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  2. Instruction: Acceptance Test Report for Dual Check Safety

Instruction: Acceptance Test Report for Dual Check Safety Users manual Page 8

Users manual
2.3. Acceptance Test of Safety Functions
The acceptance test must provoke that all of the limit values which have been set for the enabled
safety functions are exceeded in order to prove/confirm a correct function.
Indicate if the Test Execution is done at the first machine of this machine type or within
series production.
The test execution in series production is not saving any test part. Even in series
production the same adequate care has to be assured.
Try to force safe DI dual check safety alarms as above via software logic or hardware failure
simulation (preferred).
Safe DO alarm situation cannot be simulated easily. Only in case of programmable safe
I/O application, output signals are built by PMC and can be tested by forcing corresponding
signal. If there is no safe I/O application, please delete above row “Monitoring DO signal NG”
File Name: Guideline DCS Acceptance Test
Created by: Edgar Weiter at 30-Nov-04
Page 8 of 21
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Contents Summary of Instruction: Acceptance Test Report for Dual Check Safety Users manual

  • Page 1How to make Acceptance Test Report for Dual Check Safety File Name: Guideline DCS Acceptance Test Page 1 of 21 Created by: Edgar Weiter on 30-Nov-04
  • Page 2Revision History Table - Revision Status lists the latest version and date for the various sections of the specification. Versions 0.X are pre–release draft versions. Versions 1.X to X.X are post release versions. The number to the left of the decimal in the version number indicates the major versio
  • Page 3Table Of Contents Revision History ........................................................................................................................................ 2 Table Of Contents ............................................................................................................
  • Page 41. Outline The machine OEM must carry out an acceptance test for the activated Dual Check Safety functions at each machine. The acceptance test as printout is part of the accompanying documents for each machine. For this purpose GEFanuc provides a draft document in Microsoft WORD format, which the O
  • Page 52. Performing the Acceptance Test Enter the Machine Model and Type including the Serial Number of the machine on the cover page of the acceptance test 2.1. System Configuration Specify roughly the machine configuration in terms of number of axes and spindles including the listing of applied Safety F
  • Page 6Specify CNC control with detailed Software listing. Instead of listing detailed hardware configuration OEM has to attach the datasheet to the acceptance test report. The datasheet provides sufficient hardware information. Specify drive configuration plan as e.g. above. A more detailed axis report ha
  • Page 72.2. Description of Safety Functions ….. Describe roughly the above-mentioned key points of safety arrangements. File Name: Guideline DCS Acceptance Test Page 7 of 21 Created by: Edgar Weiter at 30-Nov-04
  • Page 82.3. Acceptance Test of Safety Functions The acceptance test must provoke that all of the limit values which have been set for the enabled safety functions are exceeded in order to prove/confirm a correct function. Indicate if the Test Execution is done at the first machine of this machine type or w
  • Page 9Test proper MCC control circuit by performing standard MCC off test via OPT signal. In the second part (above No. 2) of the test the timer PRM. 1946 has to be decreased (e.g. 20msec.), so that complete MCC off test cannot be executed within given time. Moreover OEM might add a test for safe system h
  • Page 10ESP Z Axis at G0 F50000 POSITION (mm) 36 mm Speed (1/min) 120 msec. Above Measurement can be done by servo waveform diagnosis too. It should be clearly linked to the measured values of measurement table (3.3 Safe Brake Monitoring Test). It depends on machine type and the risc analysis, if other axes
  • Page 11In the Test for Safe Reduced Speed Monitoring the system reaction for every safe speed for axes and spindles has to be tested. We recommend for the test to perform a Jog movement at speed, which far exceeds the limited speed set. Basically it becomes enough to verify, that system reacts with corresp
  • Page 12Safe Stop / Safe Speed X Axis Ch 2: Position (mm) Ch 1: Speed Ch 3: Velocity (mm/min) Command (mm/min) Ch 2: Position (mm) Ch 3: Velocity Command (mm/min) Ch 1: Speed (mm/min) File Name: Guideline DCS Acceptance Test Page 12 of 21 Created by: Edgar Weiter at 30-Nov-04
  • Page 13For the test of the Safe Position Deviation Monitoring halve the original values set in PRM.1829, 1838 accordingly (example: normal value for PRM.1829: 40; test setting: 20). For the test of safe stop deviation monitoring the machine will most probably come up with alarm at the next power on after t
  • Page 14Move the Axes assigned to Safe Position Switches from beyond maximum limit through the switching area to the position exceeding the minimum area. Insert the position values accordingly as shown above. If no position switch function is used, please delete this chapter. In case of spindle speed monito
  • Page 152.4. Safety Parameter In the chapter 4 of the report all the Safety Parameters of the machine to be reported have to be listed path by path. GEFanuc provides a software tool to generate this part of the report automatically. The generated PDF document has to be merged with the Word document. Please
  • Page 162.5. Completing the Certificate The Checksum to be entered above is not safety related. It provides just a general index for a subset of parameters supposed to be fixed all the time. Among this subset there are also the dual check safety parameters, which are usually password protected. Please verif
  • Page 17File Name: Guideline DCS Acceptance Test Page 17 of 21 Created by: Edgar Weiter at 30-Nov-04
  • Page 182.7. Attachment B Optional the OEM might confirm proper speed set selection in the different operation modes (machining mode, setting mode,..). This could be done by attaching screen hardcopies of the dual check safety diagnosis screens as following example shows: Door closed Normal Mode No. Action
  • Page 19Door open Safe Speed off No. Action Result Result Guard open 1 Safe State C See pictures Safe Speed off File Name: Guideline DCS Acceptance Test Page 19 of 21 Created by: Edgar Weiter at 30-Nov-04
  • Page 20Door open Safe Speed on No. Action Result Result Guard open 1 Safe State C See pictures Safe Speed on File Name: Guideline DCS Acceptance Test Page 20 of 21 Created by: Edgar Weiter at 30-Nov-04
  • Page 21ESP Reaction Test No. Action Result Result PSM - SMESON X8.4 =0 SPM - - 1 ESP Drives (7Segment display Drive System) *ESP G8.4=0 SVM1 - (push ESP Button) SVM2 - SVM3 - 2 ESP Screen DCSDGN Page 1 to 5 File Name: Guideline DCS Acceptance Test Page 21 of 21 Created by: Edgar Weiter at 30-Nov-04