly If read error occurs an alarm is generated Alarm detected CPU Alarm PW0016 SV0484 PW0008 DCS PMC PW0009 SP9016 Spindle alarm 16 3 17 CRC CHECK FUNCTION At power on and after power on the data that are related to Dual Check Safety and stor
243. the timer set time after the MCC Off signal is set to 0 96 B 64303EN 4 01 signal output 5 SIGNALS MCFVx lt Fn752 0 to 4 gt lt DCS F 004 m 0 to 4 gt for each axis Classification Function Operation In case this signal is 0 MCC is shut off through 2 channels of I O line respectively This signal is set to 0 when an alarm occurs in safety speed limit check safety machine position check or safety position error check for each servo axis machine tool builder makes a ladder program to output a signal to shut off the MCC of the path that the axis belongs when this signal is turned to 0 Output signal This signal output to both PMC but is not monitored doubly When the Dual Check Safety Function is applied this signal allows turning on MCC 0 MCC off 1 MCC on If each CPU finds out the abnormal state of the axis when Safety Check Request signal for the axis VLDVx 0 each CPU brings the axis Into controlled stop state at first In case of an alarm of Safety Speed Monitoring or Safety Machine Position Monitoring each CPU watches whether the axis is decelerated and stopped or not If the axis does not stop each CPU turns this signal corresponding to the alarm axis to 0 In case of an alarm of Safety Position Error Monitoring each CPU turns this signal corresponding to the alarm axis to 0 immediately In case of an alarm other
244. tion for doubly outputting the Spindle Excitation Off signal needs to be used For200V system A06B 6141 H002 to 55 580 A06B 6142 H002 to H055 H580 A06B 6164 H201 to H343 H580 e For400V system A06B 6151 H006 to 100 580 A06B 6152 H006 to 100 580 Moreover the following Dual Check Safety function needs to be used e Programmable Safety I O signal Section 5 4 62 3 SAFETY FUNCTIONS B 64303EN 4 01 3 21 DUAL BRAKE MONITOR FUNCTION Residual risk 3 21 1 Brake Test With the Dual Check Safety function mechanical control is exercised on the servo axis brake to secure the safety of the brake by using the doubly output Safety Brake signal BRKx This function conducts a test periodically on the servo axis brake to secure the safety of brake control mentioned above When this function is used the following risk is known to be present If a brake failure occurs between a brake test and the next brake test on the vertical axis for which the brake mechanism is not redundant a drop on the axis can occur when servo motor excitation is turned off by an emergency stop or servo alarm A brake test can be conducted for a servo axis that has a brake A brake test may be conducted only for those axes including the vertical axis that require brake control For each axis whether to conduct a brake test can be selected using parameter No 13912 As with MCC off Test a brake test is to be performed when the power is tu
245. tion provides a means for ensuring a high level of safety with the protection door opened The simplest method of ensuring safety when the protection door is open is to shut off power to the motor drive circuit by configuring a safety circuit with a safety relay module In this case however no movements can be made on a move axis rotation axis Moreover since the power is shut off some time is required before machining can be restarted This drawback can be corrected by adding a motor speed detector to ensure safety However the addition of an external detector may pose a response problem and the use of many safety relay modules results in a large and complicated power magnetic cabinet circuit With the Dual Check Safety function two independent CPUs built into the CNC monitor the speed and position of motors in dual mode An error in speed and position is detected at high speed and power to the motor is shut off via two independent paths Processing and data related to safety is cross checked by two CPUs To prevent failures from being built up a safety related hardware and software test must be conducted at certain intervals time The Dual Check Safety system need not have an external detector added Instead only a detector built into a servo motor or spindle motor is used This configuration can be implemented only when those motors detectors built into motors and amplifiers that are specified by FANUC are used The Dual Check
246. tops in the emergency stop state If the spindle does not stop in spite of the stop command the MCC is shut off If this processing is not performed power down causes the spindle motor to continue rotating at the speed prior to power down and eventually stopping in the end N CAUTION 1 When the servo alarm or spindle alarm related to the communication error or position detector is caused MCC off signal corresponding to the servo or spindle is output Shut off the MCC after executing appropriate procedure such as spindle stop operation According to the setting value of the parameter MCC off signals of all axes which belong to the same path of the spindle that causes an alarm are output Shut off the MCC after executing appropriate procedure such as spindle stop operation A controlled stop can be made based on parameter settings on occurrence of a safe speed over alarm Since the synchronous spindle motor is a synchronous motor not an induction motor power interruption causes a dynamic break stop depending on the system configuration 16 3 SAFETY FUNCTIONS B 64303EN 4 01 3 3 2 Stopping the Servo Motor 3 3 3 Stop States Safe stop state Because the servo motor is a synchronous motor power down results in a dynamic brake stop The dynamic brake stop is electric braking in which the excited rotor is isolated from the power source and the generated electric energy is used up in the winding An internal resistor
