fanuc 30iB, 31i B, 32i- B Connection Manual

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FANUC Series 30*-MODEL B FANUC Series 31*-MODEL B FANUC Series 32*-MODEL B

Dual Check Safety

CONNECTION MANUAL

B-64483EN-2/01

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

• 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 ® or ™ in the main body.

B-64483EN-2/01 DEFINITION OF WARNING, CAUTION, AND NOTE

DEFINITION OF WARNING, CAUTION, AND NOTE

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

WARNING

Applied when there is a danger of the user being injured or when there is a

danger of both the user being injured and the equipment being damaged if the approved procedure is not observed.

CAUTION

Applied when there is a danger of the equipment being damaged, if the

approved procedure is not observed.

NOTE

The Note is used to indicate supplementary information other than Warning and

Caution.

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

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B-64483EN-2/01 PREFACE

PREFACE

Description of this manual

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 CONNECTION OF TWO MCCS Appendix B, "DIRECTIVES, STANDARDS AND TECHNICAL CONDITIONS FOR 3RD PARTY SERVO / SPINDLE MOTORS & ENCODERS WHEN APPLYING FANUC / GE FANUC DUAL-CHECK SAFETY"

Applicable models

This manual can be used with the following models. The abbreviated names may be used.

Model name Abbreviation

FANUC Series 30i–B 30i –B Series 30i FANUC Series 31i–B 31i –B

FANUC Series 31i–B5 31i –B5 FANUC Series 32i–B 32i –B Series 32i

Related manuals of Series 30i- MODEL B Series 31i- MODEL B Series 32i- MODEL B

The following table lists the manuals related to Series 30i-B, Series 31i-B, Series 32i-B. This manual is indicated by an asterisk(*).

Table 1 Related manuals of Series 30i- MODEL B, Series 31i- MODEL B, Series 32i- MODEL B

Manual name Specification number

DESCRIPTIONS B-64482EN CONNECTION MANUAL (HARDWARE) B-64483EN CONNECTION MANUAL (FUNCTION) B-64483EN-1 OPERATOR’S MANUAL (Common to Lathe System/Machining Center System) B-64484EN OPERATOR’S MANUAL (For Lathe System) B-64484EN-1 OPERATOR’S MANUAL (For Machining Center System) B-64484EN-2 MAINTENANCE MANUAL B-64485EN PARAMETER MANUAL B-64490EN Programming Macro Executor PROGRAMMING MANUAL B-63943EN-2 Macro Compiler PROGRAMMING MANUAL B-66263EN C Language Executor PROGRAMMING MANUAL B-63943EN-3

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Series 31i

PREFACE B-64483EN-2/01

Manual name Specification number

PMC

PMC PROGRAMMING MANUAL B-64513EN Network PROFIBUS-DP Board CONNECTION MANUAL B-63993EN Fast Ethernet / Fast Data Server OPERATOR’S MANUAL B-64014EN DeviceNet Board CONNECTION MANUAL B-64043EN FL-net Board CONNECTION MANUAL B-64163EN CC-Link Board CONNECTION MANUAL B-64463EN Operation guidance function

MANUAL GUIDE i (Common to Lathe System/Machining Center System) OPERATOR’S MANUAL MANUAL GUIDE i (For Machining Center System) OPERATOR’S MANUAL MANUAL GUIDE i (Set-up Guidance Functions) OPERATOR’S MANUAL

Dual Check Safety

Dual Check Safety CONNECTION MANUAL B-64483EN-2 *

B-63874EN

B-63874EN-2 B-63874EN-1

Related manuals of SERVO MOTOR αi/βi series

The following table lists the manuals related to SERVO MOTOR αi/βi series

Table 2 Related manuals

Manual name Specification number

FANUC AC SERVO MOTOR αi series DESCRIPTIONS FANUC AC SERVO MOTOR αi series / FANUC AC SERVO MOTOR βi series / FANUC LINEAR MOTOR LiS series / FANUC SYNCHRONOUS BUILT-IN SERVO MOTOR DiS series PARAMETER MANUAL FANUC AC SPINDLE MOTOR αi series DESCRIPTIONS FANUC AC SPINDLE MOTOR αi/βi series, BUILT-IN SPINDLE MOTOR Bi series PARAMETER MANUAL FANUC SERVO AMPLIFIER αi series DESCRIPTIONS FANUC AC SERVO MOTOR αi series / FANUC AC SPINDLE MOTOR αi series / FANUC SERVO AMPLIFIER αi series MAINTENANCE MANUAL

CNCs that are described in this manual can be connected to following servo motors and spindle motors. Note that motors of the αi SV series, αi SP series, αi PS series, and βi SV series can be connected only when they are compatible with 30i-B. This manual mainly assumes that the FANUC SERVO MOTOR αi 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.

B-65262EN

B-65270EN

B-65272EN B-65280EN B-65282EN B-65285EN

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B-64483EN-2/01 TABLE OF CONTENTS

DEFINITION OF WARNING, CAUTION, AND NOTE................................. s-1

PREFACE....................................................................................................p-1

1 OVERVIEW .............................................................................................1

1.1 DIRECTIVE AND STANDARDS....................................................................1

1.1.1 Directives..................................................................................................................1

1.1.2 Related Safety Standards..........................................................................................1

1.1.3 Risk Analysis and Evaluation...................................................................................2

1.2 DEFINITION OF TERMS...............................................................................2

1.2.1 General Definition of Terms ....................................................................................2

1.2.2 Definition of Terms Related to the Safety Function.................................................2

1.3 BASIC PRINCIPLE OF DUAL CHECK SAFETY...........................................3

1.3.1 Features of Dual Check Safety.................................................................................3

1.3.2 Compliance with the Safety Standard (ISO13849-1, Category 3, PL d)..................3

1.3.2.1 Latent error detection and cross-check................................................................ 5

1.3.2.2 Safety monitoring cycle and cross-check cycle...................................................5

1.3.2.3 Error analysis.......................................................................................................5

1.3.2.4 Remaining risks...................................................................................................6

1.4 GENERAL INFORMATION ...........................................................................7

1.5 SAFETY FUNCTION BY FL-net....................................................................8

2 SYSTEM CONFIGURATION...................................................................9

3 SAFETY FUNCTIONS ...........................................................................10

3.1 APPLICATION RANGE...............................................................................10

3.2 BEFORE USING THE SAFETY FUNCTION...............................................11

3.2.1 Important Items to Check Before Using the Safety Function ................................11

3.2.2 MCC off Test of the Safe Stop Function ................................................................12

3.3 STOP...........................................................................................................12

3.3.1 Stopping the Spindle Motor ...................................................................................12

3.3.2 Stopping the Servo Motor ......................................................................................12

3.3.3 Stop States..............................................................................................................13

3.4 SAFETY-RELATED I/O SIGNAL MONITORING.........................................13

3.5 EMERGENCY STOP...................................................................................20

3.6 SAFE SPEED MONITORING......................................................................21

3.7 SAFE MACHINE POSITION MONITORING ...............................................22

3.8 MCC OFF TEST..........................................................................................23

3.9 SAFETY POSITION SWITCH FUNCTION..................................................25

3.10 SAFETY RELATED PARAMETERS CHECK FUNCTION...........................27

3.11 PARAMETER LOCK FUNCTION................................................................27

3.12 SEFETY POSITION ERROR MONITORING FUNCTION...........................27

3.13 AMPLIFIER CIRCUIT MONITORING FUNCTION.......................................28

3.14 SAFETY BRAKE SIGNAL OUTPUT FUNCTION ........................................28

3.15 CPU SELF TEST FUNCTION......................................................................29

3.16 RAM CHECK FUNCTION............................................................................29

3.17 CRC CHECK FUNCTION............................................................................30

3.18 SAFE STOP MONITORING ........................................................................30

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TABLE OF CONTENTS B-64483EN-2/01

3.19 BRAKE TEST ..............................................................................................31

4 INSTALLATION ....................................................................................36

4.1 OVERALL CONNECTION DIAGRAM .........................................................37

4.1.1 In case of using the I/O Link..................................................................................37

4.1.2 In case of using the I/O Link i ................................................................................38

4.1.3 In case of using PROFIBUS-DP on the DCS PMC side........................................39

5 I/O SIGNALS.........................................................................................40

5.1 OVERVIEW .................................................................................................40

5.2 SIGNAL ADDRESS.....................................................................................41

5.3 SIGNALS.....................................................................................................47

5.4 PROGRAMMABLE SAFETY I/O SIGNAL...................................................62

5.5 NOTE ON MULTI PATH CONTROL............................................................63

5.5.1 Machine Group And Multi Path Control................................................................63

6 PARAMETERS......................................................................................64

6.1 OVERVIEW .................................................................................................64

6.2 DATA TYPE.................................................................................................64

6.3 REPRESENTATION OF PARAMETERS ....................................................65

6.4 STANDARD PARAMETER SETTING TABLES...........................................66

6.5 PARAMETERS............................................................................................67

6.6 PROFIBUS-DP PARAMETER SETTINGS..................................................94

7 START-UP.............................................................................................96

7.1 START-UP OPERATION.............................................................................96

7.1.1 Acceptance Test and Report for Safety Functions .................................................96

7.2 START-UP OF THE SAFETY FUNCTION ..................................................97

7.2.1 Initial Start-up.........................................................................................................97

7.2.2 Series (2nd and Subsequent Machines) Startup .....................................................99

7.2.3 Troubleshooting .....................................................................................................99

8 ALARM MESSAGE.............................................................................100

9 DIAGNOSIS.........................................................................................108

9.1 MCC OFF TEST STATUS SCREEN.........................................................108

9.2 CROSS CHECK DATA SCREEN..............................................................109

9.3 BRAKE TEST SCREEN.............................................................................115

9.4 FLOW MONITORING SCREEN................................................................115

9.5 FEED LIMIT MONITORING SCREEN.......................................................116

9.6 SAFE MACHINE POSITIONING MONITORING SCREEN.......................119

9.7 SAFETY POSITION ERROR MONITORING SCREEN.............................119

9.8 DIAGNOSIS SCREEN...............................................................................120

10 SAMPLE SYSTEM CONFIGURATION...............................................123

10.1 SAMPLE CONFIGURATION.....................................................................123

10.1.1 Sample Configuration for One Machine Group (1)..............................................123

10.1.2 Sample Configuration for One Machine Group (2: when Multiple MCCs are

Used) ....................................................................................................................124

10.2 SAMPLE CONNECTIONS.........................................................................125

10.2.1 Emergency Stop Signal (*ESP)............................................................................125

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10.2.2 Guard Open Request Signal (ORQ).....................................................................126

10.2.3 Test Mode Signal (OPT) ......................................................................................126

10.2.4 Guard Open Inhibit Signal (*OPIHB), Monitoring Result Signal (RSVx,RSPx),

Safety check Request Signal (*VLDVx,*VLDPs) ...............................................127

10.2.5 MCC Off Signal (*MCF,*MCFVx,*MCFPs,*DCALM),

MCC Contact State Signal (*SMC) .....................................................................130

10.3 EXAMPLE OF APPLICATION...................................................................131

10.3.1 Rotating the Spindle Manually in the Emergency Stop State ..............................131

11 APPLICATION OF OTHER FUNCTIONS...........................................132

11.1 OVERVIEW ...............................................................................................132

11.2 EXTERNAL DECELERATION...................................................................132

11.2.1 Overview..............................................................................................................132

11.2.2 Specifications .......................................................................................................133

11.2.3 Signals..................................................................................................................134

11.2.3.1 Details on signals.............................................................................................134

11.2.3.2 Signal address.................................................................................................. 135

11.2.4 Parameters............................................................................................................135

11.3 SPINDLE OUTPUT CONTROL BY THE PMC ..........................................137

11.3.1 Overview..............................................................................................................137

11.3.2 Specifications .......................................................................................................138

11.3.3 Signals..................................................................................................................138

11.3.3.1 Details on signals.............................................................................................138

11.3.3.2 Signal address.................................................................................................. 139

11.3.4 Parameters............................................................................................................140

11.4 SPINDLE POSITIONING...........................................................................140

11.4.1 Overview..............................................................................................................140

11.4.2 Specifications .......................................................................................................140

11.4.3 Signals..................................................................................................................142

11.4.3.1 Details on signals.............................................................................................142

11.4.3.2 Signal address.................................................................................................. 143

11.4.4 Parameters............................................................................................................143

11.5 Cs CONTOUR CONTROL.........................................................................149

11.5.1 Overview..............................................................................................................149

11.5.2 Specifications .......................................................................................................149

11.5.3 Signals..................................................................................................................150

11.5.3.1 Details on signals.............................................................................................150

11.5.3.2 Signal address.................................................................................................. 151

11.5.4 Parameters............................................................................................................151

11.6 SPINDLE ORIENTATION..........................................................................154

11.6.1 Overview..............................................................................................................154

11.6.2 Specifications .......................................................................................................155

11.6.3 Signals..................................................................................................................155

11.6.3.1 Details on signals.............................................................................................155

11.6.3.2 Signal address.................................................................................................. 157

11.6.4 Parameters............................................................................................................157

11.6.5 Sequence...............................................................................................................159

11.7 SAFETY STOPPING FUNCTION AT OPENING PROTECTION DOOR...161

11.7.1 Overview..............................................................................................................161

11.7.2 Safety Function ....................................................................................................161

11.7.2.1 Scope ............................................................................................................... 161

11.7.2.2 Monitoring the Excitation off signals of the α

11.7.3 Connection ...........................................................................................................165

i SP.......................................... 162

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TABLE OF CONTENTS B-64483EN-2/01

11.7.3.1 Connection from connector JX4 on the α

(on the DCS PMC side)................................................................................... 166

11.7.4 Parameter..............................................................................................................166

11.7.4.1 Safe Speed Selection signal............................................................................. 166

11.7.4.2 Programmable Safety I/O signals....................................................................167

i SP series to an I/O unit

11.8 CONTROLLED AXIS DETACH .................................................................167

11.8.1 Overview..............................................................................................................167

11.8.2 Signal Sequence ...................................................................................................168

11.8.3 Specification.........................................................................................................169

11.8.4 Replacing a Spindle Head ....................................................................................170

11.8.5 Signal Sequence ...................................................................................................171

11.8.6 Specification.........................................................................................................172

11.8.7 Signal....................................................................................................................172

11.8.7.1 Details of signals..............................................................................................172

11.8.7.2 Signal address.................................................................................................. 173

11.8.8 Parameter..............................................................................................................173

11.8.9 Alarm message .....................................................................................................174

APPENDIX

A CONNECTION OF TWO MCCS..........................................................177

A.1 Overview....................................................................................................177

A.2 CONFIGURATIONS..................................................................................177

A.3 DISABLING MCC OFF TEST....................................................................180

B Directives, Standards and Technical Conditions for 3rd Party

Servo / Spindle Motors & Encoders when Applying FANUC

Dual-check Safety..............................................................................181

B.1 GENERAL .................................................................................................181

B.2 MANDATORY STANDARDS AND DIRECTIVES......................................181

B.3 SPINDLES.................................................................................................182

B.3.1 Spindle Motors – Driven by FANUC Spindle Amplifier.....................................182

B.3.2 Spindle Encoder – Speed / Position Feedback Sensor Embedded in Motor........182

B.4 SERVO......................................................................................................182

B.4.1 Servo Motors – Driven by FANUC Servo Amplifier...........................................182

B.4.2 Servo Encoder – Speed / Position Feedback Sensor Embedded in Motor...........183

B.4.2.1 Encoder with FANUC Serial Interface............................................................ 183

B.4.2.2 A/B-Phase Sine-wave Interface Connected to FANUC Interpolation Circuit.183

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B-64483EN-2/01 1.OVERVIEW

1 OVERVIEW

Setup for machining, which includes attaching and detaching a workpiece to be machined, and moving it to the machining start point while viewing it, is performed with the protection door opened. The dual check safety function provides a means for ensuring a high level of safety with the protection door opened.

