FANUC Series 0i-MODEL D, Series 0i Mate-MODEL D. CONNECTION MANUAL (HARDWARE)

B-64303EN/03

3.INSTALLATION

3.5.1.3 Cable clamp and shield processing

Signal lines basically require shield clamps. The influence of external noise can be suppressed by

properly providing the signal lines with the shield clamps.

Partially peel the sheath off a cable and expose the shield, and press the exposed portion against the

ground bar with the clamp. Care should be taken so that the ground bar and shield have a surface contact

in a larger area. (See the figure below.)

When the multipoint grounding scheme is used, care should be taken so that the ground bar for the shield

clamp and cabinet are connected at low impedance by, for example, preventing the cabinet side contact

surface from being coated.

Ground plate

Cable

Metal fittings for

clamp

Fig. 3.5.1.3 (a) Cable clamp (1)

NOTE

Select a cable with a proper length.

If the cable is too long, the noise immunity may be reduced or noise may be

caused on other cables. In addition, when the excess length is coiled, the

inductance is increased and a high voltage is induced during turning on or off of

signals. This may cause a malfunction due to a failure or noise.

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B-64303EN/03

3.INSTALLATION

Ground plate

Fig. 3.5.1.3 (d) Ground plate holes

(Reference) Outer drawings of metal fittings for clamp.

Max. 55

Fig. 3.5.1.3 (e) Outer drawings of metal fittings for clamp

Ordering specification for metal fittings for clamp

A02B-0124-K001 (8 pieces)

3.5.1.4 Cabinet

A cabinet is an important element in improving noise immunity and suppressing radiated noise. One of

the causes of problems related to noise immunity and radiated noise is faulty electrical continuity between

the metal plates that make up the cabinet. Typically, noise that becomes a problem is high-frequency

noise, against which measures must be taken in the cabinet design.

(1) Basic cabinet structure

A cabinet should basically be made of metal.

To improve noise immunity, there must be low-impedance electrical continuity between the metal

plates that make up the cabinet, which are the side plates, top plate, and bottom plate, and a

welding-type cabinet structure is recommended.

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3.INSTALLATION

B-64303EN/03

As for a cabinet welding method, bead welding is more suitable than spot welding for providing

low-impedance electrical continuity between the metal plates.

For an assembly-type cabinet structure, provide electrical continuity by bringing the metal plates

into direct contact with each other, without applying a coating to their joint surface areas.

In a structure that has the metal plates connected only with wires because of structural constraints,

low-impedance connections are more difficult to make than in a structure in which welding is made

or the metal plates are brought into direct contact with each other. It is necessary to maintain

sufficient levels of items such as the cross-sectional area of a wire to use, continuity of connections,

and contact areas.

Bead welding

Bring the metal plates into direct contact with each

other, without applying a coating to their joint areas.

NOTE

For improved noise immunity, how to provide low-impedance electrical continuity

in the cabinet is described here. To construct a protective circuit, a protective

grounding connection must be made between the metal plates by using electric

wires with a cross-sectional area appropriate for the AC input power capacity of

the unit mounted on each metal plate.

(2) Mounting units on the cabinet

The shortest possible lengths of unit ground wires should be used to make connections. A ground

wire with a small conductor diameter causes impedance to high-frequency noise to become

particularly higher, leading to an insufficient grounding effect. For the location of the ground

terminal of each unit, refer to the manual relevant to the unit. The following shows the

recommended method by which the metal plate with the unit mounted is installed on the cabinet.

Care should be taken so that the cabinet and metal plate are connected to each other on their broad

areas with no coating. It is not recommended that electrical continuity be provided only by screws,

because impedance to high frequency cannot be sufficiently low.

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B-64303EN/03

3.INSTALLATION

Cabinet

Metal

plate

Unit

Shortest connection

Continuity on areas with

with thick ground wire

no coating

Cabinet

Metal

plate

Unit

Continuity only by

Thin ground wire,

screw in a coated area

long ground wire

3.5.2

Connecting the Ground Terminal of the Control Unit

Connecting the 0 V output in the CNC to a protective circuit (ground)

The IEC 204-1 and JIS B 6015 standards specify the following:

- Protection against malfunctions due to ground faults

“To make the control circuit prevent malfunctions of a machine tool due to a ground fault and not to

prevent the machine tool from stopping, either of the ground and electronic circuits shall be connected to

a protective circuit.”

