Operator'S Manual

OPERATOR’S MANUAL
B-63494EN/01
Ȧ No part of this manual may be reproduced in any form.
Ȧ All specifications and designs are subject to change without notice.
In this manual we have tried as much as possible to describe all the

various matters.
However, we cannot describe all the matters which must not be done,
or which cannot be done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in
this manual should be regarded as ”impossible”.
B-63494EN/01 SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
This manual includes safety precautions for protecting the user and
preventing damage to the machine. Precautions are classified into
Warning and Caution according to their bearing on safety. Also,
supplementary information is described as a Note. Read the Warning,
Caution, and Note thoroughly before attempting to use the machine.
WARNING
Applied when there is a danger of the user being
injured or when there is a damage of both the user
being injured and the equipment being damaged if
the approved procedure is not observed.
CAUTION
Applied when there is a danger of the equipment
being damaged, if the approved procedure is not
observed.
NOTE
The Note is used to indicate supplementary
information other than Warning and Caution.
- Read this manual carefully, and store it in a safe place.
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B-63494EN/01 TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY PRECAUTIONS
PRECAUTIONS................................
................................................................
................................................................................................
.......................................................................................
....................................................... s-1
s-1
1 OVERVIEW
OVERVIEW................................
EW................................................................
................................................................................................
................................................................................................
.........................................................................
......................................... 1
1.1 DIRECTIVE AND STANDARDS ..................................................................................................... 3

1.1.1 Directives.................................................................................................................................... 3
1.1.2 Related Safety Standards.......................................................................................................... 3
1.1.3 Risk Analysis and Evaluation................................................................................................... 3
1.1.4 Certification Test ....................................................................................................................... 4
1.2 DEFINITION OF TERMS ................................................................................................................ 5
1.2.1 General Definition of Terms ..................................................................................................... 5
1.2.2 Definition of Terms Related to the Safety Function................................................................ 5
1.3 BASIC PRINCIPLE OF DUAL CHECK SAFETY .......................................................................... 6
1.3.1 Features of Dual Check Safety ................................................................................................. 6
1.3.2 Compliance with the Safety Standard (EN954-1, Category 3) ............................................... 7
1.3.2.1 Latent error detection and cross-check ...........................................................................................8
1.3.2.2 Safety monitoring cycle and cross-check cycle ................................................................................9
1.3.2.3 MCC off Test .....................................................................................................................................9
1.3.2.4 Error analysis .................................................................................................................................10
1.3.2.5 Remaining risks..............................................................................................................................10

1.4 GENERAL INFORMATION........................................................................................................... 12
2 SYSTEM CONFIGURATION
CONFIGURATION ................................................................
................................................................................................
...........................................................................
........................................... 14
3 SAFETY FUNCTIONS ................................................................

................................................................................................
.....................................................................................
..................................................... 16
3.1 APPLICATION RANGE ................................................................................................................. 17

3.2 BEFORE USING THE SAFETY FUNCTION............................................................................... 20
3.2.1 Important Items to Check Before Using the Safety Function .............................................. 20
3.2.2 MCC off Test of the Safe Stop Function ................................................................................. 20
3.3 STOP ................................................................................................................................................ 21
3.3.1 Stopping the Spindle Motor .................................................................................................... 21
3.3.2 Stopping the Servo Motor........................................................................................................ 22
3.3.3 Stop States ............................................................................................................................... 22
3.4 SAFE-RELATED I/O SIGNAL MONITORING ............................................................................ 24
3.5 EMERGENCY STOP ...................................................................................................................... 29
3.6 SAFE SPEED MONITORING........................................................................................................ 30
3.7 SAFE MACHINE POSITION MONITORING .............................................................................. 31
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TABLE OF CONTENTS B-63494EN/01
3.8 MCC OFF TEST .............................................................................................................................. 32
4 INSTALLATION
INSTALLATION ................................................................
................................................................................................
...............................................................................................
............................................................... 33
4.1 OVERALL CONNECTION DIAGRAM ......................................................................................... 35

4.1.1 For One-path............................................................................................................................ 35
4.1.2 For Two-path............................................................................................................................ 37
4.2 DI/DO CONNECTION (VIA THE PMC) ....................................................................................... 40
4.3 DI/DO CONNECTION (VIA THE FSSB) ...................................................................................... 41
4.3.1 FSSB I/O Connection............................................................................................................... 41
4.3.2 FSSB I/O Attachment.............................................................................................................. 43
4.3.3 FSSB I/O Specification List..................................................................................................... 47
5 I/O SIGNALS ................................................................

................................................................................................
................................................................................................
....................................................................
.................................... 48
5.1 OVERVIEW ..................................................................................................................................... 49

5.2 SIGNALS ......................................................................................................................................... 50
5.3 SIGNAL ADDRESSES.................................................................................................................... 55
5.4 SAFETY SIGNAL MODES............................................................................................................. 56
5.5 NOTES ON MULTI-PATH CONTROL ......................................................................................... 57
5.5.1 Two-CPU Two-Path Control (Without Axis Change between Paths)................................... 57
5.5.2 Two-CPU Two-Path Control (With Axis Change between Paths) ........................................ 58
5.5.3 One-CPU Two-Path Control.................................................................................................... 59
5.5.4 Two-CPU Three-Path Control................................................................................................. 60
5.5.5 Loader Control ......................................................................................................................... 61
6 PARAMETERS ................................................................
................................................................................................
................................................................................................
.................................................................
................................. 62
6.1 OVERVIEW ..................................................................................................................................... 63

6.2 PARAMETERS ................................................................................................................................ 64
6.3 PARAMETERS RELATED TO THE USE OF FSSB I/O UNIT ................................................... 72
6.4 FUNCTIONS THAT REQUIRE SPECIAL PARAMETER SETTINGS....................................... 74
6.4.1 Tandem Control ....................................................................................................................... 74
6.4.2 Simple Electronic Gear Box and Electronic Gear Box 2-pair ............................................... 74
6.4.3 Multi-path Control................................................................................................................... 74
7 START-UP ................................................................
................................................................................................
................................................................................................
........................................................................
........................................ 75
7.1 START-UP OPERATION................................................................................................................ 76

7.1.1 Acceptance Test and Report for Safety Functions................................................................. 76
7.1.2 Start-up of the Dual Check Safety Function.......................................................................... 78
7.1.2.1 Initial start-up ................................................................................................................................78
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B-63494EN/01 TABLE OF CONTENTS
7.1.2.2 Series start-up ................................................................................................................................80

7.1.3 Troubleshooting ....................................................................................................................... 80
8 MAINTENANCE ................................................................
................................................................................................
..............................................................................................
.............................................................. 81
8.1 SAFETY PRECAUTIONS............................................................................................................... 82

8.2 ALARMS AND MESSAGES ........................................................................................................... 86
8.2.1 Overview................................................................................................................................... 86
8.2.2 Servo Alarms............................................................................................................................ 87
8.2.3 Serial Spindle Alarms.............................................................................................................. 91
8.2.4 Alarms Displayed on the Spindle Unit................................................................................... 92
8.2.5 System Alarms ......................................................................................................................... 93
8.2.6 Boot System Alarms ................................................................................................................ 93
9 DIAGNOSIS ................................................................
................................................................................................
................................................................................................
......................................................................
...................................... 94
9.1 OVERVIEW ..................................................................................................................................... 95

9.2 DIAGNOSIS..................................................................................................................................... 96
10 SAMPLE SYSTEM CONFI

CONFIGURATION
GURATION ................................................................
.......................................................................................
....................................................... 97
10.1 SAMPLE CONFIGURATION......................................................................................................... 98

10.1.1 For One-path............................................................................................................................ 98
10.1.2 For Two-path (When the main side and sub side use a common MCC)............................... 99
10.1.3 For Two-path (When the main side and sub side use independent MCCs and
protection doors) .................................................................................................................... 100
10.2 SAMPLE CONNECTIONS ........................................................................................................... 101
10.2.1 Emergency Stop Signal (*ESP1, *ESP2).............................................................................. 101
10.2.2 Guard Open Request Signal (ORQ)...................................................................................... 102
10.2.3 Test Mode Signal (OPT) ........................................................................................................ 102
10.2.4 Guard Unlock Signal (*LGD), Guard Lock State Signal (GDL),
Guard State Signal (SGD)..................................................................................................... 103
10.2.5 MCC On Enable Signal (MCF), MCC Contact State Signal (*SMC).................................. 105
11 COMPONENTS LIST ................................................................

................................................................................................
.................................................................................
................................................. 106
11.1 HARDWARE COMPONENTS ..................................................................................................... 107

11.1.1 Hardware Components for Series 16i/18i/21i/160i/180i/210i/160is/180is/210is-MODEL A107
11.1.2 Hardware Components for Series 16i/18i/21i/160i/180i/210i/160is/180is/210is-MODEL B107
11.1.3 Hardware Components for Other Units............................................................................... 108
11.2 SOFTWARE COMPONENTS....................................................................................................... 109
11.3 SERVO AMPLIFIER..................................................................................................................... 111
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B-63494EN/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 magnetics
cabinet circuit.
With the dual check safety function, two independent CPUs built into
the CNC monitor the speed and position of motors in dual mode. An
error in speed and position is detected at high speed, and power to the
motor is shut off via two independent paths. Processing and data
related to safety is cross-checked by two CPUs. To prevent failures
from being built up, a safety-related hardware and software test must
be conducted at certain intervals time.
The dual check safety function need not have an external detector
added. Instead, only a detector built into a servo motor or spindle
motor is used. This configuration can be implemented only when
those motors, detectors built into motors, and amplifiers that are
specified by FANUC are used. When an abnormality related to safety
occurs, the dual check safety function stops operation safely.
The dual check safety function ensures safety with the power turned
on, so that an operator can open the protection door to work without
turning off the power. A major feature of the dual check safety
function is a very short time required from the detection of an
abnormality until the power is shut off. A cost advantage of the dual
check safety function is that external detectors and safety relays can
be eliminated or simplified.
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1.OVERVIEW B-63494EN/01
The dual check safety function consists of the following three

functions:
- Safe-related I/O signal monitoring function
- Safe speed monitoring function
- Safe machine position monitoring function
The safety function operates regardless of the NC mode. Usually, this

function should be used in the setup mode. If a position or speed
mismatch is detected by a cross-check using two CPUs, power is shut
off (MCC off) to the motor drive circuit.
The European standard certification organization has certified that

this safety function satisfies the European Safety Standard EN954-1
Category 3.
IMPORTANT
The dual check safety function cannot monitor the
stop state. For details, see the example of system
configuration.
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1.1 DIRECTIVE AND STANDARDS
1.1.1 Directives
Machine tools and their components must satisfy the EC directives

listed below.
The FANUC CNC systems with the dual check safety function are
compatible with all of these directives.
Directive
Directive 98/37/EC 1998 Safety of machinery
Directive 89/336/EEC 1989 Electromagnetic compatibility
Directive 73/23/EEC 1973 Low Voltage Equipment
1.1.2 Related Safety Standards
To be compatible with the directives, especially the machine directive,

the international standards and European standards need to be
observed.
Important safety standards

EN292-1 1991 Safety of machinery - Basic concepts,
general principles for design – Part 1:
Basic terminology, methodology
EN292-2 1991 Safety of machinery - Basic concepts,
general principles for design – Part 2:
Technical principles and specifications
EN954-1 1996 Safety of machinery - Safety-related
parts of control systems –
Part 1: General principles for design
EN1050 1996 Safety of machinery - Principles for risk
assessment
EN60204-1 1997 Safety of machinery - Electrical
equipment of machines
Part 1: General requirements
DIN V VDE0801 (1990) including Principles for computers in safety-
amendment A1(1994) related 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.
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1.1.4 Certification Test
Certification of the dual check safety function

The German certification organization TUV PS has certified that the
dual check safety function satisfies EN954-1 Category 3.
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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
Safe-related I/O signal

Safe-related I/O signals are input/output signals monitored by two
systems. These signals are valid for each feed axis and spindle with a
built-in safety function, and are used with each monitoring system.
Example: Protection door state signal
Safe stop
When a safe stop occurs, power to the drive section is shut off. The
drive section can generate neither a torque nor dangerous operation.
The following are measures for incorporating the safe stop feature:
Contactor between the line and drive system (line contactor)
Contactor between the power section and drive motor (motor
contactor)
If an external force is applied (such as a force applied onto a vertical
axis), an additional measure (such as a mechanical brake) must be
securely implemented to protect against such a force.
Safe speed
Feature for preventing the drive section from exceeding a specified
speed. A measure must be implemented to prevent a set limitation
speed from being changed by an unauthorized person.
Safe machine position

When the drive system has reached a specified positional limit, a
transition is made to the safe stop state. When a positional limit is set,
a maximum move distance traveled until a stop occurs must be
considered. A measure must be implemented to prevent a set
positional limit from being changed by an unauthorized person.
-5-
1.3 BASIC PRINCIPLE OF DUAL CHECK SAFETY
1.3.1 Features of Dual Check Safety
- Two-channel configuration with two or more independent CPUs

- Cross-check function for detecting latent errors
Detection
A servo motor detector signal is sent via the servo amplifier and is
applied to the CNC through the FSB interface. Then, it is fed to two
CPUs: a CNC CPU and a monitor CPU.
A spindle motor detector signal is sent via the spindle amplifier and is
applied to the CNC connected through the serial interface. Then, it is
fed to two CPUs: a CNC CPU and a CPU built into the spindle
amplifier.
Evaluation
The safety function is monitored independently by a CNC CPU and
monitor CPU or by a CNC CPU and spindle CPU. Each CPU cross-
checks data and results at certain intervals.
Response
If the monitoring function detects an error, the CNC CPU and monitor
CPU switch off the MCC via independent paths to shut off the power
to the feed axis and spindle.
-6-
1.3.2 Compliance with the Safety Standard (EN954-1, Category 3)
The dual check safety function satisfies the requirements of Category

3 of the safety standard EN954-1.
Category 3 requires the following:

• The safety function of a safety-related portion must not degrade
when a single failure occurs.
• Single errors must be detected at all times when natural
execution is possible.
To satisfy these requirements, the dual check safety function is

implemented using the two-channel configuration shown below.
Monitoring of servo motor and spindle motor movement

CNC Shut off power
CNC
CPU
CPU
Motor detector signal Cross-check Magnetic
of data and
Door switch signal
results
contactor
Monitor
Monitor Shut off power
CPU
CPU
CNC controller
Data output from the detector built into each motor is transferred to
the CNC through the amplifier. The safety of this path is ensured by
using motors and amplifiers specified by FANUC.
Cross-monitoring using 2 CPUs

Two CPUs built into the CNC are used to cross-monitor the safety
function. Each CPU is periodically checked for errors. If one system
fails, the servo system and spindle can be stopped safely.
Power shutoff via two paths

If an error is detected, the power is shut off via two power shutoff
paths. The paths need to be tested for built-up failures within a certain
time.
Input signal safety

Safety-related input signals such as the protection door lock/unlock
signal is monitored doubly. If a mismatch between the two
occurrences of a signal is detected, the power to the motor drive
circuit is shut off. This cross-check is constantly made.
-7-
Output signal safety

A signal is output (via two paths) to the relay used to shut off the
power to the motor drive circuit. An error is detected by a MCC off
Test. For detection of built-up failures, a MCC off Test needs to be
conducted at certain intervals. This MCC off Test is not mandatory
when machining is performed with the protection door closed.
1.3.2.1 Latent error detection and cross-check
Detection of latent errors

This detection function can detect latent software and hardware errors
in a system that has a two-channel configuration. So, the 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 24 hours)).
When the system is operating in the automatic mode
(when the protection door is closed), this detection
processing is not requested as mandatory.
Cross-check
A latent safety-related error associated with two-channel monitoring
can be detected as a result of cross-checking.
For numeric data, an allowable difference between the two channels
is set in a parameter. (For example, an allowable cross-checked
difference is set for the actual position.)
NOTE
An error detected as the result of forced latent error
detection or cross-checking leads to a safety stop
state. (See Chapter ?.).
-8-
1.3.2.2 Safety monitoring cycle and cross-check cycle
The safety function is subject to periodical monitoring in a monitoring

cycle.
Monitoring cycle: 16 ms
The cross-check cycle represents a cycle at which all data subject to

cross-checking is compared.
Cross-check cycle: 16 ms
1.3.2.3 MCC off Test
The MCC is shut off using two CPUs: a CNC CPU and monitor CPU.
To detect a latent error in the MCC shutoff paths forcibly, a MCC off
Test is conducted. This test is essential to dual check safety. A MCC
off Test must be conducted at specified times (after power-on and at
intervals of 24 hours) to check that the MCC shutoff paths operate
normally. A MCC off Test is conducted once on the CNC side and
once on the monitor side. When a MCC off Test becomes necessary,
the CNC outputs a MCC off Test execution request signal to the
PMC.
NOTE
The machine tool builder is to warn and prompt the
operator to conduct a MCC off Test when a MCC off
Test execution request signal is output. A MCC off
Test is executed by turning on the test mode signal.
MCC off Test execution condition

• All axes and the spindle must be stopped beforehand.
• All vertical axes must be secured firmly beforehand.
Select-test termination
When a MCC off Test is completed, the MCC off Test execution
request signal is turned off. After the MCC off Test execution request
signal is turned off, turn off the test mode signal.
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1.3.2.4 Error analysis
Error analysis
The table below indicates the results of system error analysis
controlled by the dual check safety function.
Error analysis when the protection door is open

Error Cause Action
Spindle safety Amplifier or control unit Safety limitation speed
excessive failure, operation error, etc. monitoring function
speed EN60204-1 Category 1/0
stop
Excessive feed Amplifier or control unit Safety limitation speed
axis speed failure, operation error, etc. monitoring function
EN60204-1 Category 1/0
stop
Feed axis Amplifier or control unit Safety limitation speed
safety machine failure, operation error, etc. monitoring function
position error EN60204-1 Category 1/0
stop
Input/output Wiring error, control unit Safety limitation speed
signal error failure, etc. monitoring function
stop
Error analysis when the protection door is closed