The simplest method of ensuring safety when the protection door is open is to shut off power to the motor drive circuit by configuring a safety circuit with a safety relay module. In this case, however, no movements can be made on a move axis (rotation axis). Moreover, since the power is shut off, some time is required before machining can be restarted. This drawback can be corrected by adding a motor speed detector to ensure safety. However, the addition of an external detector may pose a response problem, and the use of many safety relay modules results in a large and complicated power 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 an accumulation of failure, 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 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.

1.1 DIRECTIVE AND STANDARDS

1.1.1 Directives

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

Directive

Directive 2006/42/EC 2006 Safety of machinery Directive 2004/108/EC 2004 Electromagnetic compatibility Directive 2006/95/EC 2006 Low Voltage Requirement

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.

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1.OVERVIEW B-64483EN-2/01

Important safety standards

ISO 12100 -1/2 Safety of machinery – Basic concepts, general principle for design

- Part 1: Basic terminology, methodology

- Part 2: Technical principles for design

EN954-1 1997 Safety of machinery – Safety related parts of control systems –

Part 1: General principles for design

IEC 61508 Functional safety of electrical / electronic / programmable electronic

safety-related systems

ISO 13849-1 Safety of machinery – Safety-related parts of control systems –

Part 1 : General principles for design ISO 14121–1 Safety of machinery – Principles for risk assessment EN60204-1 2006 Safety of machinery – Electrical equipment of machine

Part 1 : General requirements IEC 62061 Safety of machinery Functional safety, safety–related electrical, electronic

and programmable electronic control systems

1.1.3 Risk Analysis and Evaluation

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

1.2 DEFINITION OF TERMS

1.2.1 General Definition of Terms

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

Term Definition

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

Safety stop

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

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B-64483EN-2/01 1.OVERVIEW

Safety limitation speed

When the drive system has reached a specified limitation speed, a transition is made to the safe stop state. A 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.

1.3 BASIC PRINCIPLE OF DUAL CHECK SAFETY

1.3.1 Features of Dual Check Safety

Dual Check Safety function has the following features.

- Two-channel configuration with two or more independent CPUs

- Cross-check function for detecting latent errors

Detection

A servo motor detector signal is sent via the servo amplifier and is applied to the CNC through the 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 through the FSSB interface or 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 or I/O Link i interface. Then, it is fed to two CPUs: a CNC CPU and a PMC CPU.

Evaluation

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.

Response

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.

1.3.2 Compliance with the Safety Standard (ISO13849-1, Category 3,

PL d)

The Dual Check Safety function complies with the requirements of the safety standard ISO13849-1, Category 3, Performance Level (PL) d.

NOTE

The Dual Check Safety function is not meant to guarantee that the PL d

requirements are met across the entire system. The PL value of the system as a whole is determined by the PL values of all its subsystems; therefore, the PL of the entire system needs to be evaluated by the machine tool builder. The PL value of the CNC, which is one of the subsystems, becomes d when the Dual Check Safety function is used.

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1.OVERVIEW B-64483EN-2/01

Category 3 requires the following:

- The safety function of a safety-related portion must not degrade when a single failure occurs.

- Single errors must be detected at all times when natural execution is possible.

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

Shut off power

Magn e tic contactor

Shut off power

Motor detector signal

Cross-check of data and results

Servo

Spindle

CPU

CNC

CNC CPU

CPU

Door switch signal

PMC CPU

Monitoring of servo motor and spindle motor movement

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

Cross-monitoring using 2 CPUs

Two CPUs built into the CNC are used to cross-monitor the safety function. Each CPU is periodically checked for errors. If one system fails, the servo 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 in redundant mode. 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 a MCC off Test. To detect an accumulation of failure, a MCC off Test needs to be conducted at certain intervals. This MCC off Test is not mandatory when machining is performed with the protection door closed. (The MCC off Test should be performed, before the protection door is open after the certain intervals.)

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B-64483EN-2/01 1.OVERVIEW

1.3.2.1 Latent error detection and cross-check

Detection of latent errors

This detection function can detect latent software and hardware errors in a system that has a two-channel configuration. So, the 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.

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.

Cross-check

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 stop state. (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.

- Safe speed monitoring (servo motor)

- Safe machine position monitoring (servo motor)

- Safe position error monitoring (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

1.3.2.3 Error analysis

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

Error analysis when the protection door is open

Error Cause Action

Excessive speed for Spindle axis Excessive speed for feed axis Feed axis safety machine position error Input/output signal error

Amplifier or CNC control unit failure, operation error, etc. Amplifier or CNC control unit failure, operation error, etc. Amplifier or CNC control unit failure, operation error, etc.

Wiring error, CNC control unit failure, etc. Safe-related I/O signal monitoring function

Safety limitation speed monitoring function EN60204-1 Category 1/0 stop Safety limitation speed monitoring function EN60204-1 Category 1/0 stop Safety machine position monitoring function EN60204-1 Category 1/0 stop

EN60204-1 Category 1/0 stop

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1.OVERVIEW B-64483EN-2/01

Error analysis when the protection door is closed

Error Cause Action

Input/output signal error

Wiring error, CNC control unit failure, etc. Safe-related I/O signal monitoring function

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 is not active until the CNC control unit and drive system have fully powered up.

The safety function cannot be activated if any one of the components of the CNC control unit 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) Example: An 8-pole synchronous motor can cause the axis to move by a maximum of 45 degrees. With a

ball-screw that is directly driven by, e.g.16mm per revolution, this corresponds to a maximum linear motion of approximately 2.0mm.

f) 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)

g) 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.

h) 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.

i) 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.

j) There is a parameter that MCC off test is not to be made in the self test mode at power-on as in the

case of machine adjustment. This parameter is protected, only changed by authorized person. IF

MCC off test is not conducted, MCC may not be off at stop response is measured. k) Safety machine position monitoring function does not apply to the spindle axis. l) During machine adjustment, an exact motion may be executed incorrectly until the safety functions

setup correctly and confirm test is completely.

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B-64483EN-2/01 1.OVERVIEW

m) 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. n) The delay timer is prepared for the cross-checking of the safety related I/O. 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. o) Even if <Signal State via PMC> does not match <Signal State via DCSPMC> for the time specified

by parameter No. 13810 after the CNC starts, no alarm occurs.

1.4 GENERAL INFORMATION

The following requirements must be fulfilled for the Dual-Check System:

- All conditions of the certification report have to be respected.

- Before shipping the machine, the machine tool builder has to do tests for insulation and protective

bonding.

- The procedures for the changes in the System (either HW or SW) should be referred to Maintenance

Manual (B-64485EN). When safety related components are exchanged, confirmation test regarding

safety functions can be performed according to Chapter 8.

- Programming in ladder logic should be referred to PMC Programming Manual (B-64513EN).

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 5 CNC training course.

[ CNC GENERAL 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

- Configuration of CNC

- Basic function and programming of CNC

- Operation of CNC

- Function and programming of turning machine

- Function and programming of milling machine

- Configuration and function of servo system

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

- 7 -

1.OVERVIEW B-64483EN-2/01

1.5 SAFETY FUNCTION BY FL-net

In a machine system such as a transfer line, each of its multiple stations has an operator's panel equipped with an emergency stop button. The safety circuit of the entire system needs to be configured so that the emergency stop signal is sent to all CNCs when the emergency stop button of any of these stations is pressed. To allow such a safety circuit to be built among multiple CNCs, a Safety function by FL-net is provided that uses FL-net communication. By running this Safety function by FL-net under the Dual Check Safety function, it is possible to provide all connected CNCs with a safety signal of up to 7 bits. For details, refer to the FL-net Board CONNECTION MANUAL (B-64163EN).

- 8 -

B-64483EN-2/01 2.SYSTEM CONFIGURATION

2 SYSTEM CONFIGURATION

The dual check safety function has the following components.

Applicable CNC

FANUC Series 30i-B FANUC Series 31i-B5 FANUC Series 31i-B FANUC Series 32i-B

Amplifier, Motor and I/O

For details on applicable amplifiers, motors, and I/O 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.

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3.SAFETY FUNCTIONS B-64483EN-2/01

3 SAFETY FUNCTIONS

3.1 APPLICATION RANGE

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.

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 than FANUC servo motors and spindle motors controlled by the dual check safety function, while the protective door is open

Safety function

The dual check safety function has the following safety functions:

• Safety-related I/O signal dual monitoring Emergency stop input, protective door open/close state, safety-related signals like MCC contact state Output signal for shutting off the power (MCC off signal) To detect the latent cause of an abnormal state of this output, a MCC off Test must be made.

• Spindle motor Safe speed monitoring

• Servo motor Safe speed monitoring Safe machine position monitoring Safe position error monitoring

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 input check of the safety-related I/O signal monitoring function in redundant mode and the emergency stop function are always active, regardless of whether the protective door is opened or closed.

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B-64483EN-2/01 3.SAFETY FUNCTIONS

Dual monitoring of emergency stop signal

Emergency stop

Safety related signal is checked by the CNC(DCS PMC) and the PMC in redundant mode

Safe speed of servo motor and machine position are checked by the CNC and the Servo in redundant mode

Protective door

Door lock open/close monitoring

CNC

Protective door lock signal

Dual monitoring of protective door state

CNC

DCS PMC

Cross check

Servo

Power down command

PMC

Cross check

Power down

Spindle software

Spindle amplifier

Servo amplifier

common power supply

Dual monitoring of MCC

Power

(MCC)

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

The CNC and the spindle check the safe speed of the spindle motor in redundant mode.

Spindle motor

Safe speed monitoring

Servo motor

Safe speed monitoring. Safe machine position monitoring. Safe position error monitoring.

down

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.”

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3.SAFETY FUNCTIONS B-64483EN-2/01

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 after the previous test is completed. If the CNC is turned on or if 24 hours have elapsed after the previous test is completed, a guard open request (protective door open request) should not be accepted until the test is performed. A machine tool builder must make the ladder program to realize this sequence.

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 machine must input the spindle Emergency Stop signals (*ESPA<G71.1>, *ESPB<G75.1>, and so on) in PMC. When this signal is input, the spindle slows down and stops. (A Ladder program must be created for inputting this signal in case of alarm.) The input of *EMG emergency stop input (connector CX4) of the common power supply also has the same effect. If the Emergency Stop signal is connected to emergency stop input (connector CX4) of the PSM, the spindle slows down and stops in the emergency stop state. If 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).

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.

2 A controlled stop can be made based on parameter settings on occurrence of a

safe speed over alarm.

3 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.

3.3.2 Stopping the Servo Motor

Because the servo motor is a synchronous motor, power-down results in a dynamic brake stop. The dynamic brake stop is electric braking in which the excited rotor is isolated from the power source and the generated electric energy is used up in the winding. An internal resistor provides additional braking. Unlike an induction motor, the servo motor does not coast because of this structure.

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B-64483EN-2/01 3.SAFETY FUNCTIONS

If the input of the Emergency Stop signal or an error of a safety-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. If the controlled stop cannot be done, the motor is 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.

3.3.3 Stop States

The following stop states are possible.

Safe stop state

The power to the motor is shut off (MCC off state) 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 down 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.

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.

WARNING

1 The machine tool builder must design the machine so that the machine is kept in

the stop state if the power to the servo motor driving circuit is shut off. Example) Brake mechanism that would not drop the vertical axis after the power is shut off

2 If the power to the spindle motor driving circuit is shut off, the spindle motor

continues rotating at the speed before the power-down and eventually comes to a stop. A measure must be taken so that this coasting does not affect safety.

3.4 SAFETY-RELATED I/O SIGNAL MONITORING

The Dual Check Safety function uses two-channel I/O configuration. A pair of safety-related I/O signals are provided via separate paths to two I/O modules that are respectively connected to one of the two channels. The two independent CPUs individually check the input signals. If a mismatch between two corresponding signals is found, the system enters the safe stop state. The following safety-related I/O signals are monitored or output in redundant mode:

• Emergency stop signal

• Protective door state input signal (Request to monitor for each axis)

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3.SAFETY FUNCTIONS B-64483EN-2/01

• Input signal for selecting safety speed monitoring and safety position monitoring

• MCC contact state signal

• MCC off signal (power-down)

• Brake signal

• Safety position switch signal

• Programmable safety I/O signal

To build a dual monitoring system, the machine tool builder needs to connect one of each pair of these signals to the I/O module connected to the DCS PMC side (Note 1) and the other to that connected to the PMC side (Note 2).

CNC

(DCS PMC)

(Note 1)

I/O Link

Cross-check

PMC

(Note 2)

I/O Link

I/O MODULE

DI DO

Machine side

Shown at left is an example in which the signals are connected using two-channel I/O Links. For details about connections, see Chapter 4, "INSTALLATION".

NOTE

1 Dual Check Safety PMC (DCS PMC) 2 First PMC to fifth PMC Refer to PMC PROGRAMMING MANUAL (B-64513EN).

IMPORTANT

When the Emergency Stop signal or the other safety input signal is connected to

the I/O module, it is necessary to do an enough check about ladder program which defines 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. The check period must be specified as a safety parameter.

Parameter number Name

1945 Safety-related I/O check timer

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

- Input signal for making a protective door open request

- Input signal for starting the test mode

- Output signal for requesting a MCC off Test

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B-64483EN-2/01 3.SAFETY FUNCTIONS

This section briefly describes the signals. For details, see Chapter 5, “I/O SIGNALS”. For specific

connections, see the sample system configuration in Chapter 4, “INSTALLATION” and Chapter 10, “SAMPLE SYSTEM CONFIGURATION”.