Note that for each FANUC CNC, the 0V output in the CNC is connected to a protective circuit (ground).

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3.INSTALLATION

B-64303EN/03

3.5.3

Separating Signal Lines

The cables used for the CNC machine tool are classified as listed in the following table.

Process the cables in each group as described in the action column.

Group

Signal line

Action

Primary AC power line

Bind the cables in group A separately (Note 1)

Secondary AC power line

from groups B and C, or cover group A with an

AC/DC power lines (containing the power lines for

electromagnetic shield (Note 2).

the servo and spindle motors)

See Subsection 3.5.4 and connect spark killers

AC/DC solenoid

or diodes with the solenoid and relay.

AC/DC relay

DC solenoid (24 VDC)

Connect diodes with the DC solenoid and relay.

DC relay (24 VDC)

Bind the cables in group B separately from

DI/DO cable between the I/O unit and power

group A, or cover group B with an

magnetics cabinet

electromagnetic shield.

DI/DO cable between the I/O unit and machine

Separate group B as far from group C as

24 VDC input power cables connected to the

possible.

control unit and its peripherals

It is desirable to perform shield processing.

Cable between the CNC and I/O unit

Bind the cables in group C separately from

Cable for position and velocity feedback

group A, or cover group C with an

Cable between the CNC and spindle amplifier

electromagnetic shield.

Cable for the position coder

Separate group C as far from group B as

Cable for the manual pulse generator

possible.

Be sure to perform shield processing as

Cable between the CNC and the MDI (Note 3)

described in Subsection 3.5.5.

RS-232C and RS-422 interface cable

Cable for the battery

Other cables for which shield processing is

specified

NOTE

1 Binding the cables in one group separately from another means that the groups

are placed 10 cm or more apart from one another.

2 Covering a group with an electromagnetic shield means that shielding is

provided between groups with grounded steel plates.

3 The shield is not required when the cable between the CNC and MDI is no more

than 30 cm in length.

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3.INSTALLATION

3.5.4

Noise Suppressor

The AC/DC solenoid, AC/DC relay, and other devices are used in the power magnetics cabinet.

A high pulse voltage is caused by coil inductance when these devices are turned on or off.

This pulse voltage is induced through a cable or any other component, causing the electronic circuits to be

disturbed.

Take the following measures against the pulse voltage:

See Subsection 3.5.3 for groups A and B, and use spark killers for AC circuits or diodes for DC

circuits.

See “Notes on selecting the spark killer” below for information about selection of spark killers or

diodes.

Notes on selecting the spark killer

• Use a CR-type spark killer. (Use it for AC circuits.)

(A varistor is useful in clamping the peak pulse voltage, but cannot suppress the sudden rise of the

pulse voltage. FANUC therefore recommends the use of a CR-type spark killer.)

• The reference CR values of the spark killer shall conform to the following based on the current ((I

(A)) and DC resistance of the coil in the stationary state:

Resistance (R)

: Equivalent of the DC resistance of the coil

Capacitance (C) :

(μF)

:Current of the coil in the stationary state [A]

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3.INSTALLATION

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Equivalent circuit of the spark killer

Spark killer

AC relay

Motor

Spark killer

Mount the noise eliminator near a motor or a relay coil.

NOTE

Use a CR-type noise eliminator. Varistor-type noise eliminators clamp the peak

pulse voltage but cannot suppress a sharp rising edge.

Diode (used for direct-current circuits)

Diode

Use a diode which can withstand a voltage up

DC relay

to two times the applied voltage and a current

up to two times the applied current.

3.5.5

Measures Against Surges due to Lightning

To protect equipment from surge voltages caused by lightning, install a lightning surge protector between

lines and between a line and ground. For how to install protectors, see Appendix A "FITTING A

LIGHTNING SURGE PROTECTION DEVICE" in FANUC SERVO AMPLIFIER αi series

DESCRIPTIONS (B-65282EN).

Lightning surge protector specifications

Ordering number

Specification

Remarks

For line-to-line installation:

Manufactured by Okaya Electric Industries Co., Ltd.