Error Cause Action
Input/output Wiring error, control unit Safety limitation speed
signal error failure, etc. monitoring function
stop
1.3.2.5 Remaining risks
The machine tool builder is to make a failure analysis in connection

with the control system and determine the remaining risks of the
machine.
The dual check safety function has the following remaining risks:
a) The safety function is not active until the control system and
drive system have fully powered up. The safety function cannot
be activated if any one of the components of the control or drive
is not powered on.
b) Interchanged phases of motor connections, reversal in the signal
of encoder and reversal mounting of encoder can cause an
increase in the spindle speed or acceleration of axis motion. If
abnormal speed detected, system controlled to brake to zero
speed, but no effective for above error. MCC off is not activated
until the delay time set by parameter has expired. Electrical
faults can also result in the response described above(component
failure too).
- 10 -
c) Faults in the absolute encoder can cause incorrect operation of

the safety machine position monitoring function.
d) With a 1-encoder system, encoder faults are detected in a single
channel, but by various HW and SE monitoring functions. The
parameter related to encoder must be set carefully. Depending on
the error type, a category 0 or category 1 stop function according
to EN60204-1 is activated.
e) The simultaneous failure of two power transistors in the inverter
may cause the axis to briefly(motion depend on number of pole
pairs of motor)
Example:
A 6-pole synchronous motor can cause the axis to move by
a maximum of 30 degrees. With a lead-screw that is directly
driven by, e.g.20mm per revolution, this corresponds to a
maximum linear motion of approximately 1.6mm.
f) When a limit value is violated, the speed may exceed the set
value briefly or the axis/spindle overshoot the setpoint position
to a greater or lesser degree during the period between error
detection and system reaction depending on the dynamic
response of the drive and the parameter settings(see Section
Safety-Functions)
g) The category 0 stop function according to EN60204-1 (defined
as STOP A in Safety Integrated) means that the spindles/axes are
not braked to zero speed, but coast to a stop (this may take a very
long time depending on the level of kinetic energy involved).
This must be noted, for example, when the protective door
locking mechanism is opened.
h) Drive power modules and motors must always be replaced by the
same equipment type or else the parameters will no longer match
the actual configuration and cause Dual check Safety to respond
incorrectly.
i) Dual check Safety is not capable of detecting errors in
parameterization and programming made by the machine
manufacturer. The required level of safety can only be assured
by thorough and careful acceptance.
j) There is a parameter that MCC off test is not to be made in the
self test mode at power-on as in the case of machine adjustment.
This parameter is protected, only changed by authorized person.
IF MCC off test is not conducted, MCC may not be off at stop
response is measured.
k) Safety machine position monitoring function does not apply to
rotation axis.
l) During machine adjustment, an exact motion may be executed
incorrectly untie the safety functions setup correctly and confirm
test is completely.
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1.4 GENERAL INFORMATION
The following requirements must be fulfilled for the Dual-Check

System:
• All conditions of the certification report has to be respected.
• The procedures for the changes in the System (either HW or
SW) should be referred to maintenance manual (B-63005).
When safety related components are exchanged, confirmation
test regarding safety functions can be performed accoding to
Chapter 8.
• Programming in ladder logic should be referred to programming
manual (B-61863E).
Training
FANUC Training Center provides versatile training course for the
person who is concerned with hardware installation, maintenance and
operation. FANUC recommend studying and learning in the training
center how efficiently operate FANUC products.
There are 3 CNC training course.
[CNC ELEMENTARY COURSE]

Provides basics of CNC functions, operation and programming. The
course is recommended before taking more specialized training
courses to gain best effects.
MAIN ITEMS OF TRAINING

• CNC functions
• Configuration of CNC
• Configuration and function of servo system
• Basic programming of CNC
• Part programming of milling machine
• Part programming of turning machine
• Introduction of Custom Macro function
[CNC MAINTENANCE COURSE]

To master maintenance technique that permits you to maintain and
inspect CNC, also how to restore it promptly if a trouble should
occur.

• Function and configuration of Power Unit
• Function and configuration of CNC system
• Include AC servo and AC spindle
• Self-diagnosis function
• Interface between CNC and the machine tools
• Data saving and restoring operation
• Trouble shooting
- 12 -
[CNC SE INTERFACE COURSE]

Training course offered to the engineers who design CNC machine
tools or CNC application system for the first time. This course is also
suitable for customers who provide to retrofitting, to develop an
original CNC machine tools or new application of CNC.

• Configuration of CNC system
• Interface between CNC and machine tools
• Ladder programming of machine control sequence
• Setting of parameter related to machine
• Setting of parameter related to servo and spindle
More information and course registration

Yamanakako-mura, Yamanashi Prefecture : 401-0501, JAPAN
Phone : 81-555-84-6030
Fax : 81-555-84-5540
Internet:
www.fanuc.co.jp/eschool
- 13 -
2.SYSTEM CONFIGURATION B-63494EN/01
2 SYSTEM CONFIGURATION
The dual check safety function has the following components.
Applicable CNC
FANUC Series 16i/18i/20i/21i/160is/180is/210is/160i/180i/210i
(LCD-mounted type)
FANUC Series 16i/18i/21i/160is/180is/210is/160i/180i/210i
(stand-alone type)
Number of controlled axes

- Series 20i/21i/210is/210i : 4 maximum
- Series 18i/180is/180i : 6 maximum
Number of spindle controlled axes

Amplifier
- α series servo amplifier
- α series spindle amplifier
- α series power supply module
- αi series servo amplifier
- αi series spindle amplifier
- αi series power supply module
Motor
- α series servo motor
- α series spindle motor
- β series servo motor
- αi series servo motor
- αi series spindle motor
I/O
- I/O unit (I/O Link)
- I/O module (FSSB)
Software
- Dual check software
- 14 -
B-63494EN/01 2.SYSTEM CONFIGURATION
Detector system
The detectors below can be used.
- Feed axis detector

- Servo motor built into α1000, αA64, αA32
- Separate detector (A/B phase pulse)
- αA16000i , αA1000i, αI1000i, αA64i
- βA64B, βA32B
- βΙ64B, βΙ32B
- Spindle detector
- M sensor
- MZ sensor
- BZ sensor
- Mi sensor
- MZi sensor
- BZi sensor
- 15 -
3.SAFETY FUNCTIONS B-63494EN/01
3 SAFETY FUNCTIONS
- 16 -
B-63494EN/01 3.SAFETY FUNCTIONS
3.1 APPLICATION RANGE
The dual check safety function assumes the following configuration:
A) One protective door is provided.

B) If the protective door is closed, safety is assured.
When the operator makes a request to open the protective door, the
safety functions are enabled, and the protective door can be unlocked.
While the protective door is open, the active safety functions assure
safety. When the request to open the protective door is canceled, the
protective door is locked, and the safety functions are disabled.
The dual check safety function provides these safety functions while
the protective door is open, as described above. Some of the safety
functions continue working while the protective door is closed.
WARNING
Each machine tool builder should take measures to
assure safety while the protective door is closed and
to ensure safety related to a rotation axis and travel
axis. At the same time, safety measures for the
FANUC servo motor or spindle motor need to be
taken, while the door is open.
The dual check safety function has the following safety functions:
Safe-related I/O signal monitoring

This function in redundant mode monitors I/O related to safety
(emergency stop, protective door lock/open/close state, power-down)
in redundant mode. The emergency stop, protective door
lock/open/close state, and power-down are checked in redundant
mode. If the two corresponding inputs do not match, the system
judges that an abnormal event has occurred. The power-down (MCC
off) signal is output in redundant mode (from two paths). Whether the
two-path output is normal is judged in a MCC off Test.
Safe speed monitoring

This function checks that the rotation speeds of the servo motor and
spindle motor are within a predetermined speed range, using two
CPUs in redundant mode. If a speed exceeding the range is detected,
the system judges that an abnormal event has occurred.
- 17 -
Safe machine position monitoring

This function checks that the position on a servo axis is within a
specified range, using two CPUs in redundant mode. If a position
exceeding the range is detected, the system judges that an abnormal
event has occurred.
If an abnormal event (safety error) is found, the dual check safety

function shuts off the power to the motor driving circuit, using the
two independent CPUs. The state in which the servo or spindle motor
stops because of power-down is referred to as the safe stop state. If a
safety error results in the safe stop state, the operator must turn off the
CNC, remove the cause of the error, then turn on the CNC again. The
user must conduct a MCC off Test every 24 hours in order to detect a
potential cause of error.
CAUTION
This safety function is enabled while the protective
door is open after a request to open the protective
door is made. If the request to open the protective
door is canceled and if the protective door is closed,
this safety function is disabled.
The dual input check of the safe-related I/O signal
monitoring function and the emergency stop function
are always active, regardless of whether the
protective door is opened or closed.
- 18 -
The safe speed of the

spindle motor is
checked by the CNC
CPU and spindle
CNC CPU in redundant
mode.
Dual monitoring of emergency stop
signal
Emergency
Spindle
stop CPU
CNC Cross-check
Spindle
Dual monitoring of protective door state CPU motor
SPM
Protective
door Protective door Safe speed monitoring
lock signal Servo motor
SVM
Door lock/
open/close
monitoring Cross-check
PSM Safe speed monitoring

Safe machine position
Monitor monitoring
CPU Dual monitoring of MCC
Power-
down
I/O, safe speed of the (MCC)
servo motor, and
machine position are Power-down
checked by the CNC
Dual monitoring of MCC
CPU and monitor
Dual power-down
CPU in redundant
mode. Detection of potential cause of error by
MCC off test
Safety functions
• Safe-related I/O signal monitoring
Emergency stop input, protective door lock/open/close state,
relay state for turning off the MCC
• Dual signal output
Output signal for shutting off the power (turning the MCC
off)To detect the potential cause of an abnormal state of this
output, a MCC off Test must be made.
• Spindle motor
• Servo motor
Safe machine position monitoring
- 19 -
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
n), the user must check that all safety parameters are correct and
that all safety functions are working normally. A return reference
position must be made on each axis. The user must also check
the absolute position of the machine. For details, see Chapter 8,
"START UP."
• If an absolute-position detector is used, and reference position

return has been performed once, reference position data is stored
in the CNC memory. In this case, the user need not make a
reference position check.
• If an incremental pulse coder is being used, reference position

data is lost each time the power to the CNC is turned off and
then back on. So, after the power is turned on, another reference
position return operation must be performed.
• At the every power on the safety area must be tested.
• At each power on there is a message: "Please execute safety test"

Without this message dual check safety is either not installed or
not yet activated (option bit).
3.2.2 MCC off Test of the Safe Stop Function
A MCC off Test of the safe stop function monitors the contact state of
the electromagnetic contactor (MCC), compares the state with a
command to the electromagnetic contactor, and checks that the safe
stop function works normally. The test must be carried out by the user
of the machine. This test must be carried out when the CNC is turned
on or when 24 hours have elapsed after the previous test is completed.
If the CNC is turned on or if 24 hours have elapsed after the previous
test is completed, a guard open request (protective door open request)
is not accepted until the test is performed.
- 20 -
3.3 STOP
3.3.1 Stopping the Spindle Motor
Because the spindle motor is an induction type motor, power-down

during rotation causes the motor to continue rotating for a certain
amount of time. From a safety standpoint, the motor may have to be
stopped immediately. If the CNC detects an error and judges that the
spindle can be controlled, it waits until the rotation of the spindle
stops, then shuts off the power. This wait period can be specified as a
safety parameter. For this safety parameter, two different values can
be specified. One value is used when the safety function is active (the
door is open), and the other value is used otherwise. The values must
be determined in consideration of the stop period calculated from the
spindle speed.
To implement the function, the CNC CPU and monitor CPU

individually incorporate a timer function. Normal operation of the two
CPUs are mutually checked to ensure the safety of the timers.
To speed down and stop the spindle, the PMC must input the spindle
emergency stop signals (*ESPA(G71.1), *ESPB(G75.1), and so on).
When this signal is input, the spindle slows down and stops. (A
Ladder program for inputting this signal in case of alarm must be
created.) The emergency stop input (connector CX4) of the PSM has
the same effect. If the emergency stop signal is connected to
emergency stop input (connector CX4) of the PSM, the spindle slows
down and stops in the emergency stop state.
If this processing is not performed, power-down causes the spindle

motor to continue rotating at the speed prior to power-down (and
eventually stopping in the end).
CAUTION
The CNC outputs a DO notifying of an alarm. If
necessary, the spindle should be stopped. Because
the DO output is not duplicated, this DO may not be
output when a single failure is detected. In that case,
the speed cannot be reduced, but the MCC is finally
shut off and brought into the safe stop state.
If a spindle amplifier alarm or any other state in
which the spindle motor cannot be controlled is
encountered, immediate power-down is carried out.
- 21 -
3.3.2 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. Additional
braking is provided by an internal resistor. Unlike an induction motor,
the servo motor does not coast because of this function.
If the input of the emergency stop signal or an error of a safe-related
signal or speed monitoring is detected, the CNC automatically
specifies a command to zero the speed and reduces the speed to zero
(controlled stop). After the motor slows down and stops, the power is
turned off, and the motor is brought into the dynamic brake stop state.
To slow down and stop the motor, some parameters must be specified
in the CNC. If those parameters are not specified, the motor is
immediately brought into the dynamic brake stop state. In some
circumstances where a controlled stop cannot be made, a dynamic
brake stop is unconditionally made.
3.3.3 Stop States
The following stop states are possible:
Safe stop state

The power to the motor is shut off (MCC off state). If the spindle
motor can be controlled, the power is shut off after the spindle motor
is slowed down to a stop. If the spindle motor cannot be controlled,
the power is immediately shut off.
If the servo motor can be controlled, the motor is slowed down to a

stop and then brought into the dynamic brake stop state. If the motor
cannot be controlled, the motor is immediately brought into the
dynamic brake stop state.
If the power is shut off immediately, the spindle motor continues at
the same speed prior to the abnormal event and eventually comes to a
stop. If the spindle motor can be slowed down to a stop, the operation
is performed as instructed by the PMC and then the power is shut off.
IMPORTANT
The time period until the signal for shutting off the
power (turning off the MCC) is output depends on
the parameter. Different parameters are used in the
safety monitoring state and in other states.
Safety parameter number Name
1947 MCC off timer 1 If the protective door
is closed
1948 MCC off timer 2 If the protective door
is opened
- 22 -
Controlled stop state

The power to the motor is not shut off.
The servo motor and the spindle motor are controlled to stop.
In the controlled stop state of either motor, the safety function is

active if the condition for enabling the safety function is satisfied (the
door is open). If a further abnormal event occurs, the motor is brought
into the safe stop state.
WARNING
1 The machine tool builder must design the machine
so that the machine is kept in the stop state if the
power to the servo motor driving circuit is shut off.
Example) Brake mechanism that would not drop the
vertical axis after the power is shut off
2 If the power to the spindle motor driving circuit is shut
off, the spindle motor continues rotating at the speed
before the power-down and eventually comes to a
stop. A measure must be taken so that this coasting
does not affect safety.
- 23 -
3.4 SAFE-RELATED I/O SIGNAL MONITORING
A set of safe-related I/O signals are connected to the I/O Link and the
servo FSSB through separate paths. The two independent CPUs
individually check the input signals. If a mismatch between two
corresponding signals is found, the system enters the safe stop state.
The following safe-related I/O signals are monitored or output in
redundant mode:
• Emergency stop input signal

• Protective door state input signal
• Lock state input signal
• Input signal for monitoring the MCC contact state
• Output signal for turning off the MCC (power-down)
To configure the two-path system, the machine tool builder must

connect these signals to both the I/O module and the FSSB I/O.
IMPORTANT
If the safety input signals, except for emergency stop
input signals, are connected to the I/O module, a
Ladder program must be created to establish a one-
to-one relationship between the actual input (X) and
the input to the CNC (G).
The duplicated input signals are always checked for a mismatch,

regardless of whether the safety function is active or not. When a
signal state changes, the pair of signals may not match for some
period because of a difference in response. The dual check safety
function checks whether a mismatch between the two signals
continues for a certain period of time, so that an error resulting from
the difference in response can be avoided. The check period must be
specified as a safety parameter.
Parameter No. Name

1945 Safe-related input signal check timer
The following signals are not defined as safe-related I/O signals and
are not duplicated. The signals, however, are necessary for the
system.
- Input signal for making a protective door open request

- Input signal for starting the test mode
- Output signal for specifying a command to lock the protective door
- Output signal for requesting a MCC off Test
This section briefly describes the signals. For details, see Chapter 5,
"OPERATION." For specific connections, see the sample system
configuration in Chapter 10.
- 24 -
CNC Machine
I/O UNIT
DI
I/O LINK
CNC
DO
CPU
Cross check
FSSB I/O
DI
FSSB
Monitor DO
CPU
Duplicated I/O
Symbol Signal name I/O address

*ESP Emergency stop signal <X008#4> <DI+000#0> Dual input monitoring
SGD Guard state signal <G191#4> <DI+001#4> Dual input monitoring
GDL Guard lock state signal <G191#5> <DI+001#5> Dual input monitoring
*SMC MCC contact state signal <G191#6> <DI+001#6> Dual input monitoring
MCF MCC on enable signal <F191#1> <DO+000#1> Duplicated output
ORQ Guard open request <G191#3> Input
signal
OPT Test mode signal <G191#2> Input
*LGD Guard unlock signal <F191#0> Output
RQT MCC off Test execution <F191#2> Output
request signal
Safe-related I/O
1. *ESP Emergency stop signal (input)

Emergency stop signal. The signal is monitored in redundant mode.
The signal is connected to the *ESP input of the servo amplifier as
well.
2. SGD Guard state signal (input)

The signal is provided for double monitoring of the protective door
state. The signal is connected so that it is normally set to 1 while the
protective door is closed and locked (door open) and set to 0
otherwise (door close). These states are implemented by the
combination of the safety door and safety relays. The CNC monitors
these states. If the safe speed range is exceeded in the door open state,
the system enters the safe stop state.
3. GDL Guard lock state signal (input)

This signal is not usually used.
- 25 -
4. *SMC MCC contact state signal (input)

The MCC contact state is monitored in redundant mode. In normal
operation, the MCC is active, and whether the contact of a relay is
closed cannot be detected. In the test mode, a closed contact of a relay
can be detected.
5. MCF MCC on enable signal (output)

With this signal, the MCC is shut off from both the I/O Link side and
the FSSB side.
Signals other than safe-related I/O

The following signals are not safe-related signals (are not checked in
redundant mode) but are important signals in the system. The machine
tool builder must create an appropriate Ladder program.
IMPORTANT
The Ladder program cannot be checked for an error.
Check the safety function (see Chapter 7).
6. ORQ Guard open request signal (input)

When this signal is input, the CNC checks the machine position and
speed. If both the machine position and speed are within the safe
range, the guard unlock signal (*LGD) is set to 1 (guard unlock
enabled). The machine tool builder must provide an output signal that
opens the actual protective door through the PMC. Connect the signal
output.
7. OPT Test mode signal (input)