I/O related with Dual Check Safety Function PMC(n=path(0-9)) DCS PMC (m=path(0-9) x20)

Symbol Signal name I/O address

1 *ESP Emergency Stop signal 2 *SGOPN Guard State signal Machine side signal Dual input

*VLDVx

*VLDPs

SVAn/

5 *SMC MCC Contact State signal

7 BRKx Safety Brake signal

8 SPS Safety Position Switch signal

10 *OPIHB Guard Open Inhibit signal

12 POSEx Position Information Effect signal 13 ORQ Guard Open Request signal <Gn191.3>(PMC) Input

14 OPT Test Mode signal <Gn191.2>(PMC) Input 15 RQT 16 STBT Brake Test Start signal <Gn193.2>(PMC) Input 17 RQBT

SVBn

SPAn/

SPBn

*DCALM

*MCF

*MCFVx

*MCFPs

RSVx Monitoring result signal (Servo)

RSPs Monitoring result signal (Spindle)

Safety Check Request signal

(Servo)

Safety Check Request signal

(Spindle)

Safety Speed / Safety Position

Selection signal (Servo)

Safety Speed Selection signal

(Spindle)

MCC Off signal

(for all system)

MCC Off signal

(for each machine group)

MCC Off signal

(for each servo axis)

MCC Off signal

(for each spindle)

Programmable Safety I/O

signals

MCC Off Test Execution

Request signal

Brake Test Execution Request

signal

<X0008.4,0,1> (PMC)

<X0008.4,0,1>(DCS PMC)

<Gn750.0-.7> (PMC)

<G(002+m).0-.7>(DCS PMC)

<Gn751.0-.3>(PMC)

<G(003+m).0-.3>(DCS PMC )

<Gn752/Gn753>(PMC)

<G(004+m)/G(005+m)>(DCS PMC)

<Gn754>(PMC)

<G(006+m)>(DCS PMC)

<Gn748.6>(PMC)

<G(000+m).6>(DCS PMC)

<F0748.7>(PMC)

<F000.7>(DCS PMC)

<Fn748.1>(PMC)

<F(000+m).1>(DCS PMC)

<Fn752.0-.7>(PMC)

<F(004+m).0-.7>(DCS PMC)

<Fn753.0-.3>(PMC)

<F(005+m).0-.3>(DCS PMC)

<Fn754.0-.7>(PMC)

<F(006+m).0-.7>(DCS PMC)

<Fn755-Fn758>(PMC)

<F(007+m)-F(010+m)>(DCS PMC)

<Fn191.0>(PMC)

<F(019+m).0>(DCS PMC)

<Fn750>(PMC)

<F(002+m) >(DCS PMC)

<Fn751.0-3>(PMC)

<F(003+m).0-3>(DCS PMC)

<Fn766>(PMC)

<F(018+m) >(DCS PMC)

<Fn191.2>(PMC) Output

<Fn191.3>(PMC) Output

Dual input

monitoring

Dual input

monitoring

Dual input

monitoring

Dual input

monitoring

Dual input

monitoring

Dual input

monitoring

Dual output

Dual input

monitoring

Dual output Dual output

Dual output

Safety-related I/O

1. *ESP Emergency Stop signal (input)

This signal is Emergency Stop signal and is monitored in redundant mode.

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3.SAFETY FUNCTIONS B-64483EN-2/01

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 dual 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 is 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 motor enters free run state. (The spindle motor can also enter the controlled stop state when the safe speed range is 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.

6. *DCALM, *MCF, *MCFVx, *MCFPs MCC Off 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. *MCFVx is to allow turning on MCC of each axis according to monitor safety speed or machine position or position error of servo axis. *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”.

7. BRKx Safety Brake signal (output)

These signals are output to control the brake of each servo axis.

8. SPS1 to SPS32 (SPS33 to SPS64 in case of 2 or more path) 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.

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B-64483EN-2/01 3.SAFETY FUNCTIONS

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 safety-related I/Os. Each byte of 8 byte programmable safe I/Os can be assigned on either address of X/ Y/R/D or K 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 PMC

input

output

1 No.11950 No.11970 2 No.11951 No.11971 3 No.11952 No.11972 4 No.11953 No.11973 5 No.11954 No.11974 6 No.11955 No.11975 7 No.11956 No.11976 8 No.11957 No.11977 1 No.11960 No.11980 2 No.11961 No.11981 3 No.11962 No.11982 4 No.11963 No.11983 5 No.11964 No.11984 6 No.11965 No.11985 7 No.11966 No.11986 8 No.11967 No.11987

Signals other than safety-related I/O

The following signals are not safety-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. *OPIHB Guard Open Inhibit signal (output)

When the Guard Open Request signal (ORQ) is input to “1”, the CNC sets this signal. The machine tool builder must design the PMC ladder logic by this signal. The ladder must confirm safety machine position and safety speed. If the result of confirmation is judged safe, the ladder 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, the ladder must 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 executing.

11. 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”, a 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 protective door.

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3.SAFETY FUNCTIONS B-64483EN-2/01

12. 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.

13. 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.

14. OPT Test Mode signal (input)

When the signal is input, a MCC off Test is executed. The MCC off Test checks whether the contact of the MCC is abnormally closed. When carrying out the MCC off Test manually, input this signal after the preparation of a MCC off Test is completed.

15. 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.

16. STBT Brake Test Start signal

This signal is used to start or resume a brake test. When the brake test is completed successfully, the Brake Test Execution Request signal RQBT is set to "0", causing the state of this signal to change from "1" to "0" as well. Changing the state of this signal from "1" to "0" during the brake test causes the test to be interrupted. In that case, the test ends as soon as the test sequence being executed is completed when the signal is set to "0".

17. RQBT Brake Test Execution Request signal

This signal is used to request a brake test. If the signal is set to "1", please execute the brake test. Even if this request signal is set to "1", the operation is allowed to continue until the current stage of machining is completed. To ensure safety, however, when the current stage of machining is completed, be sure to start a brake test by setting the Brake Test Start signal STBT to "1".

Guard Open Request signal and Guard Unlock signal

Door open request

24V

ORQ-I

The figure shows a sample connection of the protective door open request switch and the guard unlock signal. In the normal state, the door lock state is changed as follows before the safety monitoring state is established.

Ladder

CNC(PMC)

*OPIHB

RSVx RSPx

POSEx

F F

G ORQ

Ladder

Protective door lock

Protective door

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B-64483EN-2/01 3.SAFETY FUNCTIONS

Door lock state transition

ORQ-I ORQ

0 0 0 Locked A protective door open request is not

1 0 0 Locked A guard open request is made.

1 1 0 Locked The request is transferred to the CNC.

1 1 1 Locked The CNC receives the request.

1 1 1 1 1 Locked Reference point is established and a safe

1 1 1 1 1 Unlocked

1 1 1 1 1 Locked The door is closed and locked again.

0 1 1 1 1 Locked The guard open request is canceled.

0 0 1 1 1 Locked The CNC is notified of the release of the

0 0 0 Locked The CNC receives the release of the

*OPIHB RSVx

RSPs

POSEx

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 0. 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.

Protective

door lock

(*SGOPN)

(*SGOPN=0)

made, and the door is locked.

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

above request.

Normal operating state

Safety function is enabled.

Timing diagram from door close state to door open state

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

ORQ_P

ORQ

*OPIHB

RSVx RSPs

POSEx

ctual door unlock signal

*SGOP N (Safety related I/O signal)

ctual door unlock signal

Door closed

Door opened

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

ｔ

Door closed

(5)

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3.SAFETY FUNCTIONS B-64483EN-2/01

(1) When the Guard Open Request signal (ORQ) 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).

(Caution)

CAUTION

1 The RSVx and RSPs are redundant and output to both PMCs (PMC and

DCSPMC). Since the RSVx and RSPs signals, the monitoring results of two independent circuits, are output to two PMCs, the output 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 (PMC and DCSPMC) 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.

2 Ensure a time of 100 ms or longer (“t” in the figure) from when the door is closed

(locked) until the Guard Open Request signal (ORQ) goes off. If this time requirement is not satisfied, an alarm may be raised when the door is closed (locked). Design an operator panel to inform an operator that Guard Open Request signal (ORQ) is turned on by lighting a lamp.

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)

as instructed by the PMC (Ladder program), and then the power is shut off.

CAUTION

To enable the function to slow down and stop the servo motor, the

corresponding parameter must be specified. If the parameter is not specified, the motor immediately enters the dynamic brake stop state.

The spindle motor slows down and stops as instructed by the PMC (Ladder

program). If the PMC does not instruct this, the motor maintains the high speed prior to the power-down and coasts. If an illegal speed is specified because of a failure on the PMC side while the safety function is active (the protective door is open), the CNC enters the safe stop state.

(Caution)

and enters the dynamic brake stop. The spindle slows down to a stop

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B-64483EN-2/01 3.SAFETY FUNCTIONS

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.

NOTE

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

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 function 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 (SVAx/SVBx for feed axis, SPAs/SPBs for spindle).

Name

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

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.

Error detected CPU Alarm

CAUTION

1 When an 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 (*MCFVx) is turned to “0”.

2 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”.

3 For the spindle, bit 1 (CTLSTP) of parameter No. 4399 can be used to select a

stop method (free run stop or controlled stop) on occurrence of a safe speed excess alarm.

Safety Speed/Safety Position Selection signal Safety speed parameter

SVAx/ SPAs SVBx/ SPBs Feed axis Spindle

CNC SV0494/SP0757

SV SV0476 SP SP9069(SPINDLE ALARM 69)

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3.SAFETY FUNCTIONS B-64483EN-2/01

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.

2 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.

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.

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 enters 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 (SVAx/SVBx for feed axis).

Safety Speed/Safety Position Selection

Name

SVAx SVBx + direction - direction

Safety machine position 1 0 0 No.13831 No.13832 Safety machine position 2 1 0 No.13833 No.13834 Safety machine position 3 0 1 No.13835 No.13836 Safety machine position 4 1 1 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. This monitoring function is vaid after the reference position is established.

Error detected CPU Alarm

CNC SV0495

SV SV0477

signal

Safety machine position parameter

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.

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B-64483EN-2/01 3.SAFETY FUNCTIONS

CAUTION

2 When an “out of position error” is detected, if the axis is not stopped after the

time specified in the parameter, the MCC Off signal (*MCFVx) is turned to “0”.

The user of the machine must first carry out a reference position return in order to obtain the initial position. If the reference position return is not carried out, the check function is disabled. This check function is enabled after the reference position is established. (The function cannot be disabled by any means after the reference position is established.)

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.

While 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 occur. To avoid this alarm, set the safe machine position parameters before making a reference position return.

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.

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 an accumulation of failure. A warning message is displayed that the MCC off Test must be carried out 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.

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), 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 program must be designed to carry out the following control. <1> When MCC off Test request signal (RQT) 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 terminated

normally. But the operator can operate the machine while the protective door is closed. <2> When the MCC off Test request signal (RQT) is turned to “0”, the protective door can be unlocked.

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3.SAFETY FUNCTIONS B-64483EN-2/01

*MCF (DCS PMC)

*MCF (PMC)

*SMC (DCS PMC)

*SMC (PMC)

RQT

Example) DO state during MCC off Test

Test No.

Timer limit

Timer

1 2 3 4 5

Test completionTest start

128

Test

number

1 When the *MCF signals on both the PMC and DCSPMC sides are 1, confirm that the MCC is on.

(*SMC = 0) 2 Confirm that the MCC turns off (*SMC = 1) when the *MCF signal on the DCSPMC side is set to 0. 3 Confirm that the MCC turns on (*SMC = 0) when the *MCF signal on the DCSPMC side is returned

to 1. 4 Confirm that the MCC turns off (*SMC = 1) when the *MCF signal on the PMC side is set to 0. 5 Confirm that the MCC turns on (*SMC = 0) when the *MCF signal on the PMC side is returned to 1.

128 This state is entered when tests 1 to 5 end successfully.

Description

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 following describes notes and a timing chart during the MCC off Test.

<1> Before performing the MCC off Test, stop the feed axis and spindle. <2> 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.

<3> 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.

<4> Do not connect a peripheral device or noise filter between the MCC and the common power supply.

Otherwise, the test may not terminate normally.

<5> Enable the servo off signals (SVF1-8) 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.

<6> 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.

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B-64483EN-2/01 3.SAFETY FUNCTIONS

[Timing chart of the MCC off Test]

MCC off Test start (Signal from the user)

Vertical axis brake (Signal from the user)

During a test

Brake on

Test mode signal OPT <Gn191.2>

Servo off signal SVF8 to 1<Gn126.7 to 0>

MCC Off Test Execution Request signal RQT <Fn191.2>

Power failure backup module ready signal RDY (contact output)

500 ms or more

During the MCC off Test

Contact on

Contact off

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. And in case of 2 or more paths, up to 64 points can be specified.

When a machine position of controlled axis is within a range, which is specified by the safety parameters, this signal is output.

Parameter setting value

The signals are output after establishment of the reference position. The signal is not output before the completion of reference position return. 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 parameter 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 signal) and totally up to 4 groups 64 points can be used in the CNC system. Two areas per a path are provided to assign. It is possible to assign the group to an appropriate area.

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3.SAFETY FUNCTIONS B-64483EN-2/01

The assignment of controlled axes is set by the safety parameters (No.13880 to No.13911, No.10501 to No.10532). Safe position switch signals can be assigned to arbitrary controlled axes. All points can be also assigned to one axis. 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) .

NOTE

The machine coordinate of the safety function is based on position feed back

which is affected by mechanical factor. 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, please avoid usage to stop an axis near the boundary.

CAUTION

This function is activated only in position control mode.

• Hysteresis

Around the position switch boundary, the Safety Position Switch signal may repeatedly turn on and

off due to motor vibration. Since this condition is not convenient for using this signal, the concept of hysteresis is applied as follows.

Minimum limit of position switch

Maximum limit of position switch

Width of hysteresis Width of hysteresis

ctivated area of position switch

Fig.3.9(a) Activated area of the position switch when the Safety Position Switch signal is set to "0"

Minimum limit of position switch

ctivated area of position switch

Fig.3.9(b) Activated area of the position switch when the Safety Position Switch signal is set to "1"

Maximum limit of position switch

Suppose that the minimum limit and maximum limit of the position switch are represented by an area like those shown above. If the value of the Safety Position Switch signal used for the last measurement is "0", then the check is made in an area that takes into account the width of hysteresis (Fig. 3.9 (a)). If the value of the last used Safety Position Switch signal is "1", then the check is made in an area that does not take into account the width of hysteresis (Fig. 3.9 (b)). This reduces the fluctuation in the Safety Position Switch signal.

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B-64483EN-2/01 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 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

It is possible to lock the rewriting of the safety related parameters. The parameter No.3225 and No.3226 lock/unlock these parameters. The following parameters are locked.

No.980, No.981, No.982, 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.2000, No.2023, No.2024, No.2084, No.2085, No.2185, No.3021,No.3022,No.3225,No.3717, No.3797, No.4372, No.4438, No.4440, No.4442, No.4448, No.4545, No.10500-No.10596, No.11950-No.11957, No.11960- No.11967, No.11970-No.11977, No.11980-No.11987, No.13806, No.13811, No.13821-No.13829, No.13831-No.13838, No.13840-No.13843, No.13880-No.13911 , No.13912-No.13919, No.13920-No.13951, No.13960-No.13991

3.12 SEFETY POSITION ERROR MONITORING FUNCTION

Both the CNC and the SV check whether the servo position 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 monitoring state and the parameter of limit of deviation is shown in the following table.

Safety monitoring is activated

(In case *VLDVx =0)

Moving No.1838 No.1841 Stopping No.1839 No.1842 Servo-off No.1840 No.1840

Error detected CPU Alarm

CNC SV1072/SV1071/SV1069 SV SV0474/SV0475/SV1070

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.

CAUTION

This function is activated only in position control mode.