RAV-781BYZ-2

A06B-6077-K142

For 200VAC line

For line-to-ground installation:

TÜV approved products

RAV-781BXZ-4

For line-to-line installation:

Manufactured by Okaya Electric Industries Co., Ltd.

RAV-152BYZ-2A

A06B-6077-K143

For 400VAC line

For line-to-ground installation:

TÜV approved products

RAV-801BXZ-4

Integration type for line-to-line

Manufactured by Okaya Electric Industries Co., Ltd.

A06B-6077-K144

installation/line-to-ground installation:

For 200VAC line

RCM-601BUZ-4

TÜV approved products

* The line-to-line or line-to-ground installation type (A06B-6077-K144) and the integration type

(A06B-6077-K142) are equivalent in performance and specifications.

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3.INSTALLATION

B-64303EN/03

Installing the I/O unit for 0i

Fig. 3.6.2

3.7

SEVERE DUST/LIQUID PROTECTION OF CABINETS AND

PENDANT BOXES

Since a cabinet or pendant box, which is designed by the machine tool builder, for housing display units

or operator's panels is likely to receive dust particles, chippings, or greasy fumes, so keep the following in

mind to keep them out.

The cabinet and pendant box must be of a hermetically sealed structure.

Apply packing to the panel mounting surface to which a display and operator's panel are to be

mounted.

Apply packing to the panel mounting surfaces of other units mounted on the same case for

dust/liquid protection.

Make sure that the door packing of the cabinet and pendant box is sealed firmly.

For a cabinet or pendant box with a rear cover, apply packing to the mounting surface.

Make sure that the cable entrance is sealed with packing, connectors for conduits, etc.

Make sure that all other openings are blocked, if any.

Make sure that the display and operator's panel do not receive cutting debris and coolant directly.

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4.POWER SUPPLY CONNECTION

B-64303EN/03

4 POWER SUPPLY CONNECTION

4.1

GENERAL

This chapter explains the connection of power supply for control unit.

4.2

TURNING ON AND OFF THE POWER TO THE CONTROL

UNIT

4.2.1

Power Supply for the Control Unit

Supply power (24VDC) to the control unit from an external sources.

Provide an ON/OFF circuit for turning the AC power on and off outside the unit as shown in Fig. 4.2.1.

To minimize the effect of noise or voltage fluctuations to the CNC, it is recommended that a power to the

CNC be provided independently of the power sources to devices with large noise or load fluctuations.

Fig. 4.2.1

4.2.2

External 24 VDC Power Specification and Circuit

Configuration

Specifications of recommended external 24 VDC power supply (regulated power supply):

(The power

supply must satisfy UL1950.)

Output voltage:

+24 V ±10% (21.6 V to 26.4 V)

(including ripple voltage and noise. See the figure below.)

Output current:

The continuous load current must be larger than the current consumption of the CNC.

(At the maximum temperature inside the power magnetics cabinet in which the power supply is

located)

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4.POWER SUPPLY CONNECTION

Load fluctuations (including rush current):

The output voltage must not go out of the above range due to load fluctuations by external DO and

other factors.

Instantaneous input interruption retention time:

10 ms (for -100%), 20 ms (for -50%)

Fig 4.2.2 (a) Timing chart

Notes to take when the vertical axis exists

When the vertical axis exists, select the DC power supply that has a long voltage hold time to decrease

the amount of vertical axis falling during power-off (including a power failure).

If the operating voltage drops to less than or equal to

21.6V, the CNC releases servo activation.

Therefore, when the hold time for 24 VDC during AC power-off is too short, servo activation is released

before the breaks are applied because some peripheral circuit detects power-off. This may increase the

amount of vertical axis falling.

Generally, a power supply with sufficient power capacity tends to increase the hold time during

power-off.

Circuit configurations

The following circuit configurations are not recommended.

Forbidden

<1> Circuit examples that cannot retain the output voltage at an instantaneous interruption (the voltage

reduces to 21.6 V or below)

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4.POWER SUPPLY CONNECTION

B-64303EN/03

Example 1

Rectifier

circuit

AC input

CNC unit

Example 2

Rectifier

circuit

AC input

CNC unit

NOTE

The rectifier circuit means a circuit using diodes for full-wave rectification.