When the signal is input, a MCC off Test is executed. The MCC off
Test checks whether the contact of the MCC is closed. When carrying
out the MCC off Test manually, execute a MCC off Test by the PMC
and make necessary corrections before inputting this signal.
8. *LGD Guard unlock signal (output)

If this signal is set to 1, the protective door can be unlocked. Then, a
signal to unlock the actual protective door should be output through
the PMC.
If the protective door is unlocked while the signal is set to 0, an alarm
occurs and brings the motor into the safe stop state.
CAUTION
When the signal is set to 1, there is a time delay
(depending on the Ladder program) before the signal
to unlock the actual protective door is output.
Meanwhile, the protective door is locked, and safety
is ensured. If an error is found as a result of speed
check or machine position check during that period,
*LGD becomes 0. If a single failure occurs in this
state and if the actual protective door is unlocked, an
alarm occurs.
- 26 -
When the safety function of the CNC is enabled, this signal is output.
If the signal is output, the signal to unlock the actual protective door
should be output through the PMC.
9. RQT MCC off Test execution request signal (output)

If the execution of a MCC off Test is required, this signal is output.
At power-on, this signal is output. If this signal is output, a MCC off
Test must be executed.
Guard open request signal and guard unlock signal

CNC (PMC)
Door open request
24V
X G Protective door
Ladder ORQ
ORQ-I
F Y
LGD Ladder
LGD-O
The figure shows a sample connection of the protective door open

request switch and the guard unlock signal. In the normal state, the
following state transition takes place before the safety monitoring
state is established.
State transition
ORQ-I ORQ *LGD *LGD-O
A 0 0 0 0 A protective door open request is not made, and the Normal operating
door is locked. state
B 1 0 0 0 A guard open request is made.
C 1 1 0 0 The request is transferred to the CNC.
D 1 1 1 0 A safe speed check and a machine position check
prove that there is no failure and that the CNC can
enter the safe state.
E 1 1 1 1 The actual safety door is unlocked. Safety function
Operations can be performed with the door open. enabled
D 1 1 1 0 The door is closed and locked again.
F 0 1 1 0 The guard open request is canceled.
G 0 0 1 0 The request is transferred to the CNC.
A 0 0 0 0 The CNC exits from the safe state.
IMPORTANT
If the CNC detects that the protective door is open
(SGD is set to 0) while ORQ is set to 0, the CNC
judges that an abnormal event has occurred and
enters the safe stop state. This can occur, for
instance, when the door happens to open (or to be
unlocked) while machining is in progress with the
protective door open
- 27 -
Timing diagram from door close state to door open state
The following diagram shows the timings at which the door is opened
and closed again.
ORQ_P
ORQ
*LGD
*LGD_P1
(Actual door unlock signal)
SGD_P
SGD2
Door closed Door closed

Actual door status Door opened
(1) (2) (3) (4) (5)
(1) When the guard open request signal (ORQ) is input, it checks
that the machine position and speed are within safe ranges. Then,
the guard unlock signal (*LGD) is turned on.
(2) When *LGD goes on, the Ladder program turns on the unlock
signal. This example assumes that the protective door has an
electromagnetic lock mechanism. While the door is open, the
unlock signal is turned off.
(3) The door is open.
(4) The protective door is closed and locked. After this, the guard
open request signal (ORQ) must be turned off.
CAUTION
Reserve a time of 100 ms or longer (t in the figure)
from when the door is closed (locked) until the guard
open request signal (ORQ) goes off. If this time
requirement is not satisfied, an alarm may be raised
when the door is closed (locked).
(5) When ORQ goes off, the CNC turns *LGD off.
- 28 -
3.5 EMERGENCY STOP
The emergency stop signal is monitored in redundant mode. When the

emergency stop is input, the servo motor slows down to a stop (*) and
enters the dynamic brake stop. The spindle slows down to a stop(*) as
instructed by the PMC, and the power is shut off.
CAUTION
To enable the function to slow down and stop the
servo motor, the corresponding parameter must be
specified. If the parameter is not specified, the motor
immediately enters the dynamic brake stop state.
The spindle motor slows down and stops as
instructed by the PMC (Ladder program). If the PMC
does not instruct this, the motor maintains the high
speed prior to the power-down and coasts. If an
illegal speed is specified because of a failure on the
PMC side while the safety function is active (the
protective door is open), the CNC enters the safe
stop state.
WARNING
In the emergency stop state, the guard unlock signal
becomes 1 (the door opens). In the emergency stop
state, the processing to open or close the protective
door depends on the Ladder program created by the
machine tool builder. For instance, if the protective
door should not be opened in the emergency stop
state, a Ladder program of the processing must be
created.
When the emergency stop is canceled, an alarm may occur, depending

on the state. For instance, if the emergency stop state is canceled with
the protective door open and if no door open request is made, the
CNC judges that an error has occurred and enters the safe stop state.
IMPORTANT
Emergency Stop Button must fulfil the Standard
IEC60947-5-1.
This is mandatory.
- 29 -
3.6 SAFE SPEED MONITORING
When the guard open request signal is input, the dual check safety
function starts monitoring whether a safe speed is kept on each feed
axis and spindle. If the speed does not exceed the safe speed range
and if the machine position is in within the safe range, the guard
unlock signal is enabled. If the safe speed range is exceeded while the
protective door is open, the dual check safety function immediately
enters the safe stop state. For each feed axis and spindle, a single safe
speed range is specified in a safety parameter.
CAUTION
If an illegal speed is detected, the MCC is shut off
after the time specified in the parameter.
IMPORTANT
1 The period from when an error is detected until the
MCC is shut off can be specified in a parameter. The
period is reserved to stop the spindle safely. A large
value means that a long time is needed to shut off the
MCC. In this parameter, different values can be
specified and used when the safety function is
enabled (the protective door is open) and disabled
(normal operation is performed). The value of the
parameter for the former case must be carefully
specified.
2 A gear ratio, ball screw, and the like must be carefully
selected so that a safe speed can be kept on the feed
axis.
3 Before inputting the guard open request signal,
reduce each axial speed and spindle speed to a safe
speed range or below. If a speed exceeds the limit,
the guard open request signal is not accepted (the
door is not unlocked). If the door is forced open, the
power to the driving circuit is shut off (safe stop state).
WARNING
The safe speed monitoring function monitors whether
the traveling speed exceeds a specified limit. The
function cannot monitor the stop state (zero speed).
If an error causes a movement on the feed axis at a
speed lower than the safe speed range while the
protective door is open, for instance, the function
cannot detect this state. The machine must be
designed so that this state does not affect the safety
of the machine system.
- 30 -
3.7 SAFE MACHINE POSITION MONITORING
While the door is open, the dual check safety function checks whether
the position on each feed axis is within the safe machine position
range defined by safety parameters. If it detects a machine position
beyond the safety range, the dual check safety function immediately
enters the safe stop state.
The user of the machine must first carry out a reference position
return in order to obtain the initial position. If the reference position
return is not carried out, the check function is disabled. This check
function is enabled after the reference position is established. (The
function cannot be disabled by any means after the reference position
is established.) A safe machine position limit on each feed axis is
specified in a safety parameter.
CAUTION
The safe machine position monitoring function does
not keep monitoring the specified range. Only after
the function detects that a position on a feed axis
exceeds the range, the system enters the safe stop
state. Accordingly, in the safe stop state, an
overtravel has occurred on the feed axis. The travel
distance depends on the traveling speed and other
conditions.
At power-on, the safety function does not work. After power-on, the
CNC checks whether a reference position return is completed. If the
reference position return is completed and if the protective door is
open, safe machine position monitoring and safe speed monitoring are
performed. Then, the safety functions start working. If the reference
position return is not completed, safe machine position monitoring
cannot be performed because the coordinates are not set. In this state,
the machine position monitoring function is disabled. After a
reference position return is made, this function is enabled. Depending
on the safety parameter setting, however, an alarm may be raised. To
avoid this alarm, specify the safe machine position parameters before
making a reference position return.
- 31 -
3.8 MCC OFF TEST
A MCC off Test must be carried out in intervals of 24 hours, so that

the safety functions would not be damaged by a possible cause of
failure. A message telling that the MCC off Test must be carried out
is displayed at power-on or when 24 hours have elapsed after the
previous MCC off Test. The protective door can be opened only after
the MCC off Test is carried out accordingly.
IMPORTANT
Carry out the MCC off Test with the protective door
closed. Because the test shuts off the MCC, prepare
the system for mechanical MCC shut-off before
starting the MCC off Test.
- 32 -
B-63494EN/01 4.INSTALLATION
4 INSTALLATION
Except FSSB I/O module, the hardware installation such as field
wiring, power supply, etc. should be referred to connection manual
(B-63003EN) for CNC units and (B-65162E) for servo amplifier.
EMC problem should be referred to EMC guideline manual (A-
72937/E).
Degree of IP protection:
Servo Motors: IP55
Spindle Motors: IP54 with oil-seal, IP40 without oil-seal
Servo and Spindle amplifiers: IP1x
CNC and other accessories: Ipxx
NOTE
Servo/Spindle amplifiers, CNC are to be installed in
IP54 protected cabinets.
The peripheral units and the control unit have been designed on the
assumption that they are housed in closed cabinets.
Environmental conditions for CNC units

Condition LCD–mounted Stand–alone LCD–mounted
type control type control type control
unit and display unit unit with PC
unit (except and data server
unit with data functions
server function)
Ambient Operating 0°C to 58°C 0°C to 55°C 5°C to 53°C
Temperature Storage –20°C to 60°C
of the unit Transport
Humidity Normal 75% RH or less, no condensation 10% to 75% RH,
no condensation
Short period(less 95% RH or less, no condensation 10% to 90% RH,
than 1 month) no condensation
Vibration Operating 0.5 G or less
Non–operating 1.0 G or less
Meters above Operating Up to 1000 m Up to 1000 m
sea level Non–operating Up to 12000 m Up to 12000 m
Environment Normal machine shop environment (The environment must be
considered if the cabinets are in a location where the density of dust,
coolant, and/or organic solvent is relatively high.)
- 33 -
4.INSTALLATION B-63494EN/01
Environmental conditions for servo amplifier
The servo amplifier α series must be installed in a sealed type cabinet

to satisfy the following environmental requirements:
(1) Ambient Temperature

Ambient temperature of the unit :
0 to 55°C (at operation)
-20 to 60°C (at keeping and transportation)
(2) Humidity
Normally 90% RH or below, and condensation-free
(3) Vibration
In operation : Below 0.5G
(4) Atmosphere
No corrosive or conductive mists or drops should deposit
directly on the electronic circuits.
- 34 -
4.1 OVERALL CONNECTION DIAGRAM
4.1.1 For One-path
Mother board
LCD display unit
24V-IN(CP1A) 24 VDC power

supply
24V-OUT(CP1B) To I/O device
MDI UNIT
Soft key cable
CK2
MDI(CA55) CK1
R232(JD36A) RS-232C I/O device
R232(JD36B) RS-232C I/O device

Touch panel
HDI(JA40) High-speed skip input
Distribution-type
I/O board Manual
pulse generator
24VDC CPD1 JA3
I/O-LINK(JD1A) JD1 Operator's

panel
JD1
I/O unit, etc.
24VDC CPD1
JD1 Power
magnetics
JD1 cabinet
- 35 -
Mother board
LCD display unit
SPDL(JA41) JA7B JY2

SPM
JA7A TB2
Spindle motor
Second spindle
FSSB(COP10A) COP10B TB2 Axis 1

SVM servo motor
COP10A JF1
COP10B TB2 Axis 2

SVM servo monitor
COP10A JF1
COP10B TB2 Axis 3

SVM servo motor
COP10A JF1
(This diagram assumes the use of a 1-axis amplifier.)
Separate detector interface unit
24VDC CP11A JF101
JF102 Linear scale axis 2

COP10B
JF103 Linear scale axis 3
COP10A
JF104
JA4A Battery for absolute

position detector
FSSB I/O
DC24V CP11A CB155A

Power
magnetics
COP10B CB156A cabinet
COP10A
SV-CHK(CA54) Servo check board
- 36 -
4.1.2 For Two-path
Main board I/O module for Machine

I/O Link (JD44A) operator’s panel operator’s
JD1B CE56 panel
JD1A CE57
I/O module for Power

connector panel magnetics
JD1B CB150 cabinet
JD1A
To next I/O unit Safe-related and other signals

SPDL (JA41)
PSM
CX1A CX3
FSSB (COP10A-1) CZ1 CX4 MCC
200VAC 2φ
200VAC 3φ Emergency
stop
TB1 CXA2A
TB1 CXA2B
SPM
JA7B JYA2
JA7A CZ2
Spindle motor
TB1 CXA2A
To next SPM (JA7B)
TB1 CXA2B
Axis control card SVM1

COP10B JF1
COP10A CZ2
Servo motor
To next SVM (COP10B)
- 37 -
From previous SVM (COP10A)
Separate detector
interface unit
COP10B JF101
COP10A JF102 Separate
JF103 detector
JF104 Separate
JA4A detector
Separate
detector
Separate
detector
Battery
Safe-related signals
FSSB I/O module Power

COP10B CB155 magnetics
COP10A CB156 cabinet
- 38 -
Sub CPU board
TB1 CXA2B
SPM
SPDL (JA41)
JA7B JYA2
JA7A CZ2
Spindle motor
TB1 CXA2A
To next SPM (JA7B)
TB1 CXA2B
Axis control card SVM1
FSSB (COP10A-1) COP10B JF1
COP10A CZ2
Servo motor
to next SVM (COP10B)
From previous SVM (COP10A)
Separate detector
interface unit
COP10B JF101 Separate detector
COP10A JF102 Separate detector
Separate detector
JF103
Separate detector
JF104
Battery
JA4A
Safe-related signals
FSSB I/O module Power

magnetics
COP10B CB155 cabinet
COP10A CB156
- 39 -
4.2 DI/DO CONNECTION (VIA THE PMC)
For DI/DO signals connected via the PMC, the I/O signals of the unit
connected to the FANUC I/O Link are to be input to or output from
the following addresses, via the PMC:
→CNC
PMC→ #7 #6 #5 #4 #3 #2 #1 #0
G008 *ESPG
→CNC
PMC→ #7 #6 #5 #4 #3 #2 #1 #0
G191 *SMC1 GDL1 SGD1 ORQ OPT
→PMC
CNC→ #7 #6 #5 #4 #3 #2 #1 #0
F191 RQT MCF1 *LGD
For the meaning of each of the above signals, see Chapter 6,

"OPERATION."
Hatted signals means dual monitoring.
- 40 -
4.3 DI/DO CONNECTION (VIA THE FSSB)
For DI/DO signals connected via the FSSB, the I/O signals are to be
directly connected to the I/O unit connected to the FSSB.
4.3.1 FSSB I/O Connection
Power supply connection
External power supply
CP11A 24 VDC stabilized

1 +24V power supply
2 0V 24 VDC±10%
3
Cable
CP11A
AMP Japan
1-178288-3 (Housing)
External power supply
1-175218-5 (Contact)
Select a one that matches

+24V(1)
the pins of the external
0V(2) power supply.
Recommended cable specification: A02B-0124-K830 (5 m)

An M3 crimp terminal is provided on the external
power supply side.
The 24 VDC power input to CP11A can be drawn from CP11B for
distribution. The connection to CP11B is the same as for CP11A.
- 41 -
DI/DO connection
Pin No.
Signal name
CB155A(A01)
+24V
CB155A(B01)
*ESP2 RV CB155A(A02)
RV CB155A(A07)
RV CB155A(B07)
RV CB155A(A08)
RV CB155A(B08)
SGD2 RV CB155A(A09)
GDL2 RV CB155A(B09)
SMC2 RV CB155A(A10)
Pin No.
DOCOM
CB155A(B06)
Signal name +24V 0V

+24V stabilized
power supply
CB155A(A11)
Relay
DV
MCF2 DV CB155A(B11)
Relay
CB155A(A17,B17)
For the meanings of the above signals, see Chapter 6,

"OPERATION."
- 42 -
4.3.2 FSSB I/O Attachment
External dimensions
CP11A
CP11B
Upper:CB156A
Lower:CB155A
COP10A COP10B
- 43 -
Screw attachment
Mounting hole
machining diagram
- 44 -
CAUTION
When attaching/detaching this unit, a screwdriver is inserted at an
angle. So, a sufficiently large working space must be provided on
the both sides of this unit.
As a guideline, if the front surface of an adjacent unit is flush with
or set back from the front surface of this unit, provide about 20 mm
between the adjacent unit and this unit. If the front surface of the
adjacent stands forward of the front surface of this unit, provide
about 70 mm between the adjacent unit and this unit.
When installing this unit near the side of the cabinet, provide
about 70 mm between this unit and the cabinet.
Working space around the I/O unit
- 45 -
Attachment to a DIN rail
Attachment
DIN rail
Detachment
DIN rail
Attachment
1. Hook the unit over the top of the DIN rail.
2. Press the unit down until it snaps into place.
Detachment
1. Pull down the lock section with a standard screwdriver.
2. Pull the lower part of the unit toward you.
CAUTION
When detaching the unit, be careful not to damage
the lock section by applying excessive force.
When attaching or detaching the unit, hold the
upper and lower parts of the unit, if possible, to
prevent force from being applied to the side (where
the cooling rents are provided) of the unit.
- 46 -
4.3.3 FSSB I/O Specification List
Installation conditions
Ambient temperature Operating 0°C to 55°C
of the unit Storage, transportation -20°C to 60°C
Temperature variation 1.1°C /minute maximum
Normally
Relative humidity 75% or less
Humidity
Short term (no more than one month)
Relative humidity 95% or less
Vibration Operating 0.5G or less
Normal machining plant environment (Check is
required if the unit is to be used in an
Atmosphere environment exposed to relatively high levels of
dust or coolant, or a relatively high concentration
of organic solvents.)
(1) Use the unit in a completely sealed cabinet.
(2) Install the unit on a vertical surface, and
Other conditions provide a space of 100 mm or more above
and below the unit. Do not install equipment
that dissipates much heat under this unit.
Power supply capacity

Power supply
Supply voltage Remarks
capacity
24V±10% is fed from the CP11A
connector of the basic module. Number of DI points
0.3A+7.3mAxDI
±10% includes momentary in DI = ON state
variations and ripples.
Input signal specifications

Contact capacity 30 VDC, 16 mA or more
Leakage current between
1 mA or less (when the voltage is 26.4 V)
open contacts
Voltage drop across closed 2 V or less (including a cable voltage
contacts decrease)
Receiver delay time: 2 ms (MAX)
Delay time In addition, the FSSB transfer period and
ladder scan period need to be considered.
Output signal specifications

