DCS Basics, Tips and Tricks, and New
Features
Haresh Moradia
FANUC America Corporation
Thanks For Joining Us Today!
We Will Begin Shortly.
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Today’s Speakers
Haresh Moradia
Senior Electrical Engineer
General Industry and Automotive Segment
Email: haresh.moradia@fanucamerica.com
FANUC America Corporation
3900 W. Hamlin Rd.
Rochester Hills, Michigan 48309
www.fanucamerica.com
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Access to Controls & Audio
If you experience any audio problems, we find that the ‘Call Me’ function works best
and usually resolves most issues. You can also use the ‘I Will Call In’ function or the
‘Call Using Computer’ function via speakers or a dedicated headset.
Audio Settings
Changing Audio
Settings
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Questions
We will be taking questions using the Q&A panel that can be found at the bottom
of your screen by selecting the icon. Any questions entered in the Q&A will
be addressed at the END of today’s webinar.
Use the Q&A to Ask Questions
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Access to Webinar Files
An archive copy of today’s presentation will be made available in 1 week on our CRC
website where you will be able to download OR stream it to your desktop.
An email will be sent to all webinar registrants when that information is posted.
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Today’s Speakers
Haresh Moradia
Senior Electrical Engineer
General Industry and Automotive Segment
Email: haresh.moradia@fanucamerica.com
FANUC America Corporation
3900 W. Hamlin Rd.
Rochester Hills, Michigan 48309
www.fanucamerica.com
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Agenda



Review the fundamentals of DCS and ordering options
Configure DCS Tool Change and Safe IO Connection
Introduce the Tablet Teach Pendant DCS User Interface
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DCS Basics

Features





Check the speed and position data of motors with two independent CPUs in the robot
controller
Detect position and speed errors immediately and shut down the motor power by two
independent channels
Safety data and processes are cross-checked by two CPUs
Self-diagnosis of safety hardware and software is executed periodically to prevent
potential failure accumulation
Benefits




Do not need additional external sensors to monitor speed and position
Certified to meet the requirements of International Standard ISO13849-1 and
IEC61508 by an internationally accredited certification body
Ease of Deployment
Compact workcell deployment
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Position / Speed Check Function – J567
Checks the position or speed of the robot and shuts down the motor power if these are out of the specified limit
• Joint position and speed checks
• Check the shape models of robot arm and tool are in the specified zone or not
• Check the speed of tool center point
• Check the difference between current tool orientation and base orientation
• Enable/Disable checking by safe I/O signal
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Position / Speed Check Function – J567
Functions
• Joint Position Check Function
• Joint Speed Check Function
• Cartesian Position Check Function
–Zone Check Function
–Orientation Check Function
–Target model collision check function
• Cartesian Speed Check Function
• T1 Mode Speed Check Function
• Basic Position Check Function
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Position / Speed Check Function – J567
Fencing with required Spacing
from Restricted Space
Floor Space Reduction
Fencing with required spacing +
Stopping Distance Spacing from
Restricted Space
Operati
ng
Space
Operating
Space
Restricted Space using
DCS Position Check
Restricted Space w/
Required spacing +
Stopping Distance Spacing
Restricted
Space
using
hard stop
Required Spacing x +
Stopping Distance
Restricted
space
Fencing Requirements
using DCS Position Check
Fencing Requirements using
Mechanical Hard Stops
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SAFE I/O Connect Function – J568
• Cat.4, PL e, SIL 3 function
– Some safe I/O are Cat.3, PL d, SIL 2 because the
source function is Cat.3, PL d, SIL 2
– i.e. CPC, CSC, JPC, JSC, SLI, SLO
• 3 character type and index (i.e. SPI[1])
• Show the internal status of DCS (i.e. CPC[1])
• Status output to safety output signal
• Safe I/O has redundancy internally
– SFDI11 and SFDI21 = Safe I/O signal SPI[1]
– Signal ON when both dual channel signals ON
• Read/Set Safety I/O every 2ms
• Supports logical operations (AND, OR, NOT)
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SAFE I/O Connect Function – J568
• Safe Peripherals
• Config Change
• Safe System
• Robot Power
• Safety Internal Relays
• FL-Net
• SPI (1-64 or 1-128)
• SPO (1-64 or 1-128)
• SSI (1-14)
• SSO (1-7)
• SIR (1-64)
• Cartesian
• CCL (1-4)
• CCR(1-4)
• RPI (1-4)
• RPO (1-4)
• FSI (1-272)
• FSO (1-80)
• CPC (1-32)
• CSC (1-16)
• IO Link i Slave
• JPC (1-40)
• JSC (1-40)
•
•
•
•
• Joint
• CIP Safety
• CSI (1-64)
• CSO (1-64)
• SLI (1-64)
• SLO (1-64)
--ON
OFF
Non-Safety Data
• NSI (1-32)
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SAFE I/O Connect Function – J568
Details of SSI
– SSI[1] – SVOFF
– SSI[2] – FENCE
– SSI[3] – EXEMG
– SSI[4] – NOT USED
– SSI[5] – NTED
– SSI[6] – OPEMG
Details of SSO
–
–
–
–
–
–
–
SSO[1] – C_SVOFF
SSO[2] – C_FENCE
SSO[3] – C_EXEMG
SSO[4] – C_SVDISC
SSO[5] – C_NTED
SSO[6] – C_T1
SSO[7] – C_T2
– SSI[7] – AUTO
– SSI[8] – T1
– SSI[9] – T2
– SSI[10] – MCC
– SSI[11] – CSBP
– SSI[12] – POSSPD CHECK ENB
– SSI[13] – CONF_OK
– SSI[14] – F_IPAR_CRC
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External Mode Select Function – J569
• Operator Panel Switch Box Hardware
– R-30iB Compact Plus
– R-30iB Mini Plus
– DCS Mode Select Screen
DCS Mode Select Screen
R-30iB Compact Plus, R-30iB Mini Plus or TP Mode Select Option
• Software Options
– TP Mode Select Function – J768
• Excludes R-30iB
• Excludes R-30iB Mate
– External Mode Select Function – J569
• Operator panel must be “No mode
switch” type
– SYST-351 Mode select function mismatch
External Mode Select Function
A05B-2690-H400
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Adapter Safety Connection
 ISO13849-1, IEC61508
 Category 4
 PL e
 SIL 3
 Three Options
 DeviceNet Safety Function – J974
 EtherNet/IP Safety Function – R713
 ProfiNet Safety Function – J931
 Up to 8 bytes of Safety Inputs and Outputs
 Mapped to CSI and CSO
 Includes Safe I/O Connect (A05B-2600-J568)
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Safety Function by FL-net – J586
 Provides ability to exchange safety signals between a robot and other robots or CNCs by FL-net
 FL-net Interface (A05B-2600-J759)
 Safety function by FL-net (A05B-2600-J586)
 Includes Safe I/O Connect (A05B-2600-J568)
 Used with internal port (CD38A or CD38B)
 3 Modes for selecting behavior when attending node changed to power OFF
 Supports up to 203 safety inputs, and 70 safety outputs for 1 node
 The number of input + the number of output must be equal or less than 210
 Can use FL-net multicast
 Safety function by FL-net settings are saved in sysflsf.sv
 The limit of cable length is 100m which is same with FL-net
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Safety PMC Function – J764