<2> Circuit examples that exceed the output voltage specifications (21.6 V to 26.4 V) due to an abrupt

load change

Example 1

Regulated

AC input

power supply

CNC unit

Device with

remarkable load

fluctuations

Example 2

Regulated

AC input

power supply

CNC unit

Device with large

rush current

For a circuit configuration in <2>, connect another regulated power supply to be specifically used for the

device with remarkable load fluctuations so that the CNC and other units are not affected.

Avoid the use of a configuration in <2> if possible, even in an environment with small load fluctuations

or rush current. When two or more units are connected to the same power supply, the 24-VDC power

may not be turned on due to a failure in a unit other than the CNC. If this happens, it takes much time to

locate the failure because the CNC cannot start and no alarm indication is provided.

When the CNC and other units are connected to the same power supply because of limited space for the

power magnetics cabinet or for some other reason, careful consideration must be given to possible rush

currents and voltage fluctuations. In addition, to prevent power supply noise from entering the CNC, a

noise filter must be inserted before the power to the CNC.

(Recommended noise filter: ZGB2203-01U

manufactured by TDK)

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B-64303EN/03

4.POWER SUPPLY CONNECTION

Recommended

The following circuit configuration is recommended.

The power to the CNC and other, FANUC Servo Unit β series with an I/O link (β amplifier with an I/O

link), and so on in the sample configuration below) is assumed to be turned on or off at the same time.

(The power to any unit is not assumed to be turned on during operation or before the power to the CNC is

turned on.

On/off

Regulated

AC input

circuit

power

CNC unit

supply

I/O Unit-A

β amplifier with

an I/O link

Regulated

Device with large noise

power

or load fluctuations

supply

Fig 4.2.2 (b)

For example, the following units require 24VDC power sources.

• Various I/O Link slave units

• β servo amplifier and βi servo amplifierβ

• Separate detector unit

Caution

Turning the power to units on simultaneously when turning the power to the CNC:

When the following power-on timing condition is satisfied, the power to units is assumed to be turned on

simultaneously when the power to the CNC is turned on.

Power to the CNC

Off

Power to units

(including the Power

Mate)

Off

t1:200ms Means that the power to units (including the Power Mate) is turned on within 200 ms before

the power to the CNC is turned on.

t2:-500ms Means that the power to units (including the Power Mate) is turned on within 500 ms after

the power to the CNC is turned on.

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4.POWER SUPPLY CONNECTION

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Turning the power to units off simultaneously when turning the power to the CNC off:

This means that the power to units may be turned off within 500 ms before the power to the CNC control

unit is turned off. If the power to units is turned off earlier, alarm information is left in the NC.

Power to the CNC

Off

t1:500ms Means that the power to units are turned off within 500 ms before the power to the CNC is

turned off.

The power to the CNC must not be turned on or off with the power to units on.

4.2.3

Power-on Sequence

Turn on the power to all the units at the same time, or in the following sequence:

1 Power to the overall machine (200 VAC)

2 Servo amplifier control power supply (200 VAC)

3 Power to the slave I/O units connected via the I/O link, the separate detector interface unit, and the stand-alone

type LCD unit (24 VDC), power to the CNC controller (24 VDC), power to the separate detector (scale)

“Turning on the power to all the units at the same time” means completing the power-on operations in 1

and 2 above within 500 ms of performing power-on in 3.

Do not remove the memory backup battery (3VDC) and the separate absolute pulse coder battery (6VDC)

regardless of whether the power of the CNC controller is on or off. If the batteries are removed when

the CNC controller is off, the parameters and programs saved in the CNC controller and the position data

in the pulse coder are lost.

For information on replacing the memory backup battery, see Subsection 4.4.1.

4.2.4

Power-off Sequence

Turn off the power to all the units at the same time, or in the following sequence:

1 Power to the slave I/O units connected via the I/O link, the separate detector interface unit, and the CNC

controller (24 VDC)

2 Servo amplifier control power supply (200 VAC), power to the separate detector (scale)

3 Power to the overall machine (200 VAC)

When turning off the power of the CNC controller, be sure to turn off the power of units such as the slave

I/O devices connected through I/O Link, β amplifier with I/O Link, Power Mate and separate detector

interface unit, control power supply of the servo amplifier, and separate detector (such as a scale).