Maximum load current at 200 mA or less including momentary
ON time variations
Saturation voltage at ON
1 V (MAX) when the load current is 200 mA
time
24 V +20% or less including momentary
Dielectric voltage
variations
Output leakage current at
20 µA or less
OFF time
Driver delay time: 50 µs(MAX)
Delay time In addition, the FSSB transfer period and
ladder scan period must be considered.
- 47 -
5.I/O SIGNALS B-63494EN/01
5 I/O SIGNALS
- 48 -
B-63494EN/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).
For input signals (safety input signals), two paths are used: one path
for input to the CNC via the PMC, and the other for input to the
monitor via the FSSB. The CNC and monitor exchange the safety
input signals with each other at all times to check each other. If a
mismatch is found between a safety input signal via one path and the
same signal via the other path, the signal is assumed to be 0. If such a
state lasts for the period set in a parameter or more, the CNC and
monitor independently detect an alarm. (Dual-check for safety input
signals)
For output signals (safety output signals), two paths are used: one
path for output from the CNC via the PMC, and the other for output
from the monitor via the FSSB. The MCC-on enable signal (MCF) is
output via these two paths. When both a signal via one path and the
same signal via the other path are 1, the signal is assumed to be 1. If
either is 0, the signal is assumed to be 0. That is, if the signal (MCF1)
via the PMC and the signal (MCF2) via the FSSB are both 1, the
MCC may be turned on. If either is 0, the MCC must be turned off.
In Subsection 5.2, a signal name is followed by its symbol and

addresses <via PMC> and <via FSSB>. Then, for an input signal, its
classification, function, and operation are described, in this order. For
an output signal, its classification, function, and output condition are
described in this order.
For information about the emergency stop mode, MCC off Test mode,
and safety signal modes A/B/C/D described in Subsection 5.2, see
Subsection 5.2.2.
- 49 -
5.2 SIGNALS
Emergency stop signal

*ESP1 <X008#4>(<X1000#7> for loader control), *ESPG <G008#4>,
*ESP2 <DI+000#0>
[Classification] Input signal
[Function] Stops machine movement immediately in an emergency.
[Operation] When emergency stop signal (*ESP) is set to 0, the CNC is reset, and
an emergency stop occurs. In general, emergency stop signal (*ESP)
is specified by the pushbutton switch B contact. When an emergency
stop occurs, the servo ready signal SA is set to 0.
When emergency stop signal (*ESP) is set to 0, the emergency stop
mode is set with the dual check safety function. In this mode, the
MCC contact state signal (*SMC) is checked. When *SMC = 0
(MCC-on state ), the guard unlock signal (*LGD) is set to 0 (to
disable guard unlocking). When *SMC = 1 (MCC-off state), the guard
unlock signal (*LGD) is set to 1 (to enable guard unlocking).
CAUTION
Emergency stop signals (*ESP) via the PMC
<X008#4> (<X1000#7> for loader control) and via
the FSSB <DI+000#0> are checked each other
(dual-check for safety input signals), but *ESP via
the PMC <G008#4> is not checked.
Test mode signal

OPT <G191#2>
[Function] This signal notifies the CNC that MCC off Test mode is set with the
dual check safety function.
Test mode signal (OPT) is not input via the FSSB.
[Operation] When test mode signal (OPT) is 1, the CNC performs safety output
signal MCC off Test processing. (MCC-on enable signals
(MCF1/MCF2) is output in various patterns, and a test is conducted to
see if an appropriate MCC contact state signals (*SMC1/*SMC2)
pattern is input, respectively.) In the emergency stop state or while a
servo or spindle alarm is present, the MCC off test processing is not
performed.
If a MCC off Test is not completed within the time set in parameter
No. 1946, servo alarm No. 488 is issued.
- 50 -
CAUTION
1 While the MCC off test processing is in progress, avoid bringing the test mode signal
(OPT) to 0.
2 If multi-path control is carried out, run an MCC off test on individual paths
independently.
3 If different paths under multi-path control share the MCC, avoid carrying out an MCC
off test on those paths simultaneously. Never run the MCC off test simultaneously on
tool posts 1 and 2 under one-CPU two-path control or on tool posts 2 and 3 under
two-CPU three-path control.
4 If the MCC off test processing is in progress on one of different paths sharing the
MCC under multi-path control, the remaining paths sharing the MCC should ignore a
VRDY OFF alarm by using the following: all-axis VRDY OFF alarm ignore signal
(IGNVRY <066#0>) or axial VRDY OFF alarm ignore signals (IGNVRY1 to IGNVRY8
<G192>).
5 MCF2 via the FSSB under one-CPU two-path control is tested by the MCC off test on
tool post 1 and is not tested by the MCC off test on tool post 2. MCF2 via the FSSB
connected to tool posts 2 and 3 under two-CPU three-path control is tested by the
MCC off test on tool post 2 and is not tested by the MCC off test on tool post 3.
WARNING
While the MCC off test processing is in progress, the MCC-on enable signal (MCF)
goes high and low to turn on and off the MCC. Carry out the MCC off test in such a
state that the turning on or off of the MCC will not cause a problem.
Test No. 1 2 3 4 5
MCF1 (PMC)
MCF2 (FSSB)
*SMC1 (PMC)
*SMC2 (FSSB)
Timer limit
Timer
Test start Test completion
Example 1) Timing chart 1 of MCC off test (normal state)
Test No. 1 2 3 4
MCF1 (PMC)
MCF2 (FSSB)
*SMC1 (PMC)
*SMC2 (FSSB)
Timer limit
Alarm !!
Timer
Test start
Example 2) Timing chart 2 of MCC off test (abnormal state)
- 51 -
Guard open request signal

ORQ <G191#3>
[Function] This signal requests the CNC to unlock the guard with the dual check
safety function.
Guard open request signal (ORQ) is not input via the FSSB.
[Operation] When the guard open request signal (ORQ) is 1, the CNC, monitor
and spindle software make a machine position check and safe speed
check. If the results of the checks assure safety, guard unlock signal
(*LGD) is set to 1 (to enable guard unlocking).
When guard open request signal (ORQ) is 0, the CNC and monitor set
guard unlock signal (*LGD) to 0 (to disable guard unlocking). (In
emergency stop state, however, the guard unlock signal (*LGD) is set
to 1.)
See Subsection 5.4.
Guard state signal

SGD1 <G191#4>, SGD2 <DI+001#4>
[Function] This signal posts the guard open/closed state to the CNC and monitor
with the dual check safety function.
0: Guard open state
1: Guard closed state
[Operation] This input signal is used together with safety input signals such as
guard open request signal (ORQ) to determine a safety signal mode
that specifies the operation of the CNC, monitor, and spindle software.
For details, see Subsection 5.4.
Input this signal according to the guard state.
IMPORTANT
Interlock switch must fulfil the Standard IEC60947-5-
1. This is mandatory.
Guard lock state signal

GDL1 <G191#5>, GDL2 <DI+001#5>
[Function] This signal posts the guard lock state to the CNC and monitor with the
0: Guard unlocked state
1: Guard locked state
[Operation] This signal is usually not used, but please input same signal (GDL1)
both via PMC and via FSSB all time because dual-check for guard
lock state signal (GDL2) is executed by CNC and monitor.
- 52 -
MCC contact state signal

*SMC1 <G191#6>, *SMC2 <DI+001#6>
[Function] This signal posts the MCC state to the CNC and monitor with the dual
check safety function.
0: MCC-on state
1: MCC-off state
[Operation] When the MCC contact state signals (*SMC1 and *SMC2) are 1 in
the emergency stop state, the CNC sets the guard unlock signal
(*LGD) to 1 (to enable guard unlocking).
The MCC contact state signals (*SMC1/*SMC2) is used to check if
the MCC-on enable signals (MCF1/MCF2) operates normally in
MCC off Test mode.
Input this signal according to the MCC state.
Guard unlock signal

*LGD <F191#0>
[Classification] Output signal
[Function] This signal notifies that guard unlocking is enabled with the dual
When guard unlock signal (*LGD) is 0, the guard is locked. When
*LGD is 1, the guard is unlocked.
Guard unlock signal (*LGD) is not output via the FSSB.
[Output condition] In the following cases, this signal is set to 1 (to enable guard
unlocking):
• When emergency stop state is set, and MCC contact state signals
(*SMC1 and *SMC2) are 1 (MCC-off state)
• When guard open request signal (ORQ) is 1, the servo and
spindle motors rotate within the safe speeds, the machine is
positioned within the safety area, and MCC off Test execution
request signal (RQT) is 0
In cases other than the above, this signal is set to 0 (to disable guard
unlocking).
MCC-on enable signal

MCF1 <F191#1>,MCF2 <DO+000#1>
[Function] This signal posts notification that the MCC can be turned on with the
When either of the MCC on-enable signals (MCF1 and MCF2) is 0,
the MCC is turned on. When both MCF1 and MCF2 are 1, the MCC
is tuned on.
[Output condition] In the following cases, this signal is set to 0 (to prevent the MCC from
being turned on):
• When a safety-related alarm is issued
• When the emergency stop state is issued
In cases other than above, this signal is state to 1 (to enable the MCC
to be turned on).
- 53 -
MCC off Test execution request signal

RQT <F191#2>
[Function] This signal requests that MCC off Test mode be set, and a check is
made to determine whether the safety output signals (MCC-on enable
signal (MCF)) operate normally. When MCC off Test execution
request signal (RQT) is set to 1, set MCC off Test mode and conduct
a safety output signal MCC off Test as soon as possible.
When MCC off Test execution request signal (RQT) is 1, guard
unlock signal (*LGD) is set to 0 to disable guard unlocking even if
safety signal mode B (state in which a guard open request is input,
and the guard is closed) is set and the conditions including speed are
satisfied.
When safety signal mode C (state where a guard open request is input,
and the guard is open) is set, and MCC off Test execution request
signal (RQT) is set to 1, guard unlock signal (*LGD) is 0 to disable
guard unlocking until MCC off Test execution request signal (RQT)
is set to 0 after the guard is closed once.
When MCC off Test execution request signal (RQT) is 1, the warning
"PLEASE EXECUTE SAFE TEST" is displayed on a screen such as
a parameter screen. (On some screens, no warning is displayed.)
MCC off Test execution request signal (RQT) is not output via the
FSSB.
[Output condition] In the following cases, this signal is set to 1:
• A MCC off Test is not completed after power-on (when bit 3 of
parameter No. 1902 is 0).
• Twenty-four hours have elapsed since the completion of the last
MCC off Test.
CAUTION
1 If the current date and time lags behind the date and
time of the previously completed MCC off Test due
to a clock change or the like, it is assumed that 24
hours have elapsed since the previous MCC off Test.
2 From February 28 to March 1, the elapse of 24 hours
may be assumed even if 24 hours has not elapsed
after the completion of the previous MCC off Test.
3 MCC must have forced guided contacts and must
fulfil the Standard IEC60204 and the standard IEC
255.This is mandatory.
In the following case, this signal is set to 0:

• A MCC off Test is completed.
- 54 -
5.3 SIGNAL ADDRESSES
Via the PMC

#7 #6 #5 #4 #3 #2 #1 #0
X008 *ESP1
(For loader control) #7 #6 #5 #4 #3 #2 #1 #0

X1000 *ESP1
#7 #6 #5 #4 #3 #2 #1 #0
G008 *ESPG
#7 #6 #5 #4 #3 #2 #1 #0
G191 *SMC1 GDL1 SGD1 ORQ OPT
#7 #6 #5 #4 #3 #2 #1 #0
F191 RQT MCF1 *LGD
Via the FSSB

#7 #6 #5 #4 #3 #2 #1 #0
DI+0000 *ESP2
#7 #6 #5 #4 #3 #2 #1 #0
DI+001 *SMC2 GDL2 SGD2
#7 #6 #5 #4 #3 #2 #1 #0
DO+000 *BRK MCF2
CAUTION
1 The signals of shaded boxes are duplexed.
2 Emergency stop signals (*ESP) via the PMC
<X008#4> (<X1000#7> for loader control) and via
the FSSB <DI+000#0> are checked each other
(dual-check for safety input signals), but *ESP via
the PMC <G008#4> is not checked.
3 *ESP1 (<X008#4> or <X1000#7> for loader control)
is directly checked by the CNC. All signals via the
FSSB are directly processed by the monitor CPU.
None of the signals is processed by the PMC.
- 55 -
5.4 SAFETY SIGNAL MODES
Depending on the safety input signal state, the CNC, monitor, and
spindle software internally have one of the six modes (safety signal
modes) indicated in the table below.
Safety signal mode Safety signal state Machine state

Emergency stop mode *ESP = 0 Emergency stop state
MCC off Test mode OPT = 1 State for conducting a MCC off Test
Safety signal mode A ORQ = 0, and SGD = 1 Normal operation state
Safety signal mode B ORQ = 1, and SGD = 1 State in which a guard open request
is input, and the guard is closed
Safety signal mode C ORQ = 1, and SGD = 0 State in which a guard open request
is input, and the guard is open
Safety signal mode D ORQ = 0, and SGD = 0 Abnormal state (state in which the
guard is open although no guard
open request is input.)
In general, safety signal mode transitions are made as described

below.
Usually, safety signal mode A is set. In safety signal mode A, guard
unlock signal (*LGD) is 0, and the guard is locked.
When an emergency stop is required, emergency stop mode is set. In
emergency stop mode, the MCC contact state signal (*SMC) is
checked. When *SMC = 0 (MCC-on state), guard unlock signal
(*LGD) is set to 0 (to disable guard unlocking). When *SMC = 1
(MCC-off state), guard unlock signal (*LGD) is set to 1 (to enable
guard unlocking).
When a MCC off Test is to be conducted, MCC off Test mode is set.
In MCC off Test mode, safety output signal MCC off Test processing
is performed. (MCC-on enable signal (MCF) are output in various
patterns, and a test is conducted to determine whether appropriate
MCC contact state signal (*SMC) patterns are input respectively.)
When the guard is to be opened, safety signal mode B is set. In safety
signal mode B, the CNC, monitor, and spindle software check the
machine position and the speed on each axis. If safety is assured,
guard unlock signal (*LGD) is set to 1 to enable the guard to be
opened.
When the guard is opended in safety signal mode B after guard unlock
signal (*LGD) is set to 1, safety signal mode C is set. In safety signal
mode C, the CNC, monitor, and spindle software check the machine
position and the speed on each axis. If an abnormality is detected, an
alarm is issued, MCC-on enable signal (MCF) is set to 0, and the
MCC is turned off.
Safety signal mode D represents an abnormal state in which the guard
is open although no guard open request is made. In safety signal mode
D, an alarm is issued, the MCC-on enable signal (MCF) is set to 0,
and the MCC is turned off.
- 56 -
5.5 NOTES ON MULTI-PATH CONTROL
This section describes cautions about safe-related I/O signals that

should be taken in multi-path control.
5.5.1 Two-CPU Two-Path Control (Without Axis Change between

Paths)
If there is no axis change between paths under two-CPU two-path

control, a single independent group of safety areas can be provided
for each path (two groups of safety areas in total). Two FSSB I/O
units, that is one unit for each path, are required. (The two FSSB I/O
units are required even if just one group of safety areas is provided.)
Two groups of safety input signals are cross-checked. The first group
consists of a safety signal input to tool post 1 (DI1C: X008#4, G191 in
the figure below) and a safety signal input to the FSSB I/O unit
connected to tool post 1 (DI1M). The second group consists of a safety
signal input to tool post 2 (DI2C: X008#4, G1191) and a safety signal
input to the FSSB I/O unit connected to tool post 2 (DI2M).
Safety output signals should be provided to the safety areas, as
follows: Provide a safety signal output from tool post 1 (DO1C: F191)
and a safety signal output from the FSSB I/O unit connected to tool
post 1 (DO1M) to the safety area of tool post 1; Provide a safety signal
output from tool post 2 (DO2C: F1191) and a safety signal output from
the FSSB I/O unit connected to tool post 2 (DO2M) to the safety area
of tool post 2.
MAIN BOARD SUB BOARD
Path 1 Path 2
cross- cross-
DO1C check DO1M DO2C check DO2M
CNC Monitor CNC Monitor
DI1C
CPU CPU DI1M DI2C
CPU CPU DI2M
Safety
Safetyarea
area11 Safety
Safetyarea
area22
Guard
Guard Guard
Guard
MCC
MCC MCC
MCC
and
andsosoonon and
andsosoonon
- 57 -
5.5.2 Two-CPU Two-Path Control (With Axis Change between