247. tor movement Data output from the detector built into each motor is transferred to the CNC through the amplifier The safety of this path is ensured by using motors and amplifiers specified by FANUC Cross monitoring using 2 CPUs Two CPUs built into the CNC are used to cross monitor the safety function Each CPU is periodically checked for errors If one system fails the servo and spindle can be stopped safely Power shutoff via two paths If an error is detected the power is shut off via two power shutoff paths The paths need to be tested for built up failures within a certain time Input signal safety Safety related input signals such as the protection door lock unlock signal are monitored doubly If a mismatch between the two occurrences of a signal is detected the power to the motor drive circuit is shut off This cross check is constantly made Output signal safety A signal is output via two paths to the relay used to shut off the power to the motor drive circuit An error is detected by MCC off Test For detection of built up failures a MCC off Test needs to be conducted at certain intervals This MCC off Test 15 not mandatory when machining is performed with the protection door closed The MCC off Test should be performed before the protection door is open after the certain intervals B 64303EN 4 01 1 OVERVIEW 1 3 2 1 Latent error detection and cross check Detection of latent errors Cross check This detecti
248. unction adjustment safety limitation speed safety machine position Safe position error monitoring Test for checking the safety function Check test execution and report creation Parameter preservation Save all parameters including the safety parameters The parameters are used to start up the series Set a password A password is used to disable unauthorized persons from modifying safety parameters Before safety parameters of the equipment for which a password parameter No 3225 is set can be modified the password value must be set as the keyword parameter No 3226 Only those persons authorized to conduct a check test should know the password value Series 2nd and Subsequent Machines Startup The parameters for the safety monitoring function are transferred together with other parameters to the CNC as in the case of normal series start up Perform a safety function check test in addition to the normal start up procedure Troubleshooting Alarms related to the safety function are output on the ALARM screen Correct the cause of trouble according to the chapter describing alarms and messages in this manual When a component related to the safety function is to be replaced an authorized person must conduct a safety function check test 152 B 64303EN 4 01 8 ALARM MESSAGE ALARM MESSAGE Alarm When Dual Check Safety function finds out some abnormal condition in safety check and generates an alarm the alarm
249. ushin Kogyo Co Ltd FI30 20S Hirose Electric Co Ltd s765 B 64303EN 4 01 4 INSTALLATION FCN 247J020 G E Fujitsu 52622 2011 Molex Japan Ltd Connector FI30 20S Hirose Electric Co Ltd cannot be used as connector JD51A for the stand alone type 307 series main CPU board Recommended cable A66L 0001 0284 10P Cable length I O Link branching adapter Unit L Josia 5 The total of L4 and Lg must not exceed 10 m where L is the length of the cable between connector JD51A on the CNC and connector JD51B on the I O Link branching adapter and Lp is the length of the cable between connector JD44A 1 JD44A 2 or JD1A on the I O Link branching adapter and connector JD1B on the I O unit When all cables are accommodated in the same cabinet however a total cable length of up to 15 m is allowed Ig 4 INSTALLATION B 64303EN 4 01 Installation of the I O Link branching adapter for three channels Install the I O Link branching adapter for three channels in a hermetically sealed cabinet like the CNC External dimensions of the I O Link branching adapter for three channels JD51B JD44A 1 JD44A 2 JD1A Unit mm Allow a clearance of about 10 cm above the adapter for connection and routing of cables Installation of the I O Link branching adapter for three channels 1 Installation on the DIN rail 35 j 25 Unit mm Recommended DIN rail 2 Screwing Drilling on th