“Turning off the power to all units at the same time” means completing the power-off operations in 2 and

3 above within 500 ms before the power-off operation described in 1 above. If the power to the units

indicated in 2 or 3 is turned off other than within 500 ms of the power in 1 being turned off, alarm

information is left in the NC.

When the power is turned off or when the power is momentarily disconnected, processing must be

performed from the machine as necessary, because motor control is disabled.

For example, when movement along a vertical axis is controlled, a brake should be applied to prevent

falling. Usually, the brake clamps the motor when the servo is not activated or when the motor is not

turning. The clamp is released only when the motor is turning.

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4.POWER SUPPLY CONNECTION

When servo axis control is disabled by power-off or momentary power disconnection, the brake usually

clamps the servo motor. In this case, before the relay for clamping operates, the controlled axis may fall.

So, also consider whether the distance the axis is likely to fall will cause a problem.

When the power is turned off:

Be sure to apply a brake for clamping before turning off the power to CNC.

When the power fails:

If a power failure is detected, a brake must be applied immediately. Select the power supply with a

longer DC power retention time after AC power-off, because the servo is deactivated if the power to

CNC is turned off.

4.3

CABLE FOR POWER SUPPLY TO CONTROL UNIT

Supply the power to the control unit from an external 24 VDC power supply.

CNC control unit

External power

CP1

+24V

24VDC stabilized

power

24VDC ±10%

Cable

CP1

AMP Japan

1-178288-3 (housing)

1-175218-5 (Contact)

External power

Select a source that

+24V (1)

meets the external

0V (2)

power terminal.

Recommended cable : A02B-0124-K830(5m)

(Crimp terminal of size M3 is available on the external power side)

4.4

BATTERIES

In a system using this CNC, batteries are used as follows:

Use

Component connected to battery

Memory backup in the CNC control unit

CNC control unit

Preservation of the current position indicated by the

Separate detector interface unit

separate absolute pulse coder

Preservation of the current position indicated by the

Servo amplifier

absolute pulse coder built into the motor

4.4.1

Battery for Memory Backup in the CNC Control Unit (3 VDC)

Offset data, and system parameters are stored in SRAM in the control unit. The power to the SRAM is

backed up by a lithium battery mounted on the front panel of the control unit. The above data is not lost

even when the main battery goes dead. The backup battery is mounted on the control unit at shipping.

This battery can maintain the contents of memory for about a year.

When the voltage of the battery becomes low, alarm message "BAT" blinks on the display and the battery

alarm signal is output to the PMC. When this alarm is displayed, replace the battery as soon as possible.

In general, the battery can be replaced within two or three weeks, however, this depends on the system

configuration.

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4.POWER SUPPLY CONNECTION

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If the voltage of the battery becomes any lower, memory can no longer be backed up. Turning on the

power to the control unit in this state causes system alarm to occur because the contents of memory are

lost. Clear the entire memory and reenter data after replacing the battery.

FANUC thus recommends that the battery be replaced periodically, once a year, regardless of whether a

battery alarm is issued.

The following two kinds of batteries can be used.

• Lithium battery built into the CNC control unit.

• Two alkaline dry cells (size D) in the external battery case.

NOTE

A lithium battery is installed as standard at the factory.

When a lithium battery is used

- Replacement procedure

Prepare a new battery unit (ordering code: A02B-0309-K102).

(1) Turn on the power to the CNC. After about 30 seconds, turn off the power.

(2) Extract the old battery unit from the lower right of the rear of the CNC unit. (Hold the latch of the

battery unit, and extract the unit upward while releasing the claw from the case.)

Extract the unit while holding this portion.

(3) Mount the new battery unit. (Push the battery unit in until the claw is latched into the case.) Ensure

that the latch is engaged securely.

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4.POWER SUPPLY CONNECTION

Push the unit in until the claw is

latched into the case.

WARNING

Using other than the recommended battery may result in the battery exploding.

Replace the battery only with the specified battery (A02B-0309-K102).

CAUTION

Steps 1 to 3 should be completed within 30 minutes. Do not leave the control

unit without a battery for any longer than the specified period. Otherwise, the

contents of memory may be lost.

If steps 1 to 3 may not be completed within 30 minutes, save all contents of the

SRAM memory to the memory card beforehand. Thus, if the contents of the

SRAM memory are lost, the contents can be restored easily.