Paths)
If there is an axis change between paths under two-CPU two-path

control, a single group of safety areas can be provided. Two FSSB I/O
units, that is one unit for each path, are required. (The two FSSB I/O
units are required although just one group of safety areas is provided.)
consists of a safety signal input to tool post 1 (DI1C: X008#4, G191)
and a safety signal input to the FSSB I/O unit connected to tool post 1
(DI1M). The second group consists of a safety signal input to tool post
2 (DI2C: X008#4, G1191) and a safety signal input to the FSSB I/O
unit connected to tool post 2 (DI2M). Because just one group of safety
areas is provided, these four safety input signals (DI1C, DI1M, DI2C,
and DI2M) should be equal.
Safety output signals should be provided to the single group of safety
areas, as follows: Provide a safety signal output from tool post 1
(DO1C: F191), safety signal output from tool post 2 (DO2C: F1191),
safety signal output from the FSSB I/O unit connected to tool post 1
(DO1M), and safety signal output from the FSSB I/O unit connected to
tool post 2 (DO2M) to the single group of safety areas.
Path 1 Path 2
cross- cross-
DO1C check DO1M DO2C check DO2M
DI1C
CPU CPU DI1M DI2C
CPU CPU DI2M
Safety
Safetyarea
area
Guard
Guard
MCC
MCC
and
andsosoonon
- 58 -
5.5.3 One-CPU Two-Path Control
A single group of safety areas can be provided under one-CPU two-

path control. A single FSSB I/O unit is required.
and a safety signal input to the FSSB I/O unit (DIM). The second
group consists of a safety signal input to tool post 2 (DI2C: X008#4,
G1191) and a safety signal input to the FSSB I/O unit (DIM). Because
just a single group of safety areas is provided, these three safety input
signals (DI1C, DI2C, and DIM) should be equal.
The following three safety output signals should be provided to the
single group of safety areas: safety signal output from tool post 1
(DO1C: F191), safety signal output from tool post 2 (DO2C: F1191),
and safety signal output from the FSSB I/O unit (DOM).
MAIN BOARD
DO1C Path 1
DI1C DOM
CNC cross- Monitor
check
DO2C CPU CPU DIM
Path 2
DI2C
Safety
Safetyarea
area
Guard
Guard
MCC
MCC
and
andsosoonon
- 59 -
5.5.4 Two-CPU Three-Path Control
Under two-CPU three-path control, two groups of safety areas can be

provided: one group for tool post 1 and the other group for tool posts
2 and 3. Two FSSB I/O units are required: one unit for tool post 1 and
the other unit for tool posts 2 and 3. (The two FSSB I/O units are
required although just a single group of safety areas is provided.)
Three groups of safety input signals are cross-checked. The first

group consists of a safety signal input to tool post 1 (DI1C: X008#4,
G191) and a safety signal input to the FSSB I/O unit connected to tool
post 1 (DI1M). The second group consists of a safety signal input to
tool post 2 (DI2C: X008#4, G1192) and a safety signal input to the
FSSB I/O unit connected to tool posts 2 and 3 (DI2M). The third group
and a safety signal input to the FSSB I/O unit connected to tool posts
2 and 3 (DI2M). Because the second and third groups share the same
safety area, the three safety input signals (DI2C, DI3C, and DI2M)
should be equal.
Safety output signals should be provided to the safety areas, as

follows: Provide a safety signal output from tool post 1 (DO1C: F191)
and a safety signal output from the FSSB I/O unit connected to tool
post 1 (DO1M) to the safety area of tool post 1. Provide a safety signal
output from tool post 2 (DO2C: F1191), safety signal output from tool
post 3 (DO3C: F2191), and safety signal output from the FSSB I/O
unit connected to tool posts 2 and 3 (DO2M) to the single group of
safety areas of tool posts 2 and 3.
Path 1 DO2C Path 2

cross-
DO1C check DO1M DI2C DO2M
CNC Monitor CNC cross- Monitor
check
DI1C
CPU CPU DI1M
DO3C CPU CPU DI2M
Path 3
DI3C
Safety
Safetyarea
area11 Safety
Safetyarea
area22
Guard
Guard Guard
Guard
MCC
MCC MCC
MCC
and
andsosoonon and
andsosoonon
- 60 -
5.5.5 Loader Control
A single group of safety areas can be provided for loader control,

independently of that for the machine controlled with the main CPU
board and sub-CPU board. Besides the FSSB unit for the machine, a
single FSSB unit is required for the loader. (Even if the machine and
loader share a single safety area, the single FSSB I/O unit for the
loader is required.)
The following safety input signals are cross-checked by the loader: a
safety signal input to the loader (DILC: X1000#7, G191) and a safety
signal input to the FSSB I/O unit connected to the loader (DILM).
Provide the following safety output signals to the safety area of the
loader: a safety signal output from the loader (DOLC: F191) and a
safety signal output from the FSSB I/O unit connected to the loader
(DOLM).
MAIN BOARD LOADER BOARD
cross- cross-
DO1C check DO1M DOLC check DOLM
DI1C
CPU CPU DI1M DILC
CPU CPU DILM
Safety
Safetyarea
area11 Safety
Safetyarea
area22
Guard
Guard Guard
Guard
MCC
MCC MCC
MCC
and
andsosoonon and
andsosoonon
- 61 -
6.PARAMETERS B-63494EN/01
6 PARAMETERS
- 62 -
B-63494EN/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, monitor, and spindle software check the matching of the
parameters stored at the two locations. If a mismatch is found, an
alarm is issued.
If the setting of a safety parameter is modified, the power must be

turned off then back on. The new setting of the parameter becomes
effective after the power is turned back on.
For information about emergency stop mode, MCC off Test mode,
and safety signal modes A/B/C/D described in this section, see
Chapter 5.
Section 6.3 describes the parameters related to the use of the FSSB
I/O unit.
Section 6.4 describes the functions that require special parameter

settings.
- 63 -
6.2 PARAMETERS
1023 Servo axis number for each axis
[Data type] Byte axis

[Valid data range] 1, 2, 3, ..., number of controlled axes
Set which servo axis corresponds to each controlled axis. Usually, set
the same value for a controlled axis number and servo axis number.
A controlled axis number represents an array number for an axis type
parameter or axis type machine signal.
For details of the setting, refer to the description of FSSB setting in
the connection manual (function part).
CAUTION
To use the dual check safety function, the first servo
axis is required. To use the dual check safety
function under multi-path control, the first servo axis
cannot be changed between paths. Specific
requirements are as follows.
For one-path control, one-CPU two-path control,
and loader control:
Tool post 1 (or loader) must have an axis for
which parameter No.1023 is set to 1.
For two-CPU two-path control and two-CPU three-
path control:
Tool post 1 must have an axis for which
parameter No.1023 is set to 1, and tool post 2
must have an axis for which parameter No.1023
is set to 9.
1829 Positional deviation limit during a stop for each axis
[Data type] Word axis

[Unit of data] Detection unit
[Valid data range] 0 to 32767
Set a positional deviation limit for each axis at stop time.
If a positional deviation limit during a stop is exceeded at stop time, a
servo alarm No.410 is issued, and an immediate stop (same as an
emergency stop) is performed.
In the dual check safety function, the CNC and monitor always check
the position deviation amount on each axis. If the monitor detects that
the position deviation limit is exceeded during a stop, a servo alarm
No.474 is issued only in safety signal mode C (state in which a guard
open request is input and the guard is open).
- 64 -
1838 Positional deviation limit during movement for each axis in safety signal mode C
[Data type] 2-word axis

[Unit of data] Detection unit
Set a positional deviation limit during movement for each axis in
safety signal mode C (state in which a guard open request is input,
and the guard is opened) when the dual check safety function is used.
If a positional deviation limit during movement is exceeded during
movement, a servo alarm No.411 is issued, and an immediate stop
(same as an emergency stop) is performed.
In the dual check safety function, the CNC and monitor always check
the position deviation amount on each axis. If the monitor detects that
the position deviation limit is exceeded during moving, a servo alarm
No.475 is issued only in safety signal mode C (state in which a guard
open request is input and the guard is open).
When the guard is open, axis movement is performed at a speed not
exceeding the safe speed. So, usually, set a value smaller than a
positional deviation limit during movement (parameter No. 1828).
#7 #6 #5 #4 #3 #2 #1 #0
1902 0 DCE 0 STP
[Data type] Bit

STP When the power is turned on, a MCC off test is:
0: Conducted. (The warning "PLEASE EXECUTE MCC OFF
TEST" is displayed at power-on, and MCC off Test execution
request signal (RQT) is output.)
1: Not conducted.
CAUTION
1 The STP parameter is used temporarily, for
example, when a MCC off Test is not to be made at
power-on as in the case of machine adjustment.
Usually, set STP = 0.
2 Even when STP = 1, a MCC off Test is required if the
power is turned 24 hours or more after the
completion of the previous MCC off Test.
WARNING
Set STP = 0 after the STP parameter is used
temporarily as in the case of machine adjustment.
DCE The dual check safety function is:

0: Disabled.
1: Enabled.
- 65 -
CAUTION
Usually set the DCE = 1 in the dual check safety
function. The system cannot start-up because MCC-
on enable signal (MCF) = 0 when the DCE = 0.
WARNING
Always set bits 5 and 7 of parameter No.1902 to 0. If
one of these bits is set "1", the safety functions may
be executed incorrectly.
#7 #6 #5 #4 #3 #2 #1 #0
1904 DCN
[Data type] Bit axis

DCN The checks of the target axis by the dual check safety function are:
0: Made.
1: Not made.
CAUTION
1 The DCN bit cannot disable the checks by the dual
check safety function for all the controlled axes.
2 Set the DCN bit to 1 for the slave axis under tandem
control or for the tool axis of a simple electronic gear
box or electronic gear box 2-pair.
WARNING
The checks by the dual check safety function are not
made on an axis for which the DCN bit is set to 1. Set
the DCN bit to 0 for normal axes.
1942 Safety speed for each axis

[Unit of data]
[Valid data range]
Increment Valid data range
Unit of data
system IS-A, IS-B IS-C
Millimeter machine 1 mm/min 0 to 240000 0 to 100000
Inch machine 0.1 inch/min 0 to 96000 0 to 48000
Rotation axis 1 deg/min 0 to 240000 0 to 100000
Set a safe speed for each axis.

The CNC and monitor always check the velocity command of each
axis in the dual check safety function. If the safe speed is exceeded on
one axis at least, the guard unlock signal (*LGD) is brought to 0, to
disable guard unlocking. The state in which the safe speed is not
exceeded on any axis is one condition for setting the guard unlock
signal (*LGD) to 1 (to enable guard unlocking).
- 66 -
If the safe speed is exceeded in safety signal mode C (state in which a

guard open request is input and the guard is open), a servo alarm
No.476 or No.494 is issued for the corresponding axis.
CAUTION
The checks are made on the basis of the speed
converted to the detection unit. Accordingly, a
calculation error may occur.
1943 Safe machine position of each axis (+ direction)
1944 Safe machine position of each axis (- direction)

[Unit of data]
Increment system IS-A IS-B IS-C Unit
Millimeter machine 0.01 0.001 0.0001 mm
Inch machine 0.001 0.0001 0.00001 inch
[Valid data range] -99999999 to 99999999

Set a safe machine position for each axis.
The CNC and monitor always check the machine position on each
linear axis in the dual check safety function.
In safety signal mode B (state in which a guard open request is input,
and the guard is closed), if there is at least one linear axis whose
machine position is not in the safe machine position (safe machine
position (- direction) ≤ machine position ≤ safe machine position (+
direction)), the guard unlock signal (*LGD) is set to 0 to disable
guard unlocking. The state in which the machine positions of all
linear axes are within the safe machine positions is one condition for
setting the guard unlock signal (*LGD) to 1 (to enable guard
unlocking). If the machine position on a linear axis exceeds the safe
machine position in safety signal mode C (state in which a guard open
request is input and the guard is open), a servo alarm No.477 or
No.495 is issued.
CAUTION
The checks are made on the basis of the machine
position to the detection unit. Accordingly, a
calculation error may occur.
WARNING
1 CNC and monitor check the machine position of
each linear axis, and not check it of each rotation
axis.
2 CNC and monitor check the machine position of only
each axis whose reference position is established,
and not check it of each axis whose reference
position is not established.
- 67 -
1945 Safety input signal check timer
[Data type] Word

[Unit of data] ms
For input signals related to the dual check safety function (safety
input signals), two paths are used: one path for input to the CNC via
the PMC, and the other for input to the monitor via the FSSB. The
CNC and monitor exchange the input signals with each other at all
times to check each other. If a mismatch greater than the time set in
this parameter is detected between an input signal via one path and
the same signal via the other path, a servo alarm No.479 or No.486 is
issued. If a value of less than 16 is specified, a specification of 16 ms
is assumed.
CAUTION
Set identical values in parameters No.1945 for the
following: two tool posts under two-CPU two-path
control with axis change between paths, two tool
posts under one-CPU two-path control, or tool posts
2 and 3 under two-CPU three-path control.
1946 MCC off Test timer
[Data type] Word

[Unit of data] ms
When MCC off Test mode is set with the dual check safety function,
the CNC conducts a safety output signal MCC off Test. If a MCC off
Test is not completed within the time set in this parameter, a servo
alarm No.488 is issued.
If a value of less than 0 is specified, a specification of 10000 ms is
assumed.
1947 MCC-off timer 1
1948 MCC-off timer 2
[Data type] Word

[Unit of data] ms
When the MCC-on enable signal (MCF) needs to be set to 0 (MCC
off) with the dual check safety function for a cause such as an alarm
or emergency stop, the CNC and monitor set MCC-on enable signal
(MCF) to 0 when an MCC-off timer value has elapsed after the alarm
or emergency stop state.
If a spindle alarm is issued, however, the timers are not used. Instead,
MCC-on enable signal (MCF) is set to 0 immediately.
If the MCC is cut off while the spindle motor is rotating, the spindle
motor will continue to rotate (free-run) and stop after time. When the
- 68 -
spindle motor should stop as quickly as possible, please use these

parameters and control the spindle motor to stop, and after that cut
MCC off.
State Timer used

When a spindle alarm is issued No timer is used.
When the guard is closed MCC-off timer 1 (No. 1947)
When the guard is open MCC-off timer 2 (No. 1948)
CAUTION
2 and 3 under two-CPU three-path control. Set
identical values in parameters No.1948 likewise.
1950 Brake signal timer
[Data type] Word

[Unit of data] ms
Set a time period from when the monitor in the dual check safety
function detects that the MCC contact state signal (*SMC2) is 0
(MCC on state) until the brake release signal (*BRK) goes 1 (brake
release enabled). If a value less than 0 is specified, 2500 ms is
assumed. Usually, specify 0.
CAUTION
2 and 3 under two-CPU three-path control.
#7 #6 #5 #4 #3 #2 #1 #0
1959 0 0 0 0 0 0 0 0
[Data type] Bit

set all bits to 0.
WARNING
Always set all bits of parameter No.1959 to 0.
If 1 is set, a safety function is not worked normally.
- 69 -
2078 Monitor conversion factor (numerator) of each axis
2079 Monitor conversion factor (denominator) of each axis
[Data type] Word axis

Set the following values.
No.2078/No.2079 =
Lowest possible terms of the feedback pulse count of built-in pulse
coder per motor revolution over one million
CAUTION
1 The monitor in the dual check safety function takes in
the feedback of the built-in pulse coder. Even if a
separate position detector is used, set parameters
No.2078 and No.2079 to the values calculated on the
basis of the feedback pulse count of the built-in pulse
coder.
2 Changing parameter No.2078 or No.2079 will not cause
a P/S000 alarm (PLEASE TURN OFF POWER).
However, when making this change, turn off the power.
The changed parameter value takes effect after the
power is turned on again.
3 Parameters No.2078 and No.2079 are cleared if the
standard servo parameter setting (turning on or off the
power when the DGPR bit (bit 1 of parameter No.2000)
is set to 0) is selected. After making the standard servo
parameter setting, set parameters No.2078 and
No.2079 again.
4 Set both parameters No.2078 and No.2079 to 0 for the
slave axis under tandem control.
5 Parameters No.2078 and No.2079 are used also for the
dual position feedback function.
3225 Code for safety parameters
[Data type] 2-word

Set a code (password) for protecting against modifications to
parameters related to the dual check safety function (safety
parameters). When a code for safety parameters is set, the parameters
are locked. At this time, the setting (code) is not displayed but is
blank, and safety parameter input is disabled. If an attempt is made to
input data in a locked safety parameter, the result indicated in the
table below is produced, depending on the method of input. No
attempt is successful.
Input method Result
MDI input Warning "WRITE PROTECT"
G10 (programmable parameter input) P/S231 FORMAT ERROR IN G10 L50
Input via the reader/puncher interface No alarm is issued, but parameter
input is disabled.
- 70 -
Input through a window Completion code 7 (write protect)
A code for safety parameters can be set when the safety parameters
are not locked, that is, when the code for safety parameters is 0, or
when the code for safety parameters is the same as the key for safety
parameters (No. 3226).
The following safety parameters are protected by a code for safety
parameters:
No.1023, No.1829, No.1838, No.1902#3, No.1902#5, No.1902 #6,
No.1904#0, No.1904#1, No.1904#2, No.1904#3, No.1904#4,
No.1904#5, No1904#6, No.1942, No.1943, No.1944, No.1945,
No.1946, No.1947, No.1948, No.1950, No.1959, No.3225, No.4372
3226 Key for safety parameters
[Data type] 2-word

When the same value as the code for safety parameters is set in this
parameter, the key is opened to enable modifications to the safety
parameters. The value set in this parameter is not displayed. When the
power is turned off, the value set in this parameter is cleared,
resulting in the locked state.
CAUTION
Once a key is set, the key must be cancelled or
memory must be cleared before the safety
parameters can be modified. Moreover, the code for
the safety parameters cannot be modified. Be careful
when setting a code for safety parameters.
4372 Safe speed of each spindle
[Data type] Word

[Unit of data] min-1
Set a safe speed for each spindle in terms of motor speed.
With the dual check safety function, the CNC and spindle software
always check the speed of each spindle motor.
In safety signal mode B (state in which a guard open request is input,
and the guard is closed), if there is at least one spindle whose speed is
greater than the safe speed, guard unlock signal (*LGD) is set to 0 to
disable guard unlocking. The state in which the speeds of all spindle
motors are within the safe speeds is one condition for setting guard
unlock signal (*LGD) to 1 (to enable guard unlocking).
In safety signal mode C (state in which a guard open request is input
and the guard is open), if a spindle speed exceeds the safe speed, a
spindle alarm No.757 (No.767) or AL-69 is issued for the
corresponding spindle.
- 71 -
6.3 PARAMETERS RELATED TO THE USE OF FSSB I/O UNIT
#7 #6 #5 #4 #3 #2 #1 #0
1902 FMD
[Data type] Bit
FMD The FSSB setting mode is:

0: Automatic setting mode.
1: Manual setting 2 mode.
CAUTION
When using the dual check safety function, set the
FMD bit to 1, to select manual setting 2 mode.
#7 #6 #5 #4 #3 #2 #1 #0
1905 IO2 IO1
[Data type] Bit axis

IO1 A first FSSB I/O unit is:
0: Not used.
1: Used.
IO2 A second FSSB I/O unit is:
0: Not used.
1: Used.
CAUTION
1 The FSSB I/O unit and separate detector interface
unit (pulse module) are handled as units of the same
type on the FSSB. The term "first unit" or "second
unit" used in the following description means that the
unit is the first or second one when counted
disregarding the difference between the FSSB I/O
unit and separate detector interface unit. If one
FSSB I/O unit and one separate detector interface
unit are connected and if the separate detector
interface unit is closer to the CNC on the FSSB than
the FSSB I/O unit, for instance, the FSSB I/O unit is
referred to as the "second unit."
2 The FSSB I/O unit is controlled on the first servo
axis. Set IO1 (or IO2) to 1 for an axis for which
parameter No.1023 is set to 1 (to 9 for tool post 2
under two-CPU two-path control or two-CPU three-
path control). For the other axes, set both IO1 and
IO2 to 0.
- 72 -
1910 Address conversion table value for slave 1 of FSSB channel 1 (ATR)
:
:
[Data type] Byte

[Valid data range] 0 to 7, 16, 40, 48
Set the address conversion table values for slaves 1 to 10 of each
FSSB channel.
"Slave" is a generic term for the FSSB I/O unit, separate detector
interface unit, and servo amplifier connected to the CNC by an FSSB
optical cable. The slaves are numbered 1 to 10 in ascending order of
distance from the CNC. A two-axis amplifier has two slaves. A three-
axis amplifier has three slaves.
If a slave is a separate detector interface unit or FSSB I/O unit, set 16
for the first unit and 48 for the second unit.
CAUTION
The FSSB I/O unit and separate detector interface
unit (pulse module) are handled as units of the same
type on the FSSB. The term "first unit" or "second
unit" used in the following description means that the
unit is the first or second one when counted
disregarding the difference between the FSSB I/O
unit and separate detector interface unit. If one
FSSB I/O unit and one separate detector interface
unit are connected and if the separate detector
interface unit is closer to the CNC on the FSSB than
the FSSB I/O unit, for instance, the FSSB I/O unit is
referred to as the "second unit."
- 73 -
6.4 FUNCTIONS THAT REQUIRE SPECIAL PARAMETER

SETTINGS
6.4.1 Tandem Control
To use tandem control, set the following parameters.