250. vided only for the M series T series TH Cutting feedrate M series When to is inserted between two parameter numbers there are parameters with successive numbers between the two starting and ending parameter numbers but those intermediate parameter numbers are omitted for convenience The lower case letter x or s following the name of a bit type parameter indicates the following 1 x Bit axis type parameters Bit spindle type parameters 112 B 64303EN 4 01 6 PARAMETERS 6 4 STANDARD PARAMETER STTING TABLES Overview This section defines the standard minimum data units and valid data ranges of the CNC parameters of the real type real machine group type real path type real axis type and real spindle type The data type and unit of data of each parameter conform to the specifications of each function Explanation A Length and angle parameters type 1 Increment Unit of data system mm degree Minimum data unit Valid data range 999999 99 to 999999 99 999999 999 to 999999 999 99999 9999 to 99999 9999 inch B Length and angle parameters type 2 Increment Unit of data system 0 00001 Minimum data unit 99999 999 to 99999 999 99999 9999 to 99999 9999 9999 99999 to _ 9999 99999 Valid data range to 999999 99 to 999999 999 to 99999 9999 0 00001 113 to 99999 999 to
251. w appears This screen shows the current DO status If there is difference of DO state between PMC and DCS PMC is displayed on the left side of the address ABSOLUTE DO SIGNALS ADDRESS PMC DCSPMC F8748C1 2 FB8BB88 10000010 10000010 F8758C1 2 F88802 88888888 88888888 F8751C1 5 F8003 88888008 88088888 MODAL F0752C1 F80004 88888000 8080808088 Fe753 1 gt Fee85 888888880 88888888 649 664 F M i cH EE W FB0754C1 F 006 80000000 _ GE 5 i F0755C12 F0007 80000000 GOBDODOO 22 650 648 1 T F0756C1 F0008 80000000 00000000 Sd 667 625 S F0 57c13 F0009 80000000 _ zh Gee T FO0758C13 F0010 80000000 _ 654 613 1 SACT B MIN 18 32 26 lt LU RELATI ALL HANDLE MCC ROSS OPRT gt VE TEST HECK 164 B 64303EN 4 01 9 DIAGNOSIS SPINDLE STATUS SCREEN Press page key i and select the fourth screen The screen shown below appears When the judging result of safety function of CNC 15 not the same as other CPU the cross check alarm occurs This screen shows the cause of cross check alarm related to a spindle j afa a Cross check data about the following items for the spindle CPU and CNC CPU is displayed When no alarm is detected in a cross check the results of the current check are indicated When an alarm is detected in a cross check the held data is
252. wn to a stop the operation is performed as instructed by the PMC and then the power is shut off For the synchronous spindle motor immediate power interruption causes a dynamic break stop depending on the system configuration 17 3 SAFETY FUNCTIONS B 64303EN 4 01 Controlled stop state The power to the motor is not shut off The servo motor and the spindle motor are controlled to stop In the controlled stop state of either motor the safety function is active if the condition for enabling the safety function is satisfied the door is open If a further abnormal event occurs the motor is brought into the safe stop state by the ladder program N WARNING 1 The machine tool builder must design the machine so that the machine is kept in the stop state if the power to the servo motor driving circuit is shut off Example Brake mechanism that would not drop the vertical axis after the power is shut off If the power to the spindle motor driving circuit is shut off the spindle motor continues rotating at the speed before the power down and eventually comes to a stop A measure must be taken so that this coasting does not affect safety 18 B 64303EN 4 01 3 SAFETY FUNCTIONS 3 4 SAFE RELATED 1 0 SIGNAL MONITORING A set of safe related 1 signals are connected to the two channels of the I O respectively As for safe related I O signals pair of signals are prepared and connected to each I O through different paths The
253. ximum linear motion of approximately 2 0mm When a limit value is violated the speed may exceed the set value briefly or the axis spindle overshoot the set point position to a greater or lesser degree during the period between error detection and system reaction depending on the dynamic response of the drive and the parameter settings see Section Safety Functions The category 0 stop function according to EN60204 1 means that the spindles axes are not braked to zero speed but coast to a stop this may take a very long time depending on the level of kinetic energy involved This must be noted for example when the protective door locking mechanism is opened Amplifiers drive power modules and motors must always be replaced by the same equipment type or else the parameters will no longer match the actual configuration and cause Dual check Safety to respond incorrectly Dual check Safety is not capable of detecting errors in parameterization and programming made by the machine tool builder The required level of safety can only be assured by thorough and careful acceptance There is a parameter that MCC off test is not to be made in the self test mode at power on as in the case of machine adjustment This parameter is protected only changed by authorized person IF MCC off test is not conducted MCC may not be off at stop response is measured Safety machine position monitoring function does not apply to the spindle axis During machine adjustm

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