Safety monitoring is not activated

(In case *VLDVx =1)

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3.SAFETY FUNCTIONS B-64483EN-2/01

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 the case of the spindle amplifier, the spindle numbers kept by the CNC are compared with those kept by the spindle amplifier. The checking sequence is as follows.

[Checking sequence for servo amplifier] <1> 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.)

<2> 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] <1> When a spindle amplifier is set up for the first time, alarm SP9148 is generated. During this process,

the CNC transfers the spindle numbers to the spindle amplifier, which in turn keeps those numbers. When this occurs, the power of the entire CNC system (including the amplifier) must be turned off and then back on. If an alarm is generated because the configuration of the spindle amplifier is changed, it is necessary to send the spindle numbers to the spindle amplifier (set bit 7 of parameter No. 4541 to "1", then set it back to "0", and then turn off the power of the entire CNC system (including the amplifier)).

<2> 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”.

<3> The SP compares the spindle numbers with that kept by the spindle amplifier. If inconsistency is

found, alarm SP9070 (Spindle alarm 70) is output, and MCC Off signal (*DCALM) is turned to “0”.

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 is “0”, mechanical brake must be activated. When this signal is “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 I/O cross check error” (PW0010/PW0011).

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B-64483EN-2/01 3.SAFETY FUNCTIONS

3.15 CPU 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”.

<1> 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.

Error detected CPU ALARM

CNC PW0014 PMC PW0009

SV SV0484 SP SP9074 (Spindle alarm 74)

<2> Program flow monitoring It is confirmed whether all safety related function run normally.

Error detected CPU ALARM

CNC PW0017 / SV0490 PMC PW0008 (DCS PMC), PW0009 (PMC)

SV SV0484 SP SP9076 (Spindle alarm 76), SP0755

<3> Cross check It is checked whether the result of 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.

ALARM

SV relation SV0490/SV0484 SP relation SP9072 (Spindle alarm 72),

SP9077 (Spindle alarm 77), SP9078 (Spindle alarm 78), SP0755

PMC relation PW0008 (DCS PMC), PW0009 (PMC)

3.16 RAM CHECK FUNCTION

ECC (Error Check and Correct) function is applied to the battery back-upped file memory. Then a simple error is corrected. And, when an error that cannot be corrected occurs, an alarm 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 “0”.

1) Test at power-on The several test patterns are written to the RAM area. It is 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 sequentially 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

CNC PW0016

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3.SAFETY FUNCTIONS B-64483EN-2/01

Alarm detected CPU Alarm

SV SV0484

PMC PW0008 (DCS PMC), PW0009 (PMC)

SP 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 stored 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

Error detected Software Alarm

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

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) By 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 is moved by external power. Set the value of safety limit that does not cause an alarm when feedrate command is 0.

b) 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.

c) According to “Axis moving signal MVx <Fn102>”, check whether axis motion command is 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) 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. Add the machine oriented margin to the value of safety limit that does not cause an alarm when speed command is 0.

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B-64483EN-2/01 3.SAFETY FUNCTIONS

b) 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, Cs contouring control or spindle orientation.

3.19 BRAKE TEST

To ensure the safety of the brake, the brake signals (*BRKx) that are output in redundant mode are used to control the brake of the servo axis mechanically. To ensure the safety of this control, a periodical test is performed on the servo axis brake.

Remaining risks

This function has the following remaining risks. If the brake fails in a vertical axis without a redundant brake mechanism between the current brake test and the next, the axis may drop when the servo motor is deactivated due to an emergency stop or servo alarm.

Specifications

A brake test can be performed on servo axes that have a brake. The test needs to be done only on those axes that require brake control, such as vertical axes. Whether to perform the test can be selected on an axis-by-axis basis using a parameter. As with the MCC shut-off test, the brake test is performed when the power is turned on or when time t has elapsed since the last test (t is the value set in parameter No.

13913).

Getting started with the brake test

(1) When the power is turned on or when time t has elapsed since the last brake test (t is the value set in

parameter No. 13913), the Brake Test Execution Request signal RQBT (DO) is set to "1". When this signal is set to "1", execute a brake test. Even when the request signal is turned on, the operation is allowed to continue until the current stage of machining is completed. To ensure safety, however, execute a brake test as soon as possible.

(2) Clear all NC alarms, switch to the JOG mode, and then retract the axis eligible for the brake test to a

safe position.

(3) To start the brake test, turn on the Brake Test Start signal STBT (DI).

NOTE

Since the test involves giving the move command to the servo motor, make sure

it is performed in position control mode in the servo on state. The test will not be executed if the axis to be tested is in a mode other than the position control mode (velocity control or torque control) or in the servo off state or if the torque limit mode. An alarm is generated if the conditions are not satisfied.

Executing the brake test

(1) When the brake test execution request mentioned above is accepted, all the axes eligible for the

brake test are tested simultaneously. Using combinations of states of two brake signals *BRKx (PMC side and DCSPMC side), three different tests are executed per axis in the order shown below.

*BRKx(PMC) 0 0 1 *BRKx(DCSPMC) 0 1 0 Brake state Applied Applied Applied

Test 1 Test 2 Test 3

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3.SAFETY FUNCTIONS B-64483EN-2/01

Ending the brake test

(1) When all the axes are tested successfully, the Brake Test Execution Request signal RQBT is set to

"0". If any error occurs during the test, an alarm is generated. While the servo motor remains activated even in an alarm state, the automatic operation cannot be continued. In that case, retract the axis to a safe position manually, turn off the power, and take action to solve the problem of the brake in question. Before executing the brake test again, reset the system to clear the alarm state.

(2) When the test ends normally, set the Brake Test Start signal STBT to "0".

Test Start signal (DI：STBT)

Test Execution Request signal

RQBT)

Under test

Not under test

(DO

*BRKx(DCSPMC)

*BRKx(PMC)

Test sequence

0 1 0 1

Test 1 Test 2 Test 3

Fig. 3.19 (a) Overall time chart

NOTE

1 Execute the test in the servo on state. 2 The amount of travel, feedrate, and positional deviation value must be set in

advance using parameters.

3 Make sure that the protective door is closed when the test is executed. To

ensure safety, create a ladder program that prohibits the protective door from being opened, even if a protective door open request is issued, until the break test is executed when the Brake Test Execution Request signal RQBT is turned on after time t has elapsed (t is the value set in parameter No. 13913).

4 Do not execute the test with the protective door open. Create a ladder program

that prohibits the Brake Test Start signal STBT from being turned on so that the test cannot be executed while the protective door is open.

5 The brake test cannot be executed on axes subject to feed axis synchronization

control or synchronous, composite, or superimposed control. Before executing the test, be sure to turn off the relevant selection signal.

6 If the brake test causes an alarm, the axis can be moved manually, while the

automatic operation cannot be continued unless the alarm is cleared by the reset. Make sure that the automatic operation is performed in a safe condition. If the brake test is interrupted due to an alarm or for some other reason, the axis may not be able to be returned to its original position.

7 The override for the feedrate command is fixed at 100%, and the dry run and

rapid traverse signals are disabled.

8 The interlock and machine lock states are effective during the brake test.

- 32 -

B-64483EN-2/01 3.SAFETY FUNCTIONS

CAUTION

The axis may move during the brake test. Before the test, move the axis to a

safe place where it does not interfere with any other part.

Details of each brake test

Details of the tests

Tests 1, 2, and 3 check whether the brake is applied normally and involve the following operations.

(a) Brake signals *BRKx are output according to the test step to be executed. The torque limit value of

the axis subject to the brake test is used as the torque limit value for the brake test. The torque limit value can be set using a parameter.

(b) The NC waits for t1 (t1 is the value set in parameter No. 13914) until the brake is applied and the

command can be issued.

parameters.

(d) After issuing the command, the NC checks the positional deviation amount in order to determine

whether the brake is applied normally. If the brake is applied normally, the axis has not been moved and there is accumulated positional deviation equivalent to the specified amount of travel. The range of the positional deviation amount to be checked is equal to the corresponding positional deviation amount plus and minus the tolerance value (the value set in parameter No. 13918). The time during which the NC checks whether the brake is applied normally is specified by t2 (t2 is the value set in parameter No. 13919). If the positional deviation amount is outside the range, the NC regards the

brake as failing to be applied normally and generates an alarm. (e) After the check, the NC issues a command to reset the accumulated positional deviation amount. (f) Before executing the next test, the NC waits for t1 (t1 is the value set in parameter No. 13914).

Torque limit

*BRKx(PMC,

DCSPMC)

Command (POS)

Error monitoring

Enable

Disable

＋

Command

No command

Command

Monitored

Not monitored

Current test

(a)

(b) (c)

Command (travel amount/feedrate)

(d)

Fig. 3.19 (b) Brake test time chart

Cancel

command

(e)

(f)

Next test

Interrupting and resuming the brake test

• Changing the state of the Brake Test Start signal STBT from "1" to "0" during the brake test causes

the test to be interrupted. The test sequence being executed when the signal is set to "0" is suspended,

and the amount of travel occurring during the brake test, brake signals, and torque limit are reset. To

execute the brake test again, set this signal to "1". The brake test will resume from the beginning.

- 33 -

3.SAFETY FUNCTIONS B-64483EN-2/01

• If the brake test is interrupted by an emergency stop or servo alarm, the test is forced to end even

during a test sequence. After the servo motor is activated by the reset process, the brake signals and

torque limit are reset. Also, make sure that, during the brake test, the servo ready signal SA

<Fn000.6> is monitored in addition to the brake signals to control the brake. To execute the brake

test again, set this signal to "0" and then to "1". The brake test will resume from the beginning.

• If the brake test is interrupted due to the reset or mode change, the test sequence being executed is

suspended, while the brake signals and torque limit are not reset, leaving the test as it is when it is

interrupted. To reset the amount of travel occurring during the brake test, brake signals, and torque

limit, set the Brake Test Start signal STBT to "0" and then to "1". After all these interruption

operations are complete, it becomes possible to execute the brake test again.

- 34 -

B-64483EN-2/01 3.SAFETY FUNCTIONS

Brake configuration

This function assumes the brake configuration shown in either Fig. 3.19 (c) Brake configuration - 1 or Fig.

3.19 (d) Brake configuration - 2.

CNC (30i)

PMC

JD51A

DCS PMC

I/O Link Channel 1

I/O Link signal divider

JD44A-1

JD51B JD1A

I/O Link Channel 3

I/O Module 1

JD1B

I/O Module 2

JD1B

*BRKx

built-in motor brake

24V

CNC (30i)

PMC

JD51A

DCS PMC

I/O Link Channel 1

I/O Link

signal divider

JD44A-1

JD51B

JD1A

I/O Link Channel 3

Fig. 3.19 (c) Brake configuration - 1

I/O Module 1

*BRKx

External brake

*BRKx

JD1B

I/O Module 2

JD1B

Fig. 3.19 (d) Brake configuration - 2

24V

built-in motor brake

24V

Example in which signals are connected using a two-channel I/O Link (For details about connections, see Chapter 4, "INSTALLATION".)

- 35 -

4.INSTALLATION B-64483EN-2/01

4 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.

As for the environmental conditions for each unit, such as CNC controller, servo amplifier and etc, please refer to each connection 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

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

CAUTION

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

I/O connection configuration

The Dual Check Safety function uses two-channel I/O configuration. The safety-related I/O signals are connected via separate paths (Note 1) to two I/O modules that are respectively connected to one of the two channels. To build a dual monitoring system, the machine tool builder needs to connect one of the duplicated safety-related I/O signals to the I/O module connected to the DCS PMC side and the other to that connected to the PMC side.

CNC

(DCS PMC)

(Note 2)

I/O Link or PROFIBUS -DP (Note 4)

Cross check

PMC

(Note 3)

I/O Link

NOTE

1 I/O Link i allows the safety-related I/O signals of both the PMC and DCS PMC

sides to be connected over a single path. 2 Dual Check Safety PMC (DCS PMC) 3 First PMC to fifth PMC Refer to PMC PROGRAMMING MANUAL (B-64513EN). 4 Enable broken wire detection for the slave device connected to PROFIBUS-DP

for the safety-related I/O. For details, see Section 6.6, "PROFIBUS-DP

PARAMETER SETTINGS".

I/O MODULE

DI DO

Machine side

CNC

(DCS PMC)

(Note 2)

(Note 1)

Cross check

PMC

(Note 3)

I/O Link i (Note 1)

DCSPMC side I/O MODULE

PMC side I/O MODULE

Machine side

DI DO

- 36 -

B-64483EN-2/01 4.INSTALLATION

Note on the I/O configuration

Of the I/O Link, I/O Link i, and PROFIBUS-DP, only one of them can be assigned to the X/Y area of the DCS PMC side.

4.1 OVERALL CONNECTION DIAGRAM

4.1.1 In case of using the I/O Link

CNC Main board

3ch I/O Link

I/O Link(JD51A)

signal divider

JD51B

JD44A-1 JD44A-2

JD1A

I/O Link #1/#2 (General I/O, PMC side safety-related I/O)

Manual pulse generator

Distribution-type

I/O Link #3 (DCS PMC side safety-related I/O)

24VDC

I/O board

CPD1

JD1B

JD1A

I/O UNIT, etc.

CPD1

JD1B JD1A

I/O UNIT, etc.

CPD1 JD1B

JD1A

JA3

Operator's panel

Power magnetics cabinet

The above figure shows only the two-channel I/O Link used to input and output the safety-related I/O signals for the Dual Check Safety function. For information about other types of connection, refer to the general connection manual.

- 37 -

4.INSTALLATION B-64483EN-2/01

4.1.2 In case of using the I/O Link i

CNC Main board

I/O Link i (JD51A)

24VDC

I/O Link i

(General I/O, PMC side safety-related I/O DCS PMC side safety-related I/O)

Manual pulse generator

Distribution-type I/O board

CPD1

JA3

Operator's panel

Power magnetics cabinet

24VDC

JD1B

JD1A

I/O UNIT, etc.

CPD1

JD1B JD1A

I/O UNIT, etc.

CPD1 JD1B

JD1A

(PMC side)

(DCS PMC side)

NOTE

To establish connections using the I/O Link i, the I/O modules and all the other

components to be connected need to support the I/O Link i.

The above figure shows only the l I/O Link i used to input and output the safety-related I/O signals for the Dual Check Safety function. For information about other types of connection, refer to the general connection manual.

- 38 -

B-64483EN-2/01 4.INSTALLATION

4.1.3 In case of using PROFIBUS-DP on the DCS PMC side

CNC Main board

I/O Link(JD51A)

I/O Link or I/O Link i (General I/O, PMC side safet

PROFIBUS-DP master board

CN1

24VDC

Distribution-type I/O board

CPD1

-related I/O)

Manual pulse generator

JA3

Operator's panel

Power magnetics cabinet

PROFIBUS-DP (DCS PMC side safety-related I/O)

24VDC

Power supply

JD1B

JD1A

I/O UNIT, etc.

CPD1

JD1B JD1A

Slave device

The above figure shows only the I/O Link and PROFIBUS-DP used to input and output the safety-related I/O signals for the Dual Check Safety function. For information about other types of connection, refer to the general connection manual.