• Master axis
No special parameter settings are required.
• Slave axis
No.1904#6(DCN)=1
No.2078=0
No.2079=0
6.4.2 Simple Electronic Gear Box and Electronic Gear Box 2-pair
To use a simple electronic gear box or electronic gear box 2-pair, set
the following parameters.
• Workpiece axis
• Tool axis (EGB axis)
No.1904#6(DCN)=1
6.4.3 Multi-path Control
To use multi-path control, set the following parameters.

• Two-CPU two-path control (without axis change between paths)
• Two-CPU two-path control (with axis change between paths)
No.1023
The first servo axis cannot be changed between paths.
Accordingly, set parameter No.1023 to 1 for the axis of tool
post 1 and to 9 for the axis of tool post 2.
No.1945, No.1947, No.1948, No.1950
Set identical values for the two tool posts.
• One-CPU two-path control
No.1023
Set parameter No.1023 to 1 for the axis of tool post 1.
No.1945, No.1947, No.1948, No.1950
Set identical values for the two tool posts.
• Two-CPU three-path control (No axis change can be made
between tool post 1 and tool post 2 or 3.)
No.1023
Set parameter No.1023 to 9 for the axis of tool post 2.
No.1945, No.1947, No.1948, No.1950
Set identical values for tool posts 2 and 3.
• Loader control
- 74 -
B-63494EN/01 7.START-UP
7 START-UP
- 75 -
7.START-UP B-63494EN/01
7.1 START-UP OPERATION
The machine tool builder has to do tests for insulation and protective
bonding. Testing must be performed according to Chapter 19.2 and
19.3 of the standard IEC 60204-1 by an appropriately authorized
person and recorded.
Continuity of the protective bonding circuit

When the machine is installed and the electrical connections are
complete, including those to the power supply, the continuity of the
protective bonding circuit can be verified by a loop impedance test in
accordance with 612.6.3 of IEC 60364-6-61. For further details,
please refer to Chapter 19.2 of IEC 60204-1.
Insulation resistance tests

The insulation resistance measured at 500 V d.c. between the power
circuit conductors and the protective bonding circuit is to be not less
than 1MΩ. For further details, please refer to Chapter 19.3 of IEC
60204-1.
7.1.1 Acceptance Test and Report for Safety Functions
Acceptance test for Safety function

The machine tool builder is to conduct a dual check safety function
check test during machine start-up operation.
In this test, limits need to be exceeded to check that the dual check
safety function operates normally.
Acceptance report
A qualified person is to check each dual check safety function and
record the test results in a check report.
MOTE
When modifying dual check safety function data,
conduct an additional check test on the modified
dual check safety function and record the test results
in a check report.
Safe-related I/O monitoring test

Data cross-check operation is tested with the I/O device connector
detached.
MCC off Test check

The test mode signal is used to check that a MCC off Test is
conducted.
Negative test:
Conduct a MCC off Test by disconnecting the MCC contact
signal (input). Check that an alarm is issued and the MCC
remains to be shut off.
- 76 -
Safe speed monitoring test

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

A positional limit test is conducted by making many different
movements.
A positional limit is placed at the center of an axis, and the position is
moved at many different speeds in a rapid traverse mode. Thus, the
distance traveled on the axis until stop state is set by a stop response
is measured. The machine tool builder is to determine a safety limit
stop position including a safety margin.
Data modification
The user needs to enter the correct password before setting safety
parameters with the system. After a safety parameter is modified, a
check test needs to be conducted on the related safety function, and
the test results need to be recorded in a report.
- 77 -
7.1.2 Start-up of the Dual Check Safety Function
7.1.2.1 Initial start-up
Main flow
Disable dual check FSSB I/O setting Safety parameter
safety function input
Machine start-up
Step 1
Initial state
First, check that the machine starts up normally when the dual check
safety function is disabled.
Preparation 1 Disable the dual check Bit 6 of PRM No. 1902 = 0

safety function.
Preparation 2 Disable output (MCF), from Connect the relay for
I/O, that indicates MCC is driving based on I/O output
turned off.
CAUTION
When the dual check safety function is disabled, the
MCC on enable signal (MCF) is not output. So, make
a connection to temporarily disable MCF. To enable
the dual check safety function, reset the temporary
connection.
Step 2
FSSB I/O setting
Make the same settings as for the pulse module.
Example: When a two-axis amplifier is set as slave 1, and FSSB I/O
unit is set as slave 2
Make the settings indicated in the table below.
Parameter setting Meaning
Bit 0 of No. 1902 = 1 Manually sets the FSSB setting mode.
Bit 4 of No. 1905 = 1 Uses the first FSSB I/O unit.
No. 1910 = 0 Sets the value of parameter No. 1023 less 1
when the slave is an amplifier
No. 1911 = 1 Sets the value of parameter No. 1023 less 1
when the slave is an amplifier
No. 1912 = 16 16 when the slave is a FSSB I/O unit
Nos. 1913 to 1919 = 40 40 when there is no slave
- 78 -
Step 3
Safety parameter input
Enable the dual check safety function, and enter the safety
parameters.
Enable the dual check safety Bit 6 of PRM No. 1902
Preparation 1
function. =1
Enables output (MCF), from I/O,
Preparation 2 Enable I/O output.
that indicates MCC is turned off.
Set the safety parameters indicated in the table below.

Parameter Meaning
setting
1942 Safe speed on each axis
1943 Safe machine position (+ direction) on each axis
1944 Safe machine position (- direction) on each axis
1945 Timer for safety input signal check
1946 Timer for MCC off Test
1947 Timer 1 for MCC off
1948 Timer 2 for MCC off
1838 Positional deviation limit value in mode C
2078 Dual position feedback conversion coefficient (numerator)
2079 Dual position feedback conversion coefficient (denominator)
4372 Safe speed on each spindle
Step 4
If alarm 478 or 496 occurs, set the bit 4 of parameter No.2212 to 1,
and reset this bit to 0. Then turn off the power of the entire system
(included servo amplifier).
Step 5
Execution of general machine tests
Axis and spindle optimization
Dual check safety function adjustment (safe speed, safe machine
position)
Step 6
Test for checking the safety function
Check test execution and report creation
Step 7
Parameter preservation
Save all parameters including the safety parameters. The parameters
are used to start up the series.
Step 8
Set a password.
A password is used to disable unauthorized persons from modifying
safety parameters. Before safety parameters of the equipment for
which a password (No. 3225) is set can be modified, the password
value must be set as the keyword (No. 3226). Only those persons
authorized to conduct a check test should know the password value.
- 79 -
7.1.2.2 Series start-up
The parameters for the safety monitoring function are transferred

together with other parameters to the CNC as in the case of normal
series start-up. Perform a safety function check test in addition to the
normal start-up procedure.
7.1.3 Troubleshooting
Alarms related to the safety function are output on the ALARM

screen.
Correct the cause of trouble according to the chapter describing
alarms and messages in this manual. When a component related to the
safety function is to be replaced, an authorized person must conduct a
safety function check test.
- 80 -
B-63494EN/01 8.MAINTENANCE
8 MAINTENANCE
- 81 -
8.MAINTENANCE B-63494EN/01
8.1 SAFETY PRECAUTIONS
This section describes the safety precautions related to the use of

CNC units. It is essential that these precautions be observed by users
to ensure the safe operation of machines equipped with a CNC unit
(all descriptions in this section assume this configuration).
CNC maintenance involves various dangers. CNC maintenance must
be undertaken only by a qualified technician.
Users must also observe the safety precautions related to the machine,
as described in the relevant manual supplied by the machine tool
builder.
Before checking the operation of the machine, take time to become
familiar with the manuals provided by the machine tool builder and
FANUC.
CAUTION
Maintenance on a live system requires careful
planning, adherence to operating and maintenance
procedures, and the appropriate permits and
permissions.
These matters are the responsibility of the
owner/operator of the system and are outside the
scope of this document.
TRAINING
FANUC Training Center provides versatile training course for the
person who is concerned with hardware and software installation,
maintenance and operation. FANUC recommend studying and
learning how efficiently operate FANUC products.
QUALIFIED PERSONNEL
Only qualified personnel should be allowed to specify, apply, install,
commissioning, operate, maintain, or perform any other function
related to the products described in the product manuals. Examples of
such qualified persons are defined as follows:
• System application and design engineers who are familiar with
the safety concepts of machine tool.
• Installation, startup, and service personnel who are trained to
install and maintain such machine tool.
• Operating personnel trained to operate machine tool and trained
on the specific safety issues and requirements of the particular
equipment.
- 82 -
MAINTENANCE PARTS TO BE MAINTAINED PERIODICALLY
• Memory backup battery replacement
WARNING
When replacing the memory backup batteries, keep the power to the
machine (CNC) turned on, and apply an emergency stop to the
machine. Because this work is performed with the power on and the
cabinet open, only those personnel who have received approved safety
and maintenance training may perform this work.
When replacing the batteries, be careful not to touch the high-voltage
circuits (marked and fitted with an insulating cover).
Touching the uncovered high-voltage circuits presents an extremely
dangerous electric shock hazard.
NOTE
The CNC uses batteries to preserve the contents of
its memory, because it must retain data such as
programs, offsets, and parameters even while
external power is not applied.
If the battery voltage drops, a low battery voltage
alarm is displayed on the machine operator's panel
or CRT screen.
When a low battery voltage alarm is displayed,
replace the batteries within a week. Otherwise, the
contents of the CNC's memory will be lost.
To replace the battery, see the procedure described
in Section 2.10 of the maintenance manual B-
63005EN.
WARNINGS RELATED TO CHECK OPERATION
WARNING
1. When checking the operation of the machine with the cover
removed
(1) The user's clothing could become caught in the spindle or
other components, thus presenting a danger of injury. When
checking the operation, stand away from the machine to
ensure that your clothing does not become tangled in the
spindle or other components.
(2) When checking the operation, perform idle operation
without workpiece. When a workpiece is mounted in the
machine, a malfunction could cause the workpiece to be
dropped or destroy the tool tip, possibly scattering
fragments throughout the area. This presents a serious
danger of injury. Therefore, stand in a safe location when
checking the operation.
- 83 -
2. When checking the machine operation with the power magnetics

cabinet door opened.
(1) The power magnetics cabinet has a high-voltage section
(carrying a mark). Never touch the high-voltage section.
The high-voltage section presents a severe risk of electric
shock. Before starting any check of the operation, confirm
that the cover is mounted on the high-voltage section. When
the high-voltage section itself must be checked, note that
touching a terminal presents a severe danger of electric
shock.
(2) Within the power magnetics cabinet, internal units present
potentially injurious corners and projections. Be careful
when working inside the power magnetics cabinet.
3. Never attempt to machine a workpiece without first checking the

operation of the machine.
Before starting a production run, ensure that the machine is
operating correctly by performing a trial run using, for example,
the single block, feedrate override, or machine lock function or
by operating the machine with neither a tool nor workpiece
mounted. Failure to confirm the correct operation of the machine
may result in the machine behaving unexpectedly, possibly
causing damage to the workpiece and/or machine itself, or injury
to the user.
4. Before operating the machine, thoroughly check the entered data.

Operating the machine with incorrectly specified data may result
in the machine behaving unexpectedly, possibly causing damage
to the workpiece and/or machine itself, or injury to the user.
5. Ensure that the specified feedrate is appropriate for the intended

operation. Generally, for each machine, there is a maximum
allowable feedrate. The appropriate feedrate varies with the
intended operation. Refer to the manual provided with the
machine to determine the maximum allowable feedrate. If a
machine is run at other than the correct speed, it may behave
unexpectedly, possibly causing damage to the workpiece and/or
machine itself, or injury to the user.
6. When using a tool compensation function, thoroughly check the

direction and amount of compensation.
Operating the machine with incorrectly specified data may result
in the machine behaving unexpectedly, possibly causing damage
to the workpiece and/or machine itself, or injury to the user.
- 84 -
WARNINGS RELATED TO REPLACEMENT
WARNING
1. Always turn off the power to the CNC and the main power to the
power magnetics cabinet. If only the power to the CNC is turned
off, power may continue to be supplied to the serve section.
In such a case, replacing a unit may damage the unit, while also
presenting a danger of electric shock.
2. When a heavy unit is to be replaced, the task must be undertaken

by two persons or more. If the replacement is attempted by only
one person, the replacement unit could slip and fall, possibly
causing injury.
3. After the power is turned off, the servo amplifier and spindle
amplifier may retain voltages for a while, such that there is a
danger of electric shock even while the amplifier is turned off.
Allow at least twenty minutes after turning off the power for
these residual voltages to dissipate.
4. When replacing a unit, ensure that the new unit has the same
parameter and other settings as the old unit. (For details, refer to
the manual provided with the machine.) Otherwise,
unpredictable machine movement could damage the workpiece
or the machine itself, and present a danger of injury.
5. After replacing a safety related unit such as encoder and I/O

module, conduct a check test on the safety related and record the
test results in a check report.
WARNINGS RELATED TO PARAMETERS
WARNING
1. When machining a workpiece for the first time after modifying a
parameter, close the machine cover. Never use the automatic
operation function immediately after such a modification.
Instead, confirm normal machine operation by using functions
such as the single block function, feedrate override function, and
machine lock function, or by operating the machine without
mounting a tool and workpiece. If the machine is used before
confirming that it operates normally, the machine may move
unpredictably, possibly damaging the machine or workpiece, and
presenting a risk of injury.
2. The CNC and PMC parameters are set to their optimal values, so
that those parameters usually need not be modified. When a
parameter must be modified for some reason, ensure that you
fully understand the function of that parameter before attempting
to modify it. If a parameter is set incorrectly, the machine may
move unpredictably, possibly damaging the machine or
workpiece, and presenting a risk of injury.
- 85 -
8.2 ALARMS AND MESSAGES
8.2.1 Overview
Alarms related to the dual check safety function cannot be cancelled

by a reset. To cancel the alarms, turn off the power, remove the
causes of the alarms, then turn on the power again.
and safety signal modes A/B/C/D, see Chapter 5.
- 86 -
8.2.2 Servo Alarms
No. Meaning Description

364 n AXIS: SOFT PHASE The servo control software detected an abnormal data skip in a velocity
ALARM(INT) feedback signal on axis n (axis 1 to axis 8).
Replace the α pulse coder, or take measures to correct noise on the feedback
cable.
402 SERVO ALARM: SV CARD The axis control card is not provided.
NOT EXIST This alarm will be issued also if the eight-axis control card dedicated to dual
check safety function (5DSP card) is mounted on a machine without the dual
403 SERVO ALARM : CARD/SOFT For the axis control card, the correct servo software is not installed in flash
MISMATCH memory.
When the dual check safety function is used:
• An incorrect axis control card is mounted.
• Incorrect servo software is installed in flash memory.
• Monitor software is not installed in flash memory.
Mount the correct axis control card, and install the correct servo software and
monitor software in flash memory.
410 SERVO ALARM : n AXIS The CNC detected that the positional deviation during a stop on axis n (axis 1
EXCESS ERR to axis 8) exceeded the setting (parameter No. 1829).
Confirm a proper value is set to parameter No. 1829.
This alarm can not released by reset function at dual check safety.
411 SERVO ALARM : n AXIS The CNC detected that the positional deviation during movement on axis n
EXCESS ERR (axis 1 to axis 8) exceeded the setting in parameter No. 1828 (parameter No.
1838 when the safety signal mode C (state where a guard open request is
input, and the guard is open) is set with the dual check safety function).
Confirm a proper value is set to parameter No. 1828 or No. 1838.
This alarm can not released by reset function at dual check safety.
453 n AXIS:SPC SOFT The servo control software detected an alpha pulse coder signal error on axis
DISCONNECT ALARM n (axis 1 to axis 8).
Replace the alpha pulse coder.
470 n AXIS:ILLEGAL RAM (MNT) An error occurred in a monitor RAM check.
Replace the axis control card.
471 n AXIS:SPC SOFT The monitor detected an alpha pulse coder signal error on axis n (axis 1 to
DISCONNECT (MNT) axis 8).
Replace the α pulse coder.
473 n AXIS:SOFT PHASE The monitor detected an abnormal data skip in a velocity feedback signal on
ALARM(INT/MNT) axis n (axis 1 to axis 8).
Replace the α pulse coder, or take measures to correct noise on the feedback
cable.
474 n AXIS:EXCESS ERROR The monitor detected that the positional deviation during a stop on axis n (axis
(STOP:MNT) 1 to axis 8) exceeded the setting (parameter No. 1829) in safety signal mode
C (state in which a guard open request is input, and the guard is open).
475 n AXIS:EXCESS ERROR The monitor detected that the positional deviation during movement on axis n
(MOVE:MNT) (axis 1 to axis 8) exceeded the setting (parameter No. 1838) in safety signal
mode C (state in which a guard open request is input, and the guard is open).
- 87 -