When discarding a battery, observe the applicable ordinances or other rules of your local government.

In addition, cover the exposed pins with tape or other insulation materials to prevent a short circuit before

discarding the battery.

When using commercial alkaline dry cells (size D)

To use commercial alkaline dry cells (size D) instead of the lithium battery attached to the control unit,

install the battery unit in other than the control unit.

- Connection method

Remove the factory-mounted lithium battery from the control unit as described in the battery replacement

method above. Connect the battery cable (A02B-0309-K103) to the battery case (A02B-0236-C282). This

battery cable has the same connector as the lithium battery unit, so connect the connector to the place

where the lithium battery unit was installed as shown in the figure below. Since the connector has a

simple lock system, make sure that the lock is applied during installation.

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4.POWER SUPPLY CONNECTION

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4.4.2

Battery for Separate Absolute Pulsecoders (6VDC)

The current position data of the absolute pulse coder connected to the separate detector interface unit is

saved by the battery connected to connector JA4A of the separate detector interface unit.

If the voltage of the battery drops, DS alarms 306 to 308 are issued. When DS alarm 307 (battery

voltage drop alarm) occurs, replace the battery as soon as possible. Estimated time to run out of the

battery is 1 to 2 weeks, but the actual life depends on the number of pulse coders.

If the voltage of the battery further drops, DS alarms 306 (battery zero alarm) occurs. In this case, the

current position of the pulse coder cannot be recorded and DS alarm 300 (reference position return alarm)

occurs. Replace the battery and perform a reference position return.

Although the battery life depends on the number of pulse coders connected, it is recommended that the

battery be replaced annually regardless of the issuance of the above alarms.

Replacing a battery

Obtain four commercially available alkaline batteries (size D).

(1) Turn on the power of the machine (CNC).

(2) Loosen the screws of the battery case, and remove the cover.

(3) Replace the dry batteries in the case.

Screws

Cover

(4) After installing the new batteries, replace the cover.

(5) Turn off the power to the machine (CNC).

WARNING

If the batteries are installed incorrectly, an explosion may occur. Never use

batteries other than the specified type (Size D alkaline batteries).

CAUTION

The battery must be replaced with the power of the CNC turned on (the servo

amplifier turned on).

Note that, if batteries are replaced while no power is supplied to the CNC, the

recorded absolute position is lost.

4.4.3

Battery for Absolute Pulsecoder Built into the Motor (6VDC)

The battery for the absolute pulse coder built into the motor is installed in the servo amplifier. For the

methods of connection and replacement, refer to the maintenance manual of your servo amplifier.

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5.CONNECTION TO CNC PERIPHERALS

5.1.3

Connection with the Standard MDI Unit

Honda tsushin Kogyo Co., Ltd. (including

Control unit

MDI unit

housings)

JA2

PCR-E20FA-E20SPF1A+

(press-mount

CK1

type) or

*KEY00

*KEY01

*KEY00

*KEY01

PCR-E20FS-E20SPF1A+ (soldering type)

*KEY02

*KEY03

*KEY02

*KEY03

*KEY04

*KEY05

*KEY04

*KEY05

*KEY06

*KEY07

*KEY06

*KEY07

*COM00

*COM01

*COM00

*COM01

*COM02

*COM03

*COM02

*COM03

*COM04

*COM05

*COM04

*COM05

*COM06

*COM07

*COM06

*COM07

*COM08

*COM09

*COM08

*COM09

*COM10

*COM11

*COM10

*COM11

*KEY00

*KEY02

*KEY01

*KEY03

*KEY04

*KEY06

*KEY05

*KEY07

*COM00

*COM02

*COM01

*COM03

*COM04

*COM06

*COM05

*COM07

*COM08

*COM10

*COM09

*COM11

Shield

Grounding plate

Recommended cable specification: A02B-0309-K813(45cm)

Recommended wire specification:A66L-0001-0284#10P(#28AWG × 10 pairs)

NOTE

The MDI cable needs to be clamped to prevent a heavy load caused by vibration

from being applied to the cable. When the cable length is 50 cm or less,

however, shielding or clamping is not necessary.

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FANUC Series 0i-MODEL D, Series 0i Mate-MODEL D. CONNECTION MANUAL (HARDWARE) - page 2