- 39 -

5.I/O SIGNALS B-64483EN-2/01

5 I/O SIGNALS

5.1 OVERVIEW

The Dual Check Safety Function provides two input paths and two output paths for safe-related signals (safety signals). Input signals (safety input signals) are input via two paths; one is connected to the CNC (DCS PMC) via I/O Link channel 3, I/O Link i, or PROFIBUS-DP (Note 1) and the other is connected to the PMC via I/O Link channel 1/2 or I/O Link i (Note 1). The CNC (DCS PMC) (Note 2) and the PMC (Note 2) constantly exchange safety input signals with each other and monitor 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 PMC) and the PMC independently detect an alarm. (Dual-check for safety input signals) Output signals (safety output signals) are output via two paths; one originates from the CNC (DCS PMC) via I/O Link channel 3, I/O Link i, or PROFIBUS-DP (Note 1) and the other originates from the PMC via I/O Link channel 1/2 or I/O Link i (Note 1). The MCC Off signal (*MCF) is output via these two paths. The value of this signal is regarded as "1" only when the signals output via the two paths are both set to "1". If either of them is set to "0", the value of the signal should be regarded as "0". In other words, turning on the MCC is allowed only when the *MCF signal of the PMC side and the *MCF signal of the DCS PMC side are both set to "1", and if either of them is set to "0", the MCC needs to be turned off.

Section 5.3 shows the name of the signal, the code representing the signal, and the signal address (<PMC side> and <DCS PMC side>), as well as the classification, function, and operation (for an input signal) or the classification, function, and output condition (for an output signal).

NOTE

1 Of the I/O Link, I/O Link i, and PROFIBUS-DP, only one of them can be

assigned to the X/Y area of the DCS PMC side. 2 DCS PMC : Dual Check Safety PMC PMC: Normal PMC (First PMC to fifth PMC) Refer to PMC PROGRAMMING MANUAL (B-64513EN) for details.

- 40 -

B-64483EN-2/01 5.I/O SIGNALS

5.2 SIGNAL ADDRESS

PMC side signals

PMC (n=0 to 9 (Path number-1))

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

X0008

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

Gn008

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

Gn191 ORQ OPT

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

Gn193 STBT

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

Gn748

*SMC

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

Gn749

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

Gn750

*VLDV8 *VLDV7 *VLDV6 *VLDV5 *VLDV4 *VLDV3 *VLDV2 *VLDV1

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

Gn751

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

Gn752

SVA8 SVA7 SVA6 SVA5 SVA4 SVA3 SVA2 SVA1

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

Gn753

SVB8 SVB7 SVB6 SVB5 SVB4 SVB3 SVB2 SVB1

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

Gn754

SPB4 SPB3 SPB2 SPB1 SPA4 SPA3 SPA2 SPA1

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

Fn191 RQBT RQT *OPIHB

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

Fn748 *DCALM *MCF

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

Fn749

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

Fn750 RSV8 RSV7 RSV6 RSV5 RSV4 RSV3 RSV2 RSV1

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

Fn751 RSP4 RSP3 RSP2 RSP1

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

Fn752 *MCFV8 *MCFV7 *MCFV6 *MCFV5 *MCFV4 *MCFV3 *MCFV2 *MCFV1

*ESP *ESP *ESP

*ESP

*VLDP4 *VLDP3 *VLDP2 *VLDP1

- 41 -

5.I/O SIGNALS B-64483EN-2/01

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

Fn753 *MCFP4 *MCFP3 *MCFP2 *MCFP1

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

Fn754

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

Fn755

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

Fn756

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

Fn757

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

Fn758

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

Fn766 POSE8 POSE7 POSE6 POSE5 POSE4 POSE3 POSE2 POSE1

*BRK8 *BRK7 *BRK6 *BRK5 *BRK4 *BRK3 *BRK2 *BRK1

SPS08 SPS07 SPS06 SPS05 SPS04 SPS03 SPS02 SPS01

SPS16 SPS15 SPS14 SPS13 SPS12 SPS11 SPS10 SPS09

SPS24 SPS23 SPS22 SPS21 SPS20 SPS19 SPS18 SPS17

SPS32 SPS31 SPS30 SPS29 SPS28 SPS27 SPS26 SPS25

- 42 -

B-64483EN-2/01 5.I/O SIGNALS

DCS PMC side signals

DCS PMC (m=path(0 to 9)×20) 0 to 9: Path number-1

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

X0008

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

G000+m

*SMC

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

G001+m

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

G002+m

*VLDV8 *VLDV7 *VLDV6 *VLDV5 *VLDV4 *VLDV3 *VLDV2 *VLDV1

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

G003+m

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

G004+m

SVA8 SVA7 SVA6 SVA5 SVA4 SVA3 SVA2 SVA1

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

G005+m

SVB8 SVB7 SVB6 SVB5 SVB4 SVB3 SVB2 SVB1

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

G006+m

SPB4 SPB3 SPB2 SPB1 SPA4 SPA3 SPA2 SPA1

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

G007+m

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

G008+m

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

G019+m

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

F000+m *DCALM *MCF

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

F001+m

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

F002+m RSV8 RSV7 RSV6 RSV5 RSV4 RSV3 RSV2 RSV1

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

F003+m RSP4 RSP3 RSP2 RSP1

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

F004+m *MCFV8 *MCFV7 *MCFV6 *MCFV5 *MCFV4 *MCFV3 *MCFV2 *MCFV1

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

F005+m *MCFP4 *MCFP3 *MCFP2 *MCFP1

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

F006+m

*BRK8 *BRK7 *BRK6 *BRK5 *BRK4 *BRK3 *BRK2 *BRK1

*ESP *ESP *ESP

*VLDP4 *VLDP3 *VLDP2 *VLDP1

*ESP

- 43 -

5.I/O SIGNALS B-64483EN-2/01

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

F007+m

SPS08 SPS07 SPS06 SPS05 SPS04 SPS03 SPS02 SPS01

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

F008+m

SPS16 SPS15 SPS14 SPS13 SPS12 SPS11 SPS10 SPS09

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

F009+m

SPS24 SPS23 SPS22 SPS21 SPS20 SPS19 SPS18 SPS17

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

F010+m

SPS32 SPS31 SPS30 SPS29 SPS28 SPS27 SPS26 SPS25

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

F018+m POSE8 POSE7 POSE6 POSE5 POSE4 POSE3 POSE2 POSE1

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

F019+m *OPIHB

CAUTION

1 The hatched signals are double-checking signals. 2 The Emergency Stop signals in X address are double checking signals. 3 For the Safety Position Switch signal, the following points are provided

depending on the number of paths.

(1) When the number of paths is 1......................Up to 32 points

(2) When the number of paths is 2 or more.........Up to 64 points

4 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 (*MCF), MCC Contact State

signal (*SMC) 5 The signal (Fxxxx/Gxxxx), which is provided for each machine group, is assigned

in the path area for the smallest path number of the paths in the machine group.

Example)

When the 3rd and 5th path belong to the 2nd machine group, test Mode signal (OPT) for the 2nd machine group is assigned at G2191.2 in 3rd path area.

- 44 -

B-64483EN-2/01 5.I/O SIGNALS

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] (when the number of control axes is 8 per path or less and the number of spindles per path is 4 or less)

PMC

F0000~ G0000~

DCSPMC

F0000~ G0000~

- [For 2-path CNC] (when the number of control axes is 8 per path or less and the number of spindles is 4 per path or less)

CNC path 1

PMC

F0000~ G0000~

DCSPMC

F000~ G000~

CNC path 2

PMC

F1000~ G1000~

DCSPMC

F020~ G020~

For control axis signals, the signal layout changes depending on whether the number of control axes per path is greater than 8 or not.

(1) When the number of control axes per path is 8 or less The signal for the x-th axis of the k-th path is placed in the (x - 1)-th bit in the address (F or G) for

the k-th path in the above figure.

PMC ( n = k-1 )

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

Fn??? 8th axis 7th-axis 6th-axis 5th-axis 4th-axis 3rd-axis 2nd-axis 1st-axis

- 45 -

5.I/O SIGNALS B-64483EN-2/01

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

Gn??? 8th-axis 7th-axis 6th-axis 5th-axis 4th-axis 3rd-axis 2nd-axis 1st-axis

DCSPMC ( m = (k-1)×20 )

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

F???+m 8th-axis 7th-axis 6th-axis 5th-axis 4th-axis 3rd-axis 2nd-axis 1st-axis

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

G???+m 8th-axis 7th-axis 6th-axis 5th-axis 4th-axis 3rd-axis 2nd-axis 1st-axis

(2) When the number of control axes per path is greater than 8, the 9th and subsequent axes cannot be

placed. In this case, the interface address of the PMC is assigned by parameter No. 3021.

For example, for a 1-path 11-axis system, control axis signals can be assigned to addresses from

F0000/G0000 (PMC) and addresses from F1000/G1000 (PMC) as shown below.

PMC

Path 1

F0???

G0???

Signal of 4th axis

Signal of 7th axis

Signal of 8th axis

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

Signal of 5th axis

Signal of 6th axis

Signal of 3rd axis

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

Signal of 1st axis

Signal of 2nd axis

Signal of 10th axis

Signal of 11th axis

Signal of 9th axis

F1???

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

G1???

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

DCSPMC

When signals are assigned to PMC as shown above, the control axis signals of the DCSPMC are

placed according to the assignment.

Path 1

Signal of 8th axis

Signal of 4th axis

Signal of 7th axis

Signal of 5th axis

Signal of 6th axis

Signal of 3rd axis

Signal of 1st axis

Signal of 2nd axis

Signal of 10th axis

Signal of 11th axis

Signal of 9th axis

F000 to

F019

G000 to

G019

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

- 46 -

F020 to

F039

G020 to

G039

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

B-64483EN-2/01 5.I/O SIGNALS

NOTE

For details on setting of parameter No. 3021, see Chapter 6, "PARAMETERS".

As with spindle signals, when the number of spindles per path is greater than 4, the 5th and

subsequent axes cannot be placed. In such a case, the interface address of the PMC needs to be assigned by parameter No. 3022.

NOTE

For details on setting of parameter No. 3022, see Chapter 6, "PARAMETERS".

5.3 SIGNALS

Emergency Stop signal (input) *ESP <PMC: X0008.4, 0, 1><DCS PMC: X0008.4, 0, 1> (for each machine group) *ESP <PMC: Gn008.4><DCS PMC: G019+m.4> (for each path)

This is Emergency Stop signal. The Emergency Stop signal must be connected to the Emergency Stop input of the amplifier.

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

0: Emergency stop state 1: Normal state

[Operation] When Emergency Stop signal (*ESP) is set to 0, the CNC is reset, and the sy stem enters

emergency stop state. A machine tool builder must output a signal to shut off directly the MCC when “MCC Off signal” (*MCF) 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 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 note) 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 note) and the power is shut off.

CAUTION

1 The Emergency Stop signal for DCS PMC is assigned to each

machine group, like the signal for PMC.

<X0008.4> for 1st machine group <X0008.0> for 2nd machine group <X0008.1> for 3rd machine group

2 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.

- 47 -

5.I/O SIGNALS B-64483EN-2/01

CAUTION

3 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.

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 inhibit 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 As MCC Off signal (*MCF) is effective for each machine group,

MCC is controlled per a machine group. Then, although the Emergency Stop signal by G signal is effective for each path, design to turn on Emergency Stop by G signal of all paths in a machine group at the same time.

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)

Actual door open/close signal

Door closed

Door opened

(1) (2) (3)

(4)

ｔ

(5)

Door closed

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 RSVx/RSPs.

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B-64483EN-2/01 5.I/O SIGNALS

(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 (*MCF) to “1”.

Test Mode signal (input) OPT <PMC:Gn191.2> (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.

[Classification] Input signal (Single signal) [Function] This signal notifies CNC to enter MCC off Test mode.

0: not enter MCC off Test mode 1: enter MCC off Test mode The Test Mode signal OPT is not input on the DCS PMC side.

[Operation] 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.

CAUTION

1 While MCC off Test is being carried out, do not turn Test Mode

signal (OPT) to “0”.

2 It is not permitted to carry out MCC off Test for plural machine

groups simultaneously. Carry out MCC off Test for only one machine group independently.

3 If MCC is shared between two or more machine groups and MCC

off Test is carried out in a machine group, VRDY off alarm in another machine group, which shared MCC, must be ignored by using all axes of each path VRDY off alarm ignore signal IGNVRY <Gn066.0> or each axis VRDY off alarm ignore signal IGNVRY1 to IGNVRY8 <Gn192>.

4 The MCC shall have forced guided contacts , and must fulfill the

standard IEC60204 and IEC 60255. This is mandatory.

5 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.

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5.I/O SIGNALS B-64483EN-2/01

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 MCC 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.

Test No.

*MCF (DCS PMC) *MCF (PMC)

*SMC (DCS PMC) *SMC (PMC)

Timer limit

Timer

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

Test No.

*MCF (DCS PMC) *MCF (PMC)

1 2 3 4 5

1 2 3 4

128

Test completion Test start

*SMC (DCS PMC) *SMC (PMC)

Timer limit

Timer

Test start

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

larm

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B-64483EN-2/01 5.I/O SIGNALS

Guard Open Request signal (input) ORQ <PMC: Gn191.3>（for each machine group)

This signal is input when an operator intends to release the guard lock and open the protective door.

[Classification] Input signal (Single signal) [Function] 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

[Operation] When CNC detects that the Guard Open Request signal (ORQ) is 1, CNC returns Guard

Open Inhibit signal (*OPIHB). 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 in redundant mode. 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><DCS PMC:X machine side signal> (for

each safety door)

Input the guard state of the protective door to this signal. When the protective 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.

[Classification] Input signal (Dual signal) [Function] 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

[Operation] 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.

NOTE

As for the contacts for Guard State signal, it is recommended to

fulfill the Standard IEC60947-5-1.

MCC Contact State (input) *SMC <PMC: Gn748.6><DCS PMC: G(000+m).6> (for each machine group)

The state of MCC contact is checked in redundant mode. 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 MCC contact can be checked by performing MCC off Test.

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5.I/O SIGNALS B-64483EN-2/01

[Classification] Input signal (Dual signal) [Function] MCC 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] MCC Contact State signals (*SMC) is 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 PMC)) are 1 in the emergency stop state (*ESP=0), it is possible to design the ladder program to release the guard lock.

CAUTION

Input this signal according to the MCC state.

Safety Check Request signal (input) *VLDVx <PMC:Gn750.0 to 7><DCS PMC:G(002+m).0 to 7> (for each axis) *VLDPs <PMC:Gn751.0 to 3><DCS PMC:G(003+m).0 to 3> (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 and stops motors.

Guard Open Inhibit signal (output) *OPIHB <PMC: Fn191.0><DCS PMC: F(019+m).0> (for each machine group)

CNC returns these signals as answer when CNC detects that Guard Open Request signal (ORQ) is set to “1”.

[Classification] Output signal (Not checked in redundant mode) [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 (*OPIHB) =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).

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B-64483EN-2/01 5.I/O SIGNALS

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 <PMC:Fn750.0 to 7><DCS PMC:F(002+m).0 to 7> (for each axis) RSPs <PMC:Fn751.0 to 3><DCS PMC:F(003+m).0 to 3> (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 state 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 in redundant mode) [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.)