476 n AXIS:ILLEGAL SPEED CMD. The monitor detected that the specified speed on axis n (axis 1 to axis 8)
(MNT) exceeded the safe speed (parameter No. 1942) in safety signal mode C (state
in which a guard open request is input, and the guard is open).
When the guard is open, confirm a proper value is set to parameter No. 1942,
and the operation is done within the safe speed.
If an alarm is issued in safety signal mode C, the movement of the machine
immediately stops, and a pulse for adjusting the coordinates is generated.
Accordingly, this alarm can be issued.
477 n AXIS:ILLEGAL MACHINE The monitor detected that the machine position on axis n (axis 1 to axis 8) is
POS.(MNT) not in the safety area (parameter No. 1943 and No. 1944) in safety signal
mode C (state in which a guard open request is input, and the guard is open).
When the guard is open, confirm proper values is set to parameter No. 1943
and No. 1944, and operation is done in the safety area.
A machine position check is carried out just on a linear axis on which the
reference position has already been established. No machine position check
is made on a rotation axis or a linear axis on which the reference position has
not yet been established.
478 n AXIS:ILLEGAL AXIS DATA The monitor detected that an error occurred on axis n (axis 1 to axis 8) during
(MNT) axis data transfer.
If the alarm occurs after performing axis number setting for the servo
amplifier, set parameter No.2212#4 to 1, and reset the bit to 0, and then turn
off the power of the entire system.
In the other case, replace the servo amplifier the alarm occurred.
479 ILLEGAL SAFETY DI (MNT) The monitor detected a mismatch exceeding the set time (parameter No.
1945) between a safety input signal via the PMC and the same signal via the
FSSB.
Check the safety input signals via the PMC and via the FSSB are equal.
480 n AXIS:ILLEGAL SAFETY The monitor detected that safety signal mode D (state in which the guard is
MODE (MNT) open although no guard open request is input) was set, or the guard is open
when guard unlock signal (*LGD) is not output.
In the former, the alarm is issued for all axes. In the latter, the alarm is
issued only for the first servo axis (axis for which parameter No.1023 is set to
1 or, for tool post 2 under two-CPU two-path control or two-CPU three-path
control, an axis for which parameter No.1023 is set to 9). Check if the guard
state signal(SGD) is correctly connected.
If an alarm is issued in safety mode C (state in which a guard open request is
input and the guard is open), guard unlocking is disabled. Accordingly, this
alarm may be issued.
481 n AXIS:SAFETY PARAM The monitor detected that a safety parameter error occurred with axis n (axis
ERROR (MNT) 1 to axis 8).
Set the safety parameters again.
Relative parameters are as follows.
No.1023, No.1829, No.1838, No.1942, No.1943, No.1944, No.1945, No.1947,
No.1948, No.1950
482 n AXIS:AXIS NUMBER NOT The monitor detected that the axis number of axis n (axis 1 to axis 8) is not set
SET (MNT) with the servo amplifier.
Turn off the power of the entire system. Then an axis number is automatically
set.
483 MONITOR SAFETY An error occurred in safety functions of monitor:
FUNCTION ERROR 1 Monitor or CNC detected the inexecution of monitor safety functions.
2 A mismatch between the monitor results of the safety functions and the
servo software or CNC results of them occurred.
3 An error occurred in a monitor CPU test.
- 88 -

484 n AXIS:SERVO SAFETY An error occurred in safety functions of servo software:
FUNCTION ERR 1 Servo software or CNC detected the inexecution of servo software safety
functions.
2 A mismatch between the servo software results of the safety functions and
the monitor results of them occurred.
3 An error occurred in a servo RAM test.
4 An error occurred in a servo CPU test.
486 ILLEGAL SAFETY DI (CNC) The CNC detected a mismatch exceeding the set time (parameter No. 1945)
between a safety input signal input via the PMC and the same signal input via
the FSSB.
Check the safety input signals via the PMC and via the FSSB are equal.
487 ILLEGAL SAFETY MODE The CNC detected that safety signal mode D (state in which the guard is open
(CNC) although no guard open request is input) was set, or the guard is open when
guard unlock signal (*LGD) is not output.
Check if the guard state signal(SGD) is correctly connected.
If an alarm is issued in safety mode C (state in which a guard open request is
input and the guard is open), guard unlocking is disabled. Accordingly, this
alarm may be issued.
488 SAFE TEST OVER TIME A MCC off Test was not completed within the set time (parameter No. 1946).
Check the MCC contact.
489 SAFETY PARAM ERROR The CNC detected a safety parameter error.
(CNC) Set the safety parameters again.
No.1023, No.1829, No.1838, No.1904, No.1942, No.1943, No.1944, No.1945,
No.1946, No.1947, No.1948, No.1950, No.4372
490 CNC SAFETY FUNCTION An error occurred in safety functions of CNC:
ERROR 1 CNC or monitor detected the inexecution of CNC safety functions.
2 A mismatch between the CNC results of the safety functions and the
monitor or spindle results of them occurred.
3 An error occurred in a CNC RAM test.
4 An error occurred in a CNC CPU test.
5 Test at power-up was not executed.
Replace the CPU card.
491 LOCAL BUS TEST ERROR An error occurred in a local bus test. The mother board may be faulty.
Replace the mother board.
492 F-BUS TEST ERROR An error occurred in an F-BUS test. The mother board or option board may be
faulty.
The F-BUS test is carried out if a sub-CPU board or loader board is used.
494 n AXIS:ILLEGAL SPEED CMD. The CNC detected that the specified speed on axis n (axis 1 to axis 8)
(CNC) exceeded the setting (parameter No. 1942) in safety signal mode C (state in
which a guard open request is input, and the guard is open).
When the guard is open, confirm a proper value is set to parameter No. 1942,
and the operation is done within the safe speed.
If an alarm is issued in safety signal mode C, the movement of the machine
immediately stops, and a pulse for adjusting the coordinates is generated.
Accordingly, this alarm can be issued.
- 89 -

495 n AXIS:ILLEGAL MACHINE The CNC detected that the machine position on axis n (axis 1 to axis 8) is not
POS.(CNC) in the safety area (parameter No. 1943 and No. 1944) in safety signal mode C
(state in which a guard open request is input, and the guard is open).
When the guard is open, confirm proper values is set to parameter No. 1943
and No. 1944, and operation is done in the safety area.
A machine position check is carried out just on a linear axis on which the
reference position has already been established. No machine position check
is made on a rotation axis or a linear axis on which the reference position has
not yet been established.
496 n AXIS:ILLEGAL AXIS DATA The CNC detected that an error occurred on axis n (axis 1 to axis 8) during
(CNC) axis data transfer.
If the alarm occurs after performing axis number setting for the servo
amplifier, set parameter No.2212#4 to 1, and reset the bit to 0, and then turn
off the power of the entire system.
In the other case, replace the servo amplifier the alarm occurred.
497 n AXIS:SAFETY PARAM A safety parameter transfer error occurred on axis n (axis 1 to axis 8).
TRANS ERROR Replace the CPU card or the axis control card.
498 n AXIS:AXIS NUMBER NOT The CNC detected that the axis number of axis n (axis 1 to axis 8) is not set
SET (CNC) with the servo amplifier.
Turn off the power of the entire system. Then an axis number is automatically
set.
- 90 -
8.2.3 Serial Spindle Alarms

749 S-SPINDLE LSI It is serial communication error while system is executing after power supply on.
ERROR Check optical cable connection between main CPU board and spindle amplifier printed
board.
Replace optical cable, main CPU board, option 2 board or spindle amplifier printed
board.
If this alarm occurs when CNC power supply is turned on or when this alarm can not be
cleared even if CNC is reset, turn off the power supply also turn off the power supply in
spindle side.
755 SPINDLE-1 SAFETY An error occurred in any spindle safety functions on the first spindle.
FUNCTION ERROR 1 CNC detected that some spindle safety functions were not executed.
2 A safety parameter transfer error occurred.
Replace the CPU card or spindle amplifier module.
756 SPINDLE-1 ILLEGAL For the first spindle, the CNC detected a mismatch between the spindle amplifier
AXIS DATA connection state and spindle amplifier hardware setting.
Check the spindle amplifier connection state and spindle amplifier hardware setting.
If this alarm is issued because the spindle amplifier configuration is changed, correct the
setting on the spindle amplifier side.
757 SPINDLE-1 SAFETY For the first spindle, the CNC detected that the speed of the spindle motor exceeded the
SPEED OVER safe speed (parameter No. 4372) in safety signal mode C (state in which a guard open
request is input, and the guard is open).
Alternatively, for the first spindle, the CNC detected a mismatch between the CNC and
spindle software, as to which of the speed of the spindle motor and the safe speed
(parameter No. 4372) is greater.
When the guard is open, perform operation at a speed not exceeding the safe speed.
Check the safe speed parameter(parameter No.4372).
765 SPINDLE-2 SAFETY Same as alarm No. 755. (For the second spindle)
FUNCTION ERROR
766 SPINDLE-2 ILLEGAL Same as alarm No. 756. (For the second spindle)
AXIS DATA
767 SPINDLE-2 SAFETY Same as alarm No. 757. (For the second spindle)
SPEED OVER
7n16 SPN n :S-SPINDLE See the description of AL-16 in Subsection 8.2.4. (For the n-th spindle)
ERROR (AL-16)
ERROR (AL-69)
ERROR (AL-69)
ERROR (AL-71)
ERROR (AL-72)
ERROR (AL-74)
ERROR (AL-76)
ERROR (AL-77)
ERROR (AL-78)
- 91 -
8.2.4 Alarms Displayed on the Spindle Unit

AL-16 RAM Alarm An error occurred in a spindle RAM test.
Replace spindle amplifier module.
AL-69 Safety speed over The spindle software detected that the speed of the spindle motor exceeded the safe
speed (parameter No. 4372) in safety signal mode C (state in which a guard open
request is input, and the guard is open).
When the guard is open, perform operation at a speed not exceeding the safe speed.
Check the safe speed parameter(parameter No.4372).
AL-70 Illegal axis data The spindle software detected a mismatch between the spindle amplifier connection
state and spindle amplifier hardware setting.
Check the spindle amplifier connection state and spindle amplifier hardware setting.
AL-71 Safety parameter error The spindle software detected a safety parameter error.
Set the safety parameter again.
No.4372
AL-72 Mismatch the results of The spindle software detected a mismatch between the CNC result of the motor speed
motor speed check check and the spindle result of it.
AL-74 CPU test alarm An error occurred in a spindle amplifier CPU test.
AL-75 CRC alarm An error occurred in a spindle ROM CRC test.
AL-76 Inexecution of safety Any safety function was not executed.
functions Replace spindle amplifier module.
AL-77 Mismatch the results of The spindle software detected a mismatch between the CNC result of the axis number
axis number check check and the spindle result of it.
AL-78 Mismatch the results of The spindle software detected a mismatch between the CNC result of the safety
safety parameters parameters check and the spindle result of it.
check Replace the CPU card or spindle amplifier module.
AL-79 Inexecution of safety The safety functions at power-up for spindle were not executed. Replace the spindle
functions at power-up amplifier.
- 92 -
8.2.5 System Alarms

900 ROM PARITY Parity error of the CNC, macro, or servo ROM.
When the dual check safety function is used:
1 Parity error of the CNC, macro, or servo ROM
2 CRC error of the CNC, servo, or monitor ROM
Reinstall the indicated ROM in flash memory.
920 SERVO ALARM (1-4 Servo alarm (first to fourth axis). A watchdog alarm condition occurred, or a RAM parity
AXIS) error occurred in the axis control card.
In the dual check safety function with 4-axes control card, servo alarm (first/second axis,
or monitor).
921 SERVO ALARM (5-8 Servo alarm (fifth to eighth axis). A watchdog alarm condition occurred, or a RAM parity
AXIS) error occurred in the axis control card.
In the dual check safety function with 6-axes control card, servo alarm (monitor).
In the dual check safety function with 8-axes control card, servo alarm (fifth/sixth axis, or
monitor).
If the 8-axes control card dedicated to dual check safety function (5DSP card) is used
with the dual check safety function, a servo alarm (fifth to eight axis) is issued.
973 NON MASK An NMI of an unknown cause occurred.
INTERRUPT If the 8-axes control card dedicated to dual check safety function (5DSP card) is used
with the dual check safety function, this alarm is issued, even when a servo alarm
(monitor) is issued.
8.2.6 Boot System Alarms
Message Description
ROM PARITY ERROR: Parity error of the CNC basic ROM.
NC BASIC. HIT SELECT. When the dual check safety function is used:
1. Parity error of the CNC basic ROM
2. CRC error of the CNC basic ROM
Reinstall the CNC basic ROM in flash memory.
- 93 -
9.DIAGNOSIS B-63494EN/01
9 DIAGNOSIS
- 94 -
B-63494EN/01 9.DIAGNOSIS
9.1 OVERVIEW
The information of safety signal mode and safety input signal of the
dual check safety function is displayed.
and safety signal modes A/B/C/D, see Chapter 5.
- 95 -
9.DIAGNOSIS B-63494EN/01
9.2 DIAGNOSIS
#7 #6 #5 #4 #3 #2 #1 #0
Diagnosis No. 376 FMC FGL FGD
The current states of safety signals input via the FSSB are displayed.
FGD The state of the guard state signal (SGD2) is displayed.
FGL The state of the guard lock state signal (GDL2) is displayed.
FMC The state of the MCC contact state signal (*SMC2) is displayed.
#7 #6 #5 #4 #3 #2 #1 #0
Diagnosis No. 377 PMC PGL PGD PRQ PTS
The current states of safety signals input via the PMC are displayed.
PTS The state of the test mode signal (OPT) is displayed.
PRQ The state of the guard open request signal (ORQ) is displayed.
PGD The state of the guard state signal (SGD1) is displayed.
PGL The state of the guard lock state signal (GDL1) is displayed.
PMC The state of the MCC contact state signal (*SMC1) is displayed.
#7 #6 #5 #4 #3 #2 #1 #0
Diagnosis No. 378 ESP TST MDD MDC MDB MDA
The current safety signal mode is displayed.
MDA Safety signal mode A
MDB Safety signal mode B
MDC Safety signal mode C
MDD Safety signal mode D
TST MCC off test mode
ESP Emergency stop mode
Diagnosis No. 379 Test number of MCC off test

The test number of the MCC off test is displayed.
Zero is displayed if the system is not in the MCC off test mode.
After the MCC off test mode is selected by the input of the test mode
signal (OPT), the test number increases by 1 from 0 as the MCC off
test proceeds. When the MCC off test is completed, the test number is
128. When the test mode signal (OPT) is set to 0 to clear the MCC off
test mode, the test number is cleared to 0.
- 96 -
B-63494EN/01 10.SAMPLE SYSTEM CONFIGURATION
10 SAMPLE SYSTEM CONFIGURATION
- 97 -
10.SAMPLE SYSTEM CONFIGURATION B-63494EN/01
10.1 SAMPLE CONFIGURATION
10.1.1 For One-path
- 98 -
10.1.2 For Two-path (When the main side and sub side use a
common MCC)
- 99 -
10.1.3 For Two-path (When the main side and sub side use
independent MCCs and protection doors)
- 100 -
10.2 SAMPLE CONNECTIONS
10.2.1 Emergency Stop Signal (*ESP1, *ESP2)
+24V I/O-Link I/O UNIT
*ESP1
(X008#4)
FSSB I/O UNIT
*ESP2
(DI+000#0)
0V
PSM
CX4
ESP
NOTES
Use a two-contact emergency stop button with a forced dissociation
mechanism.
Connect the emergency stop button to the PSM, as illustrated in the
figure. When the signal is input, the spindle slows down and stops.
Input a power-down factor to [G008#4] other than the signal from the
emergency stop button.
Create a Ladder program so that [X008#4] becomes a factor of
[G008#4].
Machine side I/O-Link I/O UNIT PMC
Emergency stop
factor
Emergency X008#4
stop button
Ladder
Emergency stop factor program
other than emergency X00n#n *ESPG
stop button (G008#4)
- 101 -
10.2.2 Guard Open Request Signal (ORQ)
Guard open
+24V request button
I/O-Link I/O UNIT PMC
X00n#n Ladder program
ORQ
(G191#3)
NOTES
• Create a Ladder program of conditions for making a guard open
request and then input the program to the PMC side [G191#3].
• When the guard open request signal (ORQ) is input and when
CNC safety has been confirmed, the guard unlock signal (*LGD)
is output. If the CNC is not safe, ORQ input will not result in
output of *LGD.
• If the input of ORQ is canceled while the guard is open, the CNC
enters a safely stopped status (state in which the guard is open
although the guard open request signal is not input). Close the
guard (SGD is set to 1), then cancel this signal.
10.2.3 Test Mode Signal (OPT)
Test start button

+24V
I/O-Link I/O UNIT PMC
X00n#n Ladder program
OPT
(G191#2)
NOTES
Create a Ladder program for performing a MCC off Test, then input
the program to the PMC side [G191#2].
- 102 -
10.2.4 Guard Unlock Signal (*LGD), Guard Lock State Signal (GDL),
Guard State Signal (SGD)
+24V
Guard closed
SW1 SW2
Guard-monitoring Safety relay

limit switch
SW3 RY1
RY1
RY3
RY2
RY2
RY3
0V RY3
RY1 RY2
0V
[Sample control components] I/O Link I/O UNIT PMC

SW1/SW2: X00n#n SGD
(G191#4)
Guard state monitoring
switch with forced *LGD
(F191#0)
dissociation mechanism
Y00n#n Ladder
SW3:
program
Guard lock switch
RY1, RY2, RY3:
Safety relay FSSB I/O UNIT
SGD
(DI+001#4)
- 103 -
OPERATING PRINCIPLE
This section describes the operation of various guard monitoring limit
switches with lock mechanism and safety relays.
State transition of components
SW1 SW2 SW3 RY1 RY2 RY3 SGD
1 Guard closed CLOSE CLOSE CLOSE ON ON OFF 1
Guard locked
2 Guard closed CLOSE CLOSE OPEN OFF ON OFF 0
Guard unlocked
3 Guard opened OPEN OPEN OPEN OFF OFF ON 0
Guard unlocked
In a normal operation, the transition of 1, 2, 3, 1, 2, and so on is

repeated.
RY3 detects whether RY1 and RY2 contacts are made. If an unusual
event is detected, SGD input is turned off.
NOTES
This example does not use the guard lock state signal (GDL). If GDL
is not used, as in this example, tie [G191#5] and [DI+001#5] to 1.
The guard state is monitored, and the guard state signal (SGD) affects
the dual check safety function. The guard lock state signal (GDL)
only indicates whether an input mismatch is found. The state of the
GDL signal does not affect the dual check safety function.
The illustrated sample system determines that the guard is open (sets
SGD to 0) when the guard is unlocked.
When the guard open request signal (ORQ) is accepted and when it
has been confirmed that the CNC is in a safe state, the guard unlock
signal (*LGD) is output. Based on this signal, use a Ladder program
to create a guard unlock signal.
- 104 -
10.2.5 MCC On Enable Signal (MCF), MCC Contact State Signal