[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 <PMC: F0748.7><DCS PMC: F000.7> (for all system)

When this signal is set to "0", the MCC is shut off in redundant mode on the two-channel I/O Link side. This signal is set to “0”, when a crosscheck alarm of safety related signals or a CPU self-diagnosis alarm 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 in redundant mode) [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.

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5.I/O SIGNALS B-64483EN-2/01

NOTE

When the spindle motor (induction motor) is powered off while

rotating, the motor coasts 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 quickly 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".

MCC Off signal (output) *MCF <PMC: Fn748.1, DCS PMC: F(000+m).1> (for each machine group)

When this signal is set to "0", the MCC is shut off in redundant mode on the two-channel I/O Link side. This signal is set to “0”, when Emergency Stop signal (*ESP ) is “0” or MCC off Test is carried out. A machine tool builder makes a ladder program to output a signal to shut off MCC when this signal is turned to “0”.

[Classification] Output signal (This signal output to both PMC but is not monitored in redundant mode) [Function] 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: MCC on

[Operation] When Emergency Stop signal is input, CNC turns off this signal.

When MCC off Test is carried out, CNC turns off this signal, too.

[Output condition] In the following case, this signal turns to “0” (not permit MCC on)

- MCC off Test is carried out.

- In 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 coasts 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 quickly as possible for safety.

When the spindle is decided to be controlled even if the MCC Off

MCC Off signal (output) *MCFVx <PMC: Fn752.0 to 7><DCS PMC: F(004+m).0 to 7> (for each axis)

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. A 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”.

[Classification] Output signal (This signal output to both PMC but is not monitored in redundant mode)

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B-64483EN-2/01 5.I/O SIGNALS

[Function] When the Dual Check Safety Function is applied, this signal allows turning on MCC.

0: MCC off 1: MCC on

[Operation] 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 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 (bit0(AVM) of parameter No.10500), 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 coasts 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 quickly as possible for safety.

When the spindle is decided to be controlled even if the MCC Off

MCC Off signal (output) *MCFPs <PMC: Fn753.0 to 3><DCS PMC: F(005+m).0 to 3> (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] Output signal (This signal output to both PMC but is not monitored in redundant mode) [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) RQT <PMC:Fn191.2> (for each machine group)

[Classification] Output signal (Single signal)

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5.I/O SIGNALS B-64483EN-2/01

[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 ladder 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.

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”.

• MCC off Test is not completed after power-on (when bit 3(STP) of parameter No.10500 is 0).

• Twenty-four hours have elapsed since the completion of the last MCC off Test.

In the following case, this signal sets to “0”.

• MCC off Test is completed.

CAUTION

1 Do not turn Test Mode signal (OPT) to “0” during MCC off Test. 2 In case that there are plural machine groups in a machine, carry

out MCC off Test for each machine group independently.

3 If MCC is shared between two or more machine groups, do not

carry out MCC off Test for those machine groups at the same time.

4 If MCC is shared between two or more machine groups and MCC

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B-64483EN-2/01 5.I/O SIGNALS

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.

Safety Brake signal (output) *BRKx <PMC:Fn754.0 to 7><DCS PMC:F(006+m).0 to 7> (for each axis)

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.

[Classification] Output signal (Dual signal) [Function] 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.

[Operation] 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.

[Output condition] In the following case, this signal is “1”.

• Releasing brake state

In the following case, this signal is “0”.

• Activating brake state

The CNC changes the state of this signal even during the brake test. For information

about the control of the brake signal, see the section titled "BRAKE TEST".

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".

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5.I/O SIGNALS B-64483EN-2/01

(a) In case *BRK signal is “0”

Emergency Stop state (*ESP signal is “0”)

*ESP

*BRK

Servo alarm occurs

larm

*BRK

Power-on

Power

*BRK

(b) In case *BRK signal is “1” When emergency stop is released (*ESP signal is “1”), MCC can be enabled l

(*MCF signal is “1”). After that, when MCC is turned on, Safety Brake signal *BRK is turned to “1” after the time specified by the parameter No.1950 is elapsed.

1 0 1 0

*ESP

*MCF

MCC

*BRK

1 0

1 0 1 0

Timer for brake signal

NOTE

Periodical maintenance of a brake must be done.

Safety Position Switch signal (output) SPS1 to SPS32<PMC:Fn755 to Fn758><DCS PMC:F(007+m) to F(010+m)>

This signal shows whether the machine position of a servo axis is within the range specified by the parameter or not.

[Classification] Output signal (Dual signal) [Function] 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.

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B-64483EN-2/01 5.I/O SIGNALS

In case of 2 or more path system, another 32 points in 2 path area can be 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 No.10596).

NOTE

In a system with 3 or more paths, it is also possible to specify the

path to which the Safety Position Switch signal is to be output, by using a parameter. For the Safety Position Switch signal, 16 points can be set for an output signal (F area) per group, and up to 4 groups can be set. Two areas can be assigned to one path.

[Output condition] In the following case, this signal is set to “1”.

• The machine position of the axis is within the specified range.

In the following case, this signal is set to “0”.

• The machine position of the axis is out of the specified range.

[Note] When the axis is 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 (PW0010, PW0011).

NOTE

The Safety Position Switch signal starts to work when the reference

position of the target axis is established after the power is turned on. Until then, "0" is output. 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).

Safety Speed/Safety Position Selection signal A SVAx <PMC:Gn752.0 to 7> <DCS PMC:G(004+m).0 to 7> (for each axis) SPAs <PMC:Gn754.0 to 3> <DCS PMC:G(006+m).0 to 3> (for each spindle) Safety speed/safety position selection signal B SVBx <PMC:Gn753.0 to 7> <DCS PMC:G(005+m).0 to 7> (for each axis) SPBs <PMC:Gn754.4 to 7> <DCS PMC:G(006+m).4 to 7> (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.

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5.I/O SIGNALS B-64483EN-2/01

SVAx, SVBx

1: Select safety speed/safety machine position of the 1st axis

x 2: Select safety speed/safety machine position of the 2nd axis 3: Select safety speed/safety machine position of the 3rd axis : : : :

, SPBy

SPAy

1: Select safety speed of the 1st spindle

y 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

Selection signal SVAn SVBn SPAn SPBn

0 0

1 0

0 1

1 1

Safety limit speed Safety machine position

Parameter for

servo axis

Safety limit speed 1 Safety machine position 1

No.13821 No.4372 No.13831 No.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

Parameter

for spindle

+ direction

parameter

- direction parameter

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.

Position Information Effect signal POSEx <PMC: Fn766.0 to 7><DCS PMC: F(018+m).0 to 7> (for each axis)

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 “0”, Machine Tool Builder has to control not to open the protective door.

[Classification] Output signal (This signal output to both PMC but is not monitored in redundant mode) [Function] This signal informs whether the reference point is established or not.

0: The reference point is not established. 1: The reference point is established.

[Operation] Each CPU informs whether the reference point is established or not.

In the following case, this signal is turned to “1”.

• After the reference point is established.

• When the follow up operation of absolute pulse coder is finished after power-on

In the following case, this signal is turned to “0”.

• When the reference point is lost

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B-64483EN-2/01 5.I/O SIGNALS

：

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.

Programmable Safety I/O signals

[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/R/D or K 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

Input Signal 2

Input Signal 8

Output Signal 1

Output Signal 2

Output Signal 8

I/O Link#3, I/O Link i, or PROFIBUS-DP

CNC and PMC monitor each signal.

Input Signal 1

Input Signal 2

Input Signal 8

Output Signal 1

Output Signal 2

Output Signal 8

I/O Link#1/#2 or

I/O Link i

[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)

Input

1 No. 11950 No. 11970 2 No. 11951 No. 11971 3 No. 11952 No. 11972 4 No.11953 No.11973 5 No.11954 No.11974 6 No.11955 No.11975 7 No.11956 No.11976 8 No.11957 No.11977

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5.I/O SIGNALS B-64483EN-2/01

Signal type Combination No. CNC (DCS PMC) PMC (PMC)

Output

1 No.11960 No.11980 2 No.11961 No.11981 3 No.11962 No.11982 4 No.11963 No.11983 5 No.11964 No.11984 6 No.11965 No.11985 7 No.11966 No.11986 8 No.11967 No.11987

Brake Test Start signal STBT <PMC:Gn193.2> (for each machine group)

[Classification] Input signal (Single signal) [Function] This input signal is used to start or interrupt a brake test.

Changing the state of this signal from "0" to "1" starts the brake test. When the brake test is completed successfully, the Brake Test Execution Request signal RQBT is set to "0", causing the state of this signal to change from "1" to "0" as well. Changing the state of this signal from "1" to "0" during the brake test causes the test to be interrupted. The test sequence being executed when the signal is set to "0" is suspended, and the amount of travel occurring during the brake test, brake signals, and torque limit are reset. To execute the brake test again, set this signal to "1". The brake test will resume from the beginning.

Brake Test Execution Request signal RQBT <PMC:Fn191.3> (for each machine group)

[Classification] Output signal (Single signal) [Function] This signal is used to request a brake test. If the signal is set to "1", a brake test is

executed. Even if this request signal is set to "1", the operation is allowed to continue until the current stage of machining is completed. To ensure safety, however, when the current stage of machining is completed, be sure to start a brake test by setting the Brake Test Start signal STBT to "1". When the brake test is executed and completed successfully, this signal is set to "0".

5.4 PROGRAMMABLE SAFETY I/O SIGNAL

The Programmable Safety I/O signal is a safety signal that can be defined by the machine tool builder. The Dual Check Safety function performs dual monitoring on the system-defined safety signals and the Programmable Safety I/O signals defined by the machine tool builder. To define the Programmable Safety I/O signals, use the relevant parameters.

Turning off the Programmable Safety I/O output signal

When the state of *DCALM, *MCF, *MCFPs, or *MCFVx is found to be "0", turn off the Programmable Safety I/O output signal as necessary. (a) In case MCC off Test is carried out, When RQT=1 and OPT=1, ignore *MCF=0. (b) In case of emergency stop (*ESP=0) When *ESP=0, ignore *MCF=0.

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B-64483EN-2/01 5.I/O SIGNALS

5.5 NOTE ON MULTI PATH CONTROL

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

5.5.1 Machine Group And Multi Path Control

CNC can treat servo axes and spindles by dividing into two classes of groups, machine group and path In case that a machine has plural machine parts that are controlled independently, machine group is provided to control a part of machine in such machine. Emergency stop is prepared for each machine group. The signals for MCC off Test and protective door open/close sequence are provided for each machine group.

In case that a work piece is machined by plural cutters and plural programs at the same time, multi path control is applied. An alarm is checked by each path. If servo alarm occurs in a path, MCC of all axes in the path is shut off. In case of the alarm by safety check function, MCC of all axes in the path are shut off. Then the safety area should be set for each path basically.

When plural safety areas are defined in a path, MCC may be shut off by an alarm that occurs in another safety area. When the safety area is composed by the axes that change assignment to a path, MCC of other axes are not always shut off. So wire the MCC of all paths, which include the axes changed assignment to the path, to shut off at the same time.

The safety signals that are cross-checked are provided both on PMC and DCS PMC for each path. The state must be controlled to be equal.

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 belonging 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.

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6.PARAMETERS B-64483EN-2/01

6 PARAMETERS

6.1 OVERVIEW

The parameters related to the dual check safety function (safety parameters) are protected by a code (No.

3225) for the safety parameters. The value of a safety parameter cannot be modified unless the same value as the code for the safety parameters is set as the key (No. 3226) for the safety parameters. The safety parameters are stored in two locations on the CNC. The CNC, 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.

6.2 DATA TYPE

Parameters 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 2-word axis 2-word spindle Real Real machine group Real path Real axis Real spindle

See the Standard Parameter Setting

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).

0 or 1

-128 to 127 0 to 225

-32768 to 32767 0 to 65535

0 to ±999999999

Tables.

Some parameters handle these types of data as unsigned data.

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B-64483EN-2/01 6.PARAMETERS

NOTE

2 The machine group type allows data to be set separately for each machine

group. 3 The path type allows data to be set separately for each path. 4 The axis type allows data to be set separately for each control axis. 5 The spindle type allows data to be set separately for each spindle axis. 6 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.

6.3 REPRESENTATION OF PARAMETERS

Parameters of the bit type, bit machine group type, bit path type, bit axis type, and bit spindle type

Parameters other than the bit-type parameters above

NOTE

1 The parameters, which are described here, are related directly to

2 A parameter usable with only one path control type, namely, the

[Example 1]

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

0000 EIA NCR ISP CTV TVC

Data No. Data (Data #0 to #7 are bit positions.)

1023 Number of the servo axis for each axis

Data No. Data

Dual Check Safety function. As for the other parameters, please refer to the parameter manual (B-64490EN).

lathe system (T series) or the 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.

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.

1403

#7 #6

RTV

#5 #4 #3 #2 #1 #0

ROC

HTG HTG

T series M series

[Example 2]

The following parameter is provided only for the M series.

1411

Cutting feedrate

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T series M series

6.PARAMETERS B-64483EN-2/01

NOTE

3 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.

4 The lower-case letter "x" or "s" following the name of a bit-type

parameter indicates the following:

- ”

x” : Bit axis type parameters s” : Bit spindle type parameters

6.4 STANDARD PARAMETER SETTING 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)

Unit of data Increment system Minimum data unit Valid data range

IS-A 0.01 -999999.99 to +999999.99

deg.

inch

(B) Length and angle parameters (type 2)

Unit of data Increment system Minimum data unit Valid data range

deg.

inch

IS-B 0.001 -999999.999 to +999999.999 IS-C 0.0001 -99999.9999 to +99999.9999 IS-D 0.00001 -9999.99999 to +9999.99999 IS-E 0.000001 -999.999999 to +999.999999 IS-A 0.001 -99999.999 to +99999.999 IS-B 0.0001 -99999.9999 to +99999.9999 IS-C 0.00001 -9999.99999 to +9999.99999 IS-D 0.000001 -999.999999 to +999.999999 IS-E 0.0000001 -99.9999999 to +99.9999999

IS-A 0.01 0.00 to +999999.99 IS-B 0.001 0.000 to +999999.999 IS-C 0.0001 0.0000 to +99999.9999 IS-D 0.00001 0.00000 to +9999.99999 IS-E 0.000001 0.000000 to +999.999999 IS-A 0.001 0.000 to +99999.999 IS-B 0.0001 0.0000 to +99999.9999 IS-C 0.00001 0.00000 to +9999.99999 IS-D 0.000001 0.000000 to +999.999999 IS-E 0.0000001 0.0000000 to +99.9999999

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B-64483EN-2/01 6.PARAMETERS

Unit of data Increment system Minimum data unit Valid data range

IS-A 0.01 0.00 to +999000.00

mm/min

degree/min

inch/min

IS-B 0.001 0.000 to +999000.000 IS-C 0.0001 0.0000 to +99999.9999 IS-D 0.00001 0.00000 to +9999.99999 IS-E 0.000001 0.000000 to +999.999999 IS-A 0.001 0.000 to +96000.000 IS-B 0.0001 0.0000 to +9600.0000 IS-C 0.00001 0.00000 to +4000.00000 IS-D 0.000001 0.000000 to +400.000000 IS-E 0.0000001 0.0000000 to +40.0000000

(D)Acceleration and angular acceleration parameters

Unit of data Increment system Minimum data unit Valid data range

IS-A 0.01 0.00 to +999999.99

mm/sec2

deg./sec

inch/sec2

IS-B 0.001 0.000 to +999999.999 IS-C 0.0001 0.0000 to +99999.9999 IS-D 0.00001 0.00000 to +9999.99999 IS-E 0.000001 0.000000 to +999.999999 IS-A 0.001 0.000 to +99999.999 IS-B 0.0001 0.0000 to +99999.9999 IS-C 0.00001 0.00000 to +9999.99999 IS-D 0.000001 0.000000 to +999.999999 IS-E 0.0000001 0.0000000 to +99.9999999

Notes

(1) Values are rounded up or down to the nearest multiples of the minimum data unit. (2) A valid data range means data input limits, and may differ from values representing actual

performance.

(3) For information on the ranges of commands to the CNC, refer to Appendix, "List of Command

Ranges," in the "OPERATOR’S MANUAL (Common to Lathe System/Machining Center System)" (B-64484EN).

(4) The setting value of the parameter related with length and angle depends on whether the attribute of

the axis is diameter specification or radius specification. In case safety function, set the parameter according to the attribute of the axis at power on. Even if the attribute is changed after power on, changed value is not used by each safety function. Each safety function refers to the value that is specified at power on. .

6.5 PARAMETERS

0980 Machine group number of each path

NOTE

When this parameter is set, the power must be turned off before

operation is continued.

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6.PARAMETERS B-64483EN-2/01

[Input type] Parameter input [Data type] Byte path [Valid data range] 1 to 3

Set the machine group number which each path belongs.

NOTE

When 0 is set, each path is assumed to belong to machine group 1.

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 to 10

Set the path to which each axis belongs.

NOTE

When 0 is set, each axis is assumed to belong to path 1.

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 data range] 1 to 10

Set the path to which each spindle belongs.

NOTE

When 0 is set, each spindle is assumed to belong to path 1.

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

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B-64483EN-2/01 6.PARAMETERS

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, set a value obtained by adding 1 to the value set for the slave axis.

1240

Coordinates value of the reference position in the machine coordinate system

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, 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). But in case

that CMR≥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 IS-B and CMR=2, -499999.999 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.

Set the coordinate values of the reference position in the machine coordinate system.

1838 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.

[Input type] Parameter input [Data type] 2-word axis [Unit of data] Detection unit [Valid data range] 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 is always checked by CNC and Servo. In case that Safety Check is carried out (Safety Monitoring Request *VLDVx =“0”), the servo alarm (SV0475,SV1071) is generated when each CPU finds out that the deviation exceeds position deviation limit in moving state.

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6.PARAMETERS B-64483EN-2/01

1839 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.

[Input type] Parameter input [Data type] 2-word axis [Unit of data] Detection unit [Valid data range] 0 to 99999999

Set the positioning deviation limit in stopped state for each axis for Dual Check Safety function. If the positioning deviation exceeds the positioning deviation limit during stopped state while Safety Check is carried out (Safety Monitoring Request *VLDVx =“0”), a servo alarm (SV0474, SV1072) is generated, and operation is stopped immediately (as in emergency stop). 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.

1840 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

operation is continued.

[Input type] Parameter input [Data type] 2-word axis [Unit of data] Detection unit [Valid data range] 0 to 99999999

Set the positioning deviation limit in servo-off state for each axis for Dual Check Safety function. If the positioning deviation exceeds the positioning deviation limit during servo-off, a servo alarm (SV1069,SV1070) is generated, and operation is stopped immediately (as in emergency stop). In Dual Check Safety function, position deviation is always checked by CNC and Servo. Servo alarm (SV1069,SV1070) is generated when each CPU finds out that the deviation exceeds position deviation limit in servo-off state.

1841

Position deviation limit of each axis in moving state during other than Safety Check is carried out

NOTE

When this parameter is set, the power must be turned off before

operation is continued.

[Input type] Parameter input [Data type] 2-word axis [Unit of data] Detection unit [Valid data range] 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 *VLDVx=“1”).

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B-64483EN-2/01 6.PARAMETERS

In case that Safety Check is 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. If 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.

1842

Position deviation limit of each axis in stopped state during other than Safety Check is carried out

NOTE

When this parameter is set, the power must be turned off before

operation is continued.

[Input type] Parameter input [Data type] 2-word axis [Unit of data] Detection unit [Valid data range] 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.

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

1902 DCE

NOTE

When this parameter is set, the power must be turned off before

operation is continued.

[Input type] Parameter input [Data type] Bit

#6 DCE 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.

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6.PARAMETERS B-64483EN-2/01

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.

2 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.

MCC Off signal *MCF (for each machine group)

•

The state of MCC Off signal *MCF on the PMC and DCSPMC

sides changes depending on the state of the emergency stop signal on the PMC side (the state of the emergency stop signal on the DCSPMC side has no effect). The MCC off Test is disabled.

Brake signal *BRKx (for each axis)

•

Brake signal *BRKx operates only on the PMC side. Note that

the signal on the DCSPMC side always indicates the brake release state. The output signals other than the above are described below.

(1) The following signals always indicate "1" on both the PMC and

DCSPMC sides.

- MCC Off signal *DCALM (one for each system)

- MCC Off signals *MCFVx (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

DCSPMC 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

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

1904 DCN

NOTE

When this parameter is set, the power must be turned off before

operation is continued.

[Input type] Parameter input [Data type] Bit axis

#6 DCN The checks of the target axis by Dual Check Safety function are:

0: carried out. 1: not carried out.

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B-64483EN-2/01 6.PARAMETERS

NOTE

1 It is not possible to inhibit each check of Dual Check Safety

Function of all axes by the parameter DCN.

2 Set the DCN bit to 1 for the dummy axis under tandem control or

for the tool axis of a electronic gear box or electronic gear box 2-pair.

3 The checks by the dual check safety function are not carried out on

an axis for which the DCN bit is set to 1. Set the DCN bit to 0 for normal axes.

1945 Safety-related I/O check 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 1000

There are two paths for the safety-related I/O signals (those duplicated by the Dual Check Safety function): one on the PMC side and the other on the DCS PMC side. The CNC CPU and the PMC CPU constantly exchange their I/O signals with each other and monitor 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, PW0012 or PW0013 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

The same value is applied to each path that belongs to a machine

group.

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 a value of less than 0 is specified, it is assumed that 10000 ms is specified.

NOTE

The same value is applied to each path that belongs to a machine

group.

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6.PARAMETERS B-64483EN-2/01

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

• 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.

• When there is no spindle (spindle for which *VLDPs = 1 is set) not being monitored for its safety in the machine group, 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.

• When a crosscheck alarm or CPU self diagnosis alarm occurs, MCC Off signal *DCALM (one for each system) is 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

The same value is applied for each path that belongs to a machine

group.

1950 Brake signal 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

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

The same value is applied for each path that belongs to a machine

group.

3021 Address to which an axis signal is assigned

NOTE

When this parameter is set, the power must be turned off before

operation is continued.

[Input type] Parameter input

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B-64483EN-2/01 6.PARAMETERS

[Data type] Byte axis

[Valid data range] 0 to 7, 10 to 17, 20 to 27, ... , 90 to 97

For each axis of the CNC, set a PMC interface address. Set a value according to the tables below.

Value of parameter No. 3021 (the second digit)

Setting value Input signal address Output signal address

0 G0000 to G0767 F0000 to F0767 1 G1000 to G1767 F1000 to F1767

⋅ ⋅ ⋅

9 G9000 to G9767 F9000 to F9767

Value of parameter No. 3021 (the first digit)

Setting value Input signal address Output signal address

0 #0 #0 1 #1 #1

⋅ ⋅ ⋅

7 #7 #7

[Example of setting]

Axis number No.3021 Signal allocation

1 0 +J1<G0100.0>, -J1<G0102.0>, ZP1<F0090.0>, ... 2 1 +J2<G0100.1>, -J2<G0102.1>, ZP2<F0090.1>, ... 3 2 +J3<G0100.2>, -J3<G0102.2>, ZP3<F0090.2>, ... 4 10 +J4<G1100.0>, -J4<G1102.0>, ZP4<F1090.0>, ... 5 11 +J5<G1100.1>, -J5<G1102.1>, ZP5<F1090.1>, ...

If eight or less axes are used per path, the following signal allocation results when 0 is set

for all axes: Axis 1 of path 1 = Setting equivalent to 0 Axis 2 of path 1 = Setting equivalent to 1

Axis 1 of path 2 = Setting equivalent to 10

NOTE

Set this parameter when more than eight axes are used per path. The valid data range varies, depending on the system software.

3022 Address to which a spindle signal is assigned

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 data range] 0to3,10to13,20to23, ... ,90to93

For each axis of the CNC, set a PMC interface address.

Set a value according to the tables below.

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6.PARAMETERS B-64483EN-2/01

Value of parameter No. 3022 (the second digit)

Setting value Input signal address Output signal address

0 G0000 to G0767 F0000 to F0767 1 G1000 to G1767 F1000 to F1767

⋅ ⋅ ⋅

9 G9000 to G9767 F9000 to F9767

Value of parameter No. 3022 (the first digit)

Setting value Input signal address Output signal address

0 Bit position A Bit position A 1 Bit position B Bit position B 2 Bit position C Bit position C 3 Bit position D Bit position D

(The bit positions A, B, C and D vary, depending on the type of signal.)

[Example of setting]

Spindle number No.3022 Sign al allo catio n

1 0 TLMLA<G0070.0>, TLMHA<G0070.1>, ALMA<F0045.0>, ... 2 1 TLMLB<G0074.0>, TLMHB<G0074.1>, ALMB<F0049.0>, ... 3 10 TLMLA<G1070.0>, TLMHA<G1070.1>, ALMA<F1045.0>, ... 4 11 TLMLB<G1074.0>, TLMHB<G1074.1>, ALMB<F1049.0>, ...

If four or less axes are used per path, the following signal allocation results when 0 is set

for all axes:

Axis 1 of path 1 = Setting equivalent to 0

Axis 2 of path 1 = Setting equivalent to 1

Axis 1 of path 2 = Setting equivalent to 10

NOTE

Set this parameter when more than four axes are used per path. The valid data range varies, depending on the system software.

3225 Code for safety parameters

NOTE

When this parameter is set, the power must be turned off before

operation is continued.

[Input type] Parameter input [Data type] 2-word [Valid data range] 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 Result

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)

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B-64483EN-2/01 6.PARAMETERS

If the value other than “0” is set to this parameter, the safety parameter is not displayed.

The 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.980, No.981, No.982, 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.2000, No.2023,

No.2024, No.2084, No.2085, No.2185, No.3021, No.3022, No.3225, No.3717, No.3797,

No.4372, No.4438, No.4440, No.4442, No.4448, No.4545, No.10500, No.10501-

No.10596, No.11950-No.11957, No.11960-No.11967, No.11970-No.11977, No.11980-

No.11987, No.13806, No.13811, No.13821-No.13829, No.13831-No.13838, No.13840-

No.13843, No.13880-No.13911, No.13912-No.13919, No.13920-No.13951, No.13960-

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.

3226 Key for safety parameters

NOTE

When this parameter is set, the power must be turned off before

operation is continued.

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

When the same value as the code for safety parameters No.3225 is set in this parameter,

the key is opened to enable modifications to the safety parameters. The value set in this

parameter is not displayed.

When the value other than 0 is set to the code for safety parameters No.3225 and the

value is different from this parameter, the key is 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

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 data range] 0 to Maximum number of controlled spindle 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.

- 77 -

6.PARAMETERS B-64483EN-2/01

n: Spindle motor connected to amplifier number n is used.

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

3797 DCN

NOTE

When this parameter is set, the power must be turned off before

operation is continued.

[Input type] Parameter input [Data type] Bit spindle

#0 DCN 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.

4372 Safe speed 1 for each spindle

4438 Safe speed 2 for each spindle

4440 Safe speed 3 for each spindle

4442 Safe speed 4 for each spindle

NOTE

When these parameters are 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

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

4399 CTLSTP

[Input type] Parameter input

[Data type] Bit spindle

#1 CTLSTP When the safe speed over alarm is detected:

-1

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.

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.)

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B-64483EN-2/01 6.PARAMETERS

4448 Stop 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

-1

[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

10500 STP APM AVM

NOTE

When at 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 In case that a servo alarm occurs,

0: MCC off signal (*MCFVx) is turned to “0” when some servo alarm occurs.

1: MCC off signal (*MCFVx) is turned to “0” when any servo alarm occurs.

In case that this parameter is set to “1”, MCC off signal (*MCFVx) of all axes, which

belong to the same path as the alarm axis, are turned to “0” when a servo alarm occurs.

#1 APM In case that a spindle alarm (SPxxxx) occurs

0: MCC off signal (*MCFPs) is turned to “0” when some spindle alarm occurs.

1: MCC off signal (*MCFPs) is turned to “0” when any spindle alarm occurs.

In case that this parameter is set to “1”, MCC off signal (*MCFPs) of all spindles, which

belong to the same path as the alarm spindle, are turned to “0” when a spindle alarm

occurs.

#3 STP 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 out.

CAUTION

1 The STP parameter is used temporarily, for example, when a MCC

off Test is not to be made at power-on as in the case of machine adjustment.

2 After adjustment, set STP = 0.

- 79 -

6.PARAMETERS B-64483EN-2/01

CAUTION

3 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.

4 The same value must be set to the path that belongs to the same

machine group.

5 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.

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

10597 SDS DPN IDD

[Input type] Parameter input

[Data type] Bit path

#0 IDD On the Dual Check Safety Diagnosis screen, the following information is:

0: Not displayed.

1: Displayed.

• Safety speed limit （unit: mm/min, inch/min, deg/min）

• Safe feed limit/safe machine position selection signal

• Safe feed limit/safe machine position selection signal in case of an alarm

• Programmable Safety I/O signal

NOTE

When using the virtual MDI key function, do not set this parameter to

"1".

#1 DPN The ALARM INFORMATION screen for the cross check by the Dual Check Safety

function displays:

0: CNC-side address

1: PMC-side address and PMC path number

#3 SDS In the CROSS CHECK DATA screen of the Dual Check Safety Diagnosis screen, the

code name of the signal is:

0: Not displayed.

1: Displayed.

13810 Power-on safety-related I/O check start timer

NOTE

When this parameter is set, the power must be turned off before

operation is continued.

[Input type] Parameter input [Data type] Word [Unit of data] msec [Valid data range] 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.

- 80 -

B-64483EN-2/01 6.PARAMETERS

13811 Hysteresis width of position switch (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, inch, deg (Machine unit) [Least unit of data] According to the input increment of corresponding axis [Valid data range] 0 or positive 9 digit of least input increment of data (Refer to standard parameter setting

table(B). But in case that CMR≥1, 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.

Around the position switch boundary for the Dual Check Safety function, the Safety

Position Switch signal may repeatedly turn on and off due to motor vibration. According

to this problem, position switch is inconvenient to use. So “hysteresis” described below is

applied.

Minimum limit of position switch

Width of hysteresis

Fig.6.5(a) Activated area of the position switch when the Safety Position Switch signal is set to "0"

Minimum limit of position switch

Fig.6.5(b) Activated area of the position switch when the Safety Position Switch signal is set to "1"

ctivated area of position switch

Maximum limit of position switch

Width of hysteresis

Maximum limit o f position switch

Suppose that the minimum limit and maximum limit of the position switch are

represented by an area like those shown above. If the value of the Safety Position Switch

signal used for the last measurement is "0", then the check is made in an area that takes

into account the width of hysteresis (Fig. 6.5 (a)). If the value of the last used Safety

Position Switch signal is "1", then the check is made in an area that does not take into

account the width of hysteresis (Fig. 6.5 (b)). This reduces the fluctuation in the Safety

Position Switch signal.

- 81 -

6.PARAMETERS B-64483EN-2/01

13821 Safety limit speed 1 in position control for each axis

13822 Safety limit speed 2 in position control for each axis

13823 Safety limit speed 3 in position control for each axis

13824 Safety limit speed 4 in position 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] 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 the speed is exceeded the safety limit 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 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 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.

CAUTION

1 The safety speed checks are made on the basis of the speed

converted to the detection unit. Accordingly, a calculation error may occur.

2 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

3 For diameter specification, set the speed by the diameter (use

changes in diameter/rev or in diameter/min).

13825 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.

- 82 -

B-64483EN-2/01 6.PARAMETERS

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 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 For diameter specification, set the speed by the diameter (use

changes in diameter/rev or in diameter/min).

2 In case of velocity control, set the value calculated by the following

-1

formula to this parameter when R(min

) is the velocity, at which the

axis is regarded as stopped.

Setting value = R * PLS * Minimum data unit (Machine unit) * N / CMR

PLS: Pulse per one revolution of motor (Detection unit)

CMR: Command multiplier N: In case of diameter specification, N=2.

In other case, N=1.

Minimum data unit: Refer to “STANDARD PARAMETER

SETTING TABLE”.

13826 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

13829 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] min

[Valid data range] 0 to maximum motor speed

13831 Safety machine position 1 for each axis (+ direction)

13832 Safety machine position 1 for each axis (- direction)

13833 Safety machine position 2 for each axis (+ direction)

13834 Safety machine position 2 for each axis (- direction)

13835 Safety machine position 3 for each axis (+ direction)

13836 Safety machine position 3 for each axis (- direction)

13837 Safety machine position 4 for each axis (+ direction)

-1

This parameter sets the safety speed 1 to 4 for each axis in velocity control mode in Dual

Check Safety function.

- 83 -

6.PARAMETERS B-64483EN-2/01

13838 Safety machine position 4 for each axis (- direction)

NOTE

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≥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 IS-B and CMR=2, -499999.999 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.

Set a safe machine position for each axis.

CNC and Servo always check the machine position on each axis in 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

corresponding 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.

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.

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.

2 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.

13840 Address to which safety position switch 1 to 16 are assigned

13841 Address to which safety position switch 17 to 32 are assigned

13842 Address to which safety position switch 33 to 48 are assigned

13843 Address to which safety position switch 49 to 64 are assigned

- 84 -

B-64483EN-2/01 6.PARAMETERS

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 to 1, 10 to 11, 20 to 21, ... , 90 to 91

According to this parameter, the address to output 64 points of position switch signals can

be assigned for each 16 points. The assigning addresses are F*755 to F*756 (PMC) /

F(007+m) to F(008+m) (DCS PMC) and F*757 to F*758 (PMC) / F(009+m) to

F(010+m) (DCS PMC) in each path. (*: 0 to 9 [path])

The units of this parameter value specifies which address the signal of each path should

be output to, “F*755 to F*756” (PMC) / “F(007+m) to F(008+m)” (DCS PMC) or

“F*757 to F*758” (PMC) / “F(009+m) to F(010+m)” (DCS PMC).

Setting value Assigned address

0 F*755 to F*756(PMC),

F(007+m) to F(008+m) (DCS PMC)

1 F*757 to F*758(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.

Setting value Output path

0 Path 1 1 Path 2

...

9 Path 10

The relationship between parameter settings and assigned addresses is shown below.

Setting value Assigned address (PMC) Assigned address (DCS PMC)

00 F0755 - F0756 F007 - F008 01 F0757 - F0758 F009 - F010 10 F1755 - F1756 F027 - F028 11 F1757 - F1758 F029 - F030 20 F2755 - F2756 F047 - F048 21 F2757 - F2758 F049 - F050 30 F3755 - F3756 F067 - F068 31 F3757 - F3758 F069 - F070 40 F4755 - F4756 F087 - F088 41 F4757 - F4758 F089 - F090 50 F5755 - F5756 F107 - F108 51 F5757 - F5758 F109 - F110 60 F6755 - F6756 F127 - F128 61 F6757 - F6758 F129 - F130 70 F7755 - F7756 F147 - F148 71 F7757 - F7758 F149 - F150 80 F8755 - F8756 F167 - F168 81 F8757 - F8758 F169 - F170 90 F9755 - F9756 F187 - F188 91 F9757 - F9758 F189 - F190

- 85 -

6.PARAMETERS B-64483EN-2/01

[Example]

Parameter No. Setting value Ou tput address of position switch signal

13840 00 F755-F756 (1st to 16th position switch)(PMC)

F007-F008 (1st to 16th position switch)(DCS PMC)

13841 01 F757-F758 (17th to 32nd position switch) (PMC)

F009-F010 (17th to 32nd position switch)(DCS PMC)

13842 50 F5755-F5756 (33rd to 48th position switch) (PMC)

F107-F108 (33rd to 48th position switch)(DCS PMC)

13843 71 F7757-F7758 (49th to 64th position switch) (PMC)

F149-F150 (49th 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

PMC) Position switch 33 to 48: F1755-F1756 (PMC) / F027-F028 (DCS

PMC) Position switch 49 to 64: F1757-F1758 (PMC) / F029-F030 (DCS

PMC) 2 Do not assign two or more position switch to the same address. 3 The specifiable range depends on the system software.

13880 Axis corresponding to the 1st safe position switch

13881 Axis corresponding to the 2nd safe position switch

: :

13910 Axis corresponding to the 31st safe position switch

13911 Axis corresponding to the 32nd safe position switch

10501 Axis corresponding to the 33rd safe position switch

10502 Axis corresponding to the 34th safe position switch

: :

10531 Axis corresponding to the 63rd safe position switch

10532 Axis corresponding to the 64th safe position switch

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 to Number of controlled axes

Specify the control axis number corresponding to each of the first to 64th safety position switches sequentially. If the machine coordinate value of the associated axis is within the range specified by the parameter, the corresponding Safety Position Switch signal is output on the PMC side and DCS PMC side.

- 86 -

B-64483EN-2/01 6.PARAMETERS

WARNING

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 bit 6 (DCN) of

parameter No.1904 is 1 (Dual Check Safety is disabled) is not

output. 2 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.

13920 The maximum limit of the 1st safe position switch

13921 The maximum limit of the 2nd safe position switch

: :

13950 The maximum limit of the 31st safe position switch

13951 The maximum limit of the 32nd safe position switch

10533 The maximum limit of the 33rd safe position switch

10534 The maximum limit of the 34th safe position switch

: :

10563 The maximum limit of the 63rd safe position switch

10564 The maximum limit of the 64th safe position switch

NOTE

When these parameters are set, the power must be turned off

before operation is continued.

[Input type] Parameter input [Data type] Real [Unit of data] mm, inch, deg (machine unit) [Min. unit of data] Depend on the increment system of the reference axis

[Valid data range] 9 digit of minimum unit of data (refer to standard parameter setting table (A)). But in case

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.

These parameters set the maximum limit of the 1st through 64th safe position switches.

CAUTION

1 When the machine position is equal to parameter setting value, it is

regarded that the machine position is within the range. 2 When the setting of operation range is “maximum limit < minimum

limit”, the corresponding safe position switch is not output. 3 After safety position switch parameters Nos. 13920 to 13951 and

10533 to 10564 have been set, the power must be turned off then

back on for the setting to become effective.

- 87 -

6.PARAMETERS B-64483EN-2/01

13960 The minimum limit of the 1st safe position switch

13961 The minimum limit of the 2nd safe position switch

: :

13990 The minimum limit of the 31st safe position switch

13991 The minimum limit of the 32nd safe position switch

10565 The minimum limit of the 33rd safe position switch

10566 The minimum limit of the 34th safe position switch

: :

10595 The minimum limit of the 63rd safe position switch

10596 The minimum limit of the 64th safe position switch

NOTE

When these parameters are set, the power must be turned off

before operation is continued.

[Input type] Parameter input [Data type] Real [Unit of data] mm, inch, deg (machine unit) [Min. unit of data] Depend on the increment system of the reference axis [Min. unit of data] Depend on the increment system of the reference axis

[Valid data range] 9 digit of minimum unit of data (refer to standard parameter setting table (A)). But in case

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.

These parameters set the minimum limit of the 1st through 64th safe position switches.

CAUTION

1 When the machine position is equal to parameter setting value, it is

regarded that the machine position is within the range. 2 When the setting of operation range is “maximum limit < minimum

limit”, the corresponding safe position switch is not output. 3 After safety position switch parameters Nos. 13960 to 13991 and

10565 to 10596 have been set, the power must be turned off then

back on for the setting to become effective.

13912 Brake test enable/disable

NOTE

When this parameter is set, the power must be turned off before

operation is continued.

[Input type] Parameter input [Data type] Byte axis

- 88 -

B-64483EN-2/01 6.PARAMETERS

[Unit of data] None [Valid data range] 0,1

Select whether to enable or disable the brake test. Set "0" to disable the test and "1" to enable it.

13913 Brake test interval

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] Hour [Valid data range] 0 to 168

Set the interval of time between the last brake test and the next one. When the time set in this parameter has elapsed after the brake test ends, the Brake Test Execution Request signal RQBT is set to "1". If "0" is set, the interval is assumed to be 8 hours.

13914 Time t1 allowed to elapse after the output of the brake signal until the brake is applied

NOTE

When this parameter is set, the power must be turned off before

operation is continued.

[Input type] Parameter input [Data type] 2-word axis [Unit of data] ms [Valid data range] 0 to 999999999

To control when to output the *BRKx signal and move command during the brake test for an individual axis, set the time allowed to elapse after the *BRKx signal is controlled until the brake is applied, as well as the time allowed to elapse after the *BRKx signal is controlled until the brake is released. If the time for applying the brake differs from the time for releasing it, set the longer time. If "0" is set, the time is assumed to be 400 ms.

13915 Brake test current limit override value

NOTE

When this parameter is set, the power must be turned off before

operation is continued.

[Input type] Parameter input [Data type] 2-word axis [Unit of data] (100/255)% [Valid data range] 0 to 255

Set the current limit override value for the brake test. The relationship between the value set in this parameter and the torque limit override value is as follows. Torque limit override value = (set value/255) × 100 (%) If "0" is set, 12% is assumed.

- 89 -

6.PARAMETERS B-64483EN-2/01

13916 Amount of travel specified for the 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 axis [Unit of data] mm, inch, degree (machine unit) [Min. 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) Set the amount of travel to be specified for each axis at the time of the brake test. If "0" is set, 1.000 mm is assumed.

CAUTION

If this parameter specifies a value that is smaller than the tolerance

value (No. 13918) for the positional deviation to be checked by the

brake test, the brake test may fail to be executed normally.

NOTE

When the diameter is specified ("1" is set in bit 3(DIAx) of parameter

No. 1006), set the diameter value.

13917 Feedrate specified for the 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 axis [Unit of data] mm/min, inch/min, degree/min (machine unit) [Min. 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 the feedrate to be specified for each axis at the time of the brake test. If "0" is set, 10 mm/min is assumed.

13918 Tolerance value for the positional deviation amount checked by the brake test

NOTE

When this parameter is set, the power must be turned off before

operation is continued.

[Input type] Parameter input [Data type] 2-word axis [Unit of data] Detection unit [Valid data range] 0 to 999999999

- 90 -

fanuc 30iB, 31i B, 32i- B Connection Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

DEFINITION OF WARNING, CAUTION, AND NOTE

PREFACE

TABLE OF CONTENTS

1 OVERVIEW

1.1 DIRECTIVE AND STANDARDS

1.1.1 Directives

1.1.2 Related Safety Standards

1.1.3 Risk Analysis and Evaluation

1.2 DEFINITION OF TERMS

1.2.1 General Definition of Terms

1.2.2 Definition of Terms Related to the Safety Function

1.3 BASIC PRINCIPLE OF DUAL CHECK SAFETY

1.3.1 Features of Dual Check Safety

1.3.2.1 Latent error detection and cross-check

1.3.2.2 Safety monitoring cycle and cross-check cycle

1.3.2.3 Error analysis

1.3.2.4 Remaining risks

1.4 GENERAL INFORMATION

1.5 SAFETY FUNCTION BY FL-net

2 SYSTEM CONFIGURATION

3 SAFETY FUNCTIONS

3.1 APPLICATION RANGE

3.2 BEFORE USING THE SAFETY FUNCTION

3.2.1 Important Items to Check Before Using the Safety Function

3.2.2 MCC off Test of the Safe Stop Function

3.3 STOP

3.3.1 Stopping the Spindle Motor

3.3.2 Stopping the Servo Motor

3.3.3 Stop States

3.4 SAFETY-RELATED I/O SIGNAL MONITORING

3.5 EMERGENCY STOP

3.6 SAFE SPEED MONITORING

3.7 SAFE MACHINE POSITION MONITORING

3.8 MCC OFF TEST

3.9 SAFETY POSITION SWITCH FUNCTION

3.10 SAFETY RELATED PARAMETERS CHECK FUNCTION

3.11 PARAMETER LOCK FUNCTION

3.12 SEFETY POSITION ERROR MONITORING FUNCTION

3.13 AMPLIFIER CIRCUIT MONITORING FUNCTION

3.14 SAFETY BRAKE SIGNAL OUTPUT FUNCTION

3.15 CPU SELF TEST FUNCTION

3.16 RAM CHECK FUNCTION

3.17 CRC CHECK FUNCTION

3.18 SAFE STOP MONITORING

3.19 BRAKE TEST

4 INSTALLATION

4.1 OVERALL CONNECTION DIAGRAM

4.1.1 In case of using the I/O Link

4.1.2 In case of using the I/O Link i

4.1.3 In case of using PROFIBUS-DP on the DCS PMC side

5 I/O SIGNALS

5.1 OVERVIEW

5.2 SIGNAL ADDRESS

5.3 SIGNALS

5.4 PROGRAMMABLE SAFETY I/O SIGNAL

5.5 NOTE ON MULTI PATH CONTROL

5.5.1 Machine Group And Multi Path Control

6 PARAMETERS

6.1 OVERVIEW

6.2 DATA TYPE

6.3 REPRESENTATION OF PARAMETERS

6.4 STANDARD PARAMETER SETTING TABLES

6.5 PARAMETERS