(*SMC)
+24V I/O Link I/O UNIT PMC
*SMC1
X00n#n
(G191#6)
MCF1
Y00n#n
(F191#1)
0V
FSSB I/O UNIT
*SMC2
(DI+001#6)
MCF
(DO+000#1)
0V
PSM
200A
200B
CX3
MCC
U
V
W
Electromagnetic contactor (MAIN MCC)
NOTES
With the MCF signal of the PMC side, allocate [F191#1] to general-
purpose output.
On the FSSB side, directly connect [DO+000#1].
Also connect MCF to PSM, as illustrated in the figure. If an error
occurs in the PSM, the PSM turns off the MCC.
- 105 -
11.COMPONENTS LIST B-63494EN/01
11 COMPONENTS LIST
- 106 -
B-63494EN/01 11.COMPONENTS LIST
11.1 HARDWARE COMPONENTS
11.1.1 Hardware Components for Series

16i/18i/21i/160i/180i/210i/160is/180is/210is-MODEL A
Specification number Specification number

No. Description Remarks
Of primary component of secondary component
1 Main board A20B-8100-0130 A20B-8100-013X A20B-8100-014X
A20B-8100-054X
2 CPU card A20B-3300-0170 A20B-3300-0050 A20B-3300-0070
A20B-3300-0260
3 Servo card A17B-3300-0200 A20B-3300-012X A20B-3300-020X
A20B-3300-024X
4 DRAM MODULE A20B-3900-0131 A20B-3900-003X A20B-3900-004X
A20B-3900-013X
5 SRAM MODULE A20B-3900-0060 A20B-3900-005X A20B-3900-006X
A20B-3900-002X
6 FROM MODULE A20B-3900-0011 A20B-3900-001X A20B-3900-007X
11.1.2 Hardware Components for Series

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

1 Main board A20B-8100-0660 A20B-8100-066X A16B-3200-042X
A20B-8100-079X
2 CPU card A20B-3300-0311 A20B-3300-031X A20B-3300-029X
3 Servo card A20B-3300-0244 A20B-3300-024X
A17B-3300-0500
4 FROM/SRAM MODULE A20B-3900-0160 A20B-3900-016X
A20B-3900-018X
5 Power supply module A20B-8100-0720 A20B-8100-0851
6 Sub CPU board A20B-8002-0190 A16B-2203-0751
7 Loader control board A20B-8100-0830 A16B-2203-0740
- 107 -
11.1.3 Hardware Components for Other Units

1 FSSB ADDITIONAL A20B-2100-0270
DETECTOR INTERFACE
2 I/O module A20B-2100-0150 A20B-2002-0400
A20B-2100-0410 A20B-2002-0401
A20B-2100-0411 A20B-2100-0320
A20B-2002-0470 A20B-2002-0520
A20B-2002-0521
3 I/O Unit base module A20B-9001-0020 A20B-9001-0040 A20B-2000-0550
A20B-2000-0510
4 I/O Unit interface module A20B-8000-0410 A20B-8000-0420 A20B-8000-0710
A20B-8000-0820
5 DC digital input module A20B-9000-0901 A20B-9000-0970 A20B-9000-0971
A20B-9000-0902 A20B-9001-0011 A20B-9001-0010
A20B-9001-0281 A20B-8000-0341
A20B-9000-0972 A20B-9001-0280
A20B-9001-0490 A20B-8000-0510
6 DC digital output module A20B-9000-0921 A20B-9001-0220 A20B-8002-0070
A20B-8000-0440 A20B-8000-0510
A20B-9001-0490 A20B-8000-0740
A20B-8000-0741 A20B-9001-0680
A20B-9001-0681 A20B-8000-0760
A20B-8000-0780
7 DC digital input/output A20B-8000-0750 A20B-8000-0751
module A20B-8000-0730 A20B-8000-0731
8 AC digital input module A20B-8000-0341 A20B-9001-0940
9 AC digital output module A20B-8000-0470 A20B-8000-0480
A20B-8000-0321 A20B-8000-0880
10 Relay output module A20B-9001-0200 A20B-8000-0101
A20B-8000-0500
11 FSSB I/O module A20B-2100-0390
- 108 -
11.2 SOFTWARE COMPONENTS
[i series MODEL A CNC software]

Series / Version Functions
FS16i-TA
B1F2 CNC functions for lathe with up to 8 servo
FS160i-TA
B1F4 axes and up to 2 spindle axes.
FS160is-TA
FS18i-TA
BEF2 CNC functions for lathe with up to 6 servo
FS180i-TA
BEF4 axes and up to 2 spindle axes.
FS180is-TA
FS21i-TA
DEF2 CNC functions for lathe with up to 4 servo
FS210i-TA
DEF4 axes and up to 2 spindle axes.
FS210is-TA
CNC functions for manual lathe with up to 2
FS20i-TA D1F1
servo axes and up to 1 spindle axis
FS16i-MA
B0F2 CNC functions for machining center with up
FS160i-MA
B0F4 to 8 servo axes and up to 2 spindle axes.
FS160is-MA
FS18i-MA
BDF2 CNC functions for machining center with up
FS180i-MA
BDF4 to 6 servo axes and up to 2 spindle axes.
FS180is-MA
FS21i-MA
DDF2 CNC functions for machining center with up
FS210i-MA
DDF4 to 4 servo axes and up to 2 spindle axes.
FS210is-MA
CNC functions for manual milling machine
FS20i-FA D0F1 with up to 4 servo axes and up to 1 spindle
axis.
[i series MODEL B CNC software]

FS16i-TB
CNC functions for lathe with up to 8 servo
FS160i-TB B1H1
axes and up to 2 spindle axes.
FS160is-TB
FS18i-TB
FS180i-TB BEH1
FS180is-TB
FS21i-TB
FS210i-TB DEH1
FS210is-TB
FS16i-MB
CNC functions for machining center with up
FS160i-MB B0H1
to 8 servo axes and up to 2 spindle axes.
FS160is-MB
FS18i-MB5 CNC functions for machining center with up
FS180i-MB5 BDH5 to 6 servo axes and up to 2 spindle axes.
FS180is-MB5 Simultaneously controlled axes : max 5 axes
FS18i-MB CNC functions for machining center with up
FS180i-MB BDH1 to 6 servo axes and up to 2 spindle axes.
FS180is-MB Simultaneously controlled axes : max 4 axes
FS21i-MB
CNC functions for machining center with up
FS210i-MB DDH1
to 4 servo axes and up to 2 spindle axes.
FS210is-MB
- 109 -
[Monitor software]
Monitor 90A9 / 03 Monitor functions
Monitor 90B9 / 01 Monitor functions
[Servo control software]

Servo 90A5 / 01 Servo functions
Servo 90B0 / 09 Servo functions
Servo 90B7 / 04 Learning control
[Spindle software]
Spindle 9D20 / 10 Spindle functions
Spindle 9D50 / 04 Spindle functions
- 110 -
11.3 SERVO AMPLIFIER
No. Description Module Name Specification number Remarks

1 Power Supply Module PSM-5.5 A06B-6077-H106
(Standard) PSM-11 A06B-6077-H111
PSM-15 A06B-6087-H115
PSM-26 A06B-6087-H126
PSM-30 A06B-6087-H130
PSM-37 A06B-6087-H137
PSM-45 A06B-6087-H145
PSM-55 A06B-6087-H155
PSM-5.5i A06B-6110-H006
PSM-11i A06B-6110-H011
PSM-15i A06B-6110-H015
PSM-26i A06B-6110-H026
PSM-30i A06B-6110-H030
PSM-37i A06B-6110-H037
2 Power Supply Module PSMR-1 A06B-6081-H101
(Resister Discharge type) PSMR-3 A06B-6081-H103
PSMR-5.5 A06B-6081-H106
3 Servo Amplifier Module SVM1-2 A06B-6096-H121
(1 axis type) SVM1-4 A06B-6096-H122
SVM1-12 A06B-6096-H101
SVM1-20 A06B-6096-H102
SVM1-40S A06B-6096-H103
SVM1-40L A06B-6096-H104
SVM1-80 A06B-6096-H105
SVM1-130 A06B-6096-H106
SVM1-130S A06B-6096-H116
SVM1-240 A06B-6096-H107
SVM1-360 A06B-6096-H108
SVM1-20i A06B-6114-H103
SVM1-40i A06B-6114-H104
SVM1-80i A06B-6114-H105
SVM-160i A06B-6114-H106
SVM1-360i A06B-6114-H109
4 Servo Amplifier Module SVM2-12/12 A06B-6096-H201
(2 axes type) SVM2-12/20 A06B-6096-H202
SVM2-20/20 A06B-6096-H203
SVM2-12/40 A06B-6096-H204
SVM2-20/40 A06B-6096-H205
SVM2-40/40 A06B-6096-H206
SVM2-40/80 A06B-6096-H207
SVM2-80/80 A06B-6096-H208
SVM2-40L/40L A06B-6096-H209
SVM2-4/4i A06B-6114-H201
SVM2-20/20i A06B-6114-H205
SVM2-20/40i A06B-6114-H206
SVM2-40/40i A06B-6114-H207
SVM2-40/80i A06B-6114-H208
- 111 -
No. Description Module Name Specification number Remarks

4 Servo Amplifier Module SVM2-80/80i A06B-6114-H209
(2 axes type) SVM2-80/160i A06B-6114-H210
SVM2-160/160i A06B-6114-H211
5 Servo Amplifier Module SVM3-12/12/12 A06B-6096-H301
(3 axes type) SVM3-12/12/20 A06B-6096-H302
SVM3-12/20/20 A06B-6096-H303
SVM3-20/20/20 A06B-6096-H304
SVM3-12/12/40 A06B-6096-H305
SVM3-12/20/40 A06B-6096-H306
SVM3-20/20/40 A06B-6096-H307
SVM3-4/4/4i A06B-6114-H301
SVM3-20/20/20i A06B-6114-H303
SVM3-20/20/40i A06B-6114-H304
6 Spindle Amplifier Module SPM-2.2-1 A06B-6102-H202#H520
(SPM HRV Type I ) SPM-5.5-1 A06B-6102-H206#H520
SPM-11-1 A06B-6102-H211#H520
SPM-15-1 A06B-6102-H215#H520
SPM-22-1 A06B-6102-H222#H520
SPM-26-1 A06B-6102-H226#H520
SPM-30-1 A06B-6102-H230#H520
SPM-45-1 A06B-6102-H245#H520
SPM-55-1 A06B-6102-H255#H520
7 Spindle Amplifier Module SPM-2.2-4 A06B-6102-H102#H520
(SPM HRV Type IV ) SPM-5.5-4 A06B-6102-H106#H520
SPM-11-4 A06B-6102-H111#H520
SPM-15-4 A06B-6102-H115#H520
SPM-22-4 A06B-6102-H122#H520
SPM-26-4 A06B-6102-H126#H520
SPM-30-4 A06B-6102-H130#H520
SPM-45-4 A06B-6102-H145#H520
SPM-55-4 A06B-6102-H155#H520
8 Spindle Amplifier Module SPM-2.2i A06B-6111-H002#H550
(SPM HRV Type A ) SPM-5.5i A06B-6111-H006#H550
SPM-11i A06B-6111-H011#H550
SPM-15i A06B-6111-H015#H550
SPM-22i A06B-6111-H022#H550
SPM-26i A06B-6111-H026#H550
SPM-30i A06B-6111-H030#H550
9 Spindle Amplifier Module SPM-2.2i A06B-6112-H002#H550
(SPM HRV Type B ) SPM-5.5i A06B-6112-H006#H550
SPM-11i A06B-6112-H011#H550
SPM-15i A06B-6112-H015#H550
SPM-22i A06B-6112-H022#H550
SPM-26i A06B-6112-H026#H550
SPM-30i A06B-6112-H030#H550
- 112 -
B-63494EN/01 INDEX
INDEX
For Two-path..................................................... 37
A
For Two-path (When the main side and sub side
ALARMS AND MESSAGES ............................ 86
use a common MCC) ..................................... 99
Alarms Displayed on the Spindle Unit ........... 92
For Two-path (When the main side and sub side
APPLICATION RANGE................................... 17
use independent MCCs and protection doors)
B ...................................................................... 100
FSSB I/O Attachment....................................... 43
BASIC PRINCIPLE OF DUAL CHECK
FSSB I/O Connection........................................ 41
SAFETY........................................................... 6
FSSB I/O Specification List.............................. 47
BEFORE USING THE SAFETY FUNCTION 20
FUNCTIONS THAT REQUIRE SPECIAL
Boot System Alarms ......................................... 93
PARAMETER SETTINGS............................ 74
C
G
Certification Test ................................................ 4
General Definition of Terms .............................. 5
Compliance with the Safety Standard (EN954-1,
GENERAL INFORMATION ............................ 12
Category 3) ...................................................... 7
Guard lock state signal..................................... 52
COMPONENTS LIST..................................... 106
Guard open request signal ............................... 52
D
Guard Open Request Signal (ORQ) ............... 102
DEFINITION OF TERMS ................................. 5 Guard state signal ............................................ 52
Definition of Terms Related to the Safety Guard unlock signal.......................................... 53
Function .......................................................... 5 Guard Unlock Signal (*LGD), Guard Lock State
DI/DO CONNECTION (VIA THE FSSB) ....... 41 Signal (GDL), Guard State Signal (SGD).. 103
DI/DO CONNECTION (VIA THE PMC)......... 40
H
DIAGNOSIS................................................ 94, 96
HARDWARE COMPONENTS....................... 107
DIRECTIVE AND STANDARDS ...................... 3
Hardware Components for Other Units........ 108
Directives ............................................................ 3
Hardware Components for Series
E 16i/18i/21i/160i/180i/210i/160is/180is/210is-
EMERGENCY STOP........................................ 29 MODEL A .................................................... 107
Emergency stop signal ..................................... 50 Hardware Components for Series
Emergency Stop Signal (*ESP1, *ESP2)....... 101 16i/18i/21i/160i/180i/210i/160is/180is/210is-
Error analysis ................................................... 10 MODEL B .................................................... 107
ety monitoring cycle and cross-check cycle ....... 9
I
F
I/O SIGNALS .................................................... 48
Features of Dual Check Safety .......................... 6 Important Items to Check Before Using the
For One-path............................................... 35, 98 Safety Function ............................................. 20
i-1
Initial start-up .................................................. 78 SAFE SPEED MONITORING ......................... 30

INSTALLATION............................................... 33 SAFETY FUNCTIONS..................................... 16
SAFETY I/O MONITORING............................ 24
L
SAFETY PRECAUTIONS ............................ 1, 82
Latent error detection and cross-check ............. 8
Safety Signal Modes ......................................... 56
Loader Control .................................................. 61
SAMPLE CONFIGURATION .......................... 98
M SAMPLE CONNECTIONS ............................ 101
SAMPLE SYSTEM CONFIGURATION ......... 97
MAINTENANCE .............................................. 81
Serial Spindle Alarms....................................... 91
MCC contact state signal ................................. 53
Series start-up................................................... 80
MCC off Test ....................................................... 9
Servo Alarms..................................................... 87
MCC OFF TEST ............................................... 32
SERVO AMPLIFIER ...................................... 111
MCC off Test execution request signal............ 54
Signal Addresses............................................... 55
MCC off Test of the Safe Stop Function.......... 20
SIGNALS........................................................... 50
MCC On Enable Signal (MCF), MCC Contact
Simple Electronic Gearbox and Two Groups of
State Signal (*SMC) ................................... 105
Electronic Gearboxes .................................... 74
MCC-on enable signal ...................................... 53
SOFTWARE COMPONENTS ........................ 109
Multi-path Control............................................ 74
START-UP......................................................... 75
N
Start-up of the Safety Function ....................... 78
NOTES ON MULTI-PATH CONTROL........... 57 START-UP OPERATION ................................. 76
STOP.................................................................. 21
O
Stop States ........................................................ 22
One-CPU Two-Path Control ............................ 59
Stopping the Servo Motor................................. 22
OVERALL CONNECTION DIAGRAM........... 35
Stopping the Spindle Motor ............................. 21
Overview ........................................................... 86
System Alarms .................................................. 93
P SYSTEM CONFIGURATION .......................... 14
PARAMETERS ........................................... 62, 64 T

PARAMETERS RELATED TO THE USE OF
Tandem Control ................................................ 74
FSSB I/O UNIT............................................. 72
Test mode signal ............................................... 50
R Test Mode Signal (OPT) ................................. 102
Troubleshooting ................................................ 80
Related Safety Standards .................................. 3
Two-CPU Three-Path Control.......................... 60
Remaining risks................................................ 10
Two-CPU Two-Path Control (With Axis Change
Risk Analysis and Evaluation............................ 3
between Paths) .............................................. 58
S
Two-CPU Two-Path Control (Without Axis
SAFE MACHINE POSITION MONITORING 31 Change between Paths) ................................ 57
-2-
Revision Record
Dual Check Safety OPERATOR’S MANUAL (B-63494EN)
01 Feb., 2002
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OPERATOR’S MANUAL

In this manual we have tried as much as possible to describe all the

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

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

1.3.2.2 Safety monitoring cycle and cross-check cycle ................................................................................9

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

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

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

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

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

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

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

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

5.1 OVERVIEW ..................................................................................................................................... 49

6.1 OVERVIEW ..................................................................................................................................... 63

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

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

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

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

10 SAMPLE SYSTEM CONFI

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

11 COMPONENTS LIST ................................................................

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

The simplest method of ensuring safety when the protection door is

The dual check safety function consists of the following three

The safety function operates regardless of the NC mode. Usually, this

The European standard certification organization has certified that

1.1 DIRECTIVE AND STANDARDS

Machine tools and their components must satisfy the EC directives

1.1.2 Related Safety Standards

To be compatible with the directives, especially the machine directive,

Important safety standards

1.1.3 Risk Analysis and Evaluation

According to the machine directive, the manufacturer of a machine or

1.1.4 Certification Test

Certification of the dual check safety function

1.2 DEFINITION OF TERMS

1.2.1 General Definition of Terms

Reliability and safety

1.2.2 Definition of Terms Related to the Safety Function

Safe-related I/O signal

Safe machine position

1.3 BASIC PRINCIPLE OF DUAL CHECK SAFETY

1.3.1 Features of Dual Check Safety

- Two-channel configuration with two or more independent CPUs

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

The dual check safety function satisfies the requirements of Category

Category 3 requires the following:

To satisfy these requirements, the dual check safety function is

Monitoring of servo motor and spindle motor movement

Cross-monitoring using 2 CPUs

Power shutoff via two paths

Input signal safety

Output signal safety

1.3.2.1 Latent error detection and cross-check

Detection of latent errors

1.3.2.2 Safety monitoring cycle and cross-check cycle

The safety function is subject to periodical monitoring in a monitoring

The cross-check cycle represents a cycle at which all data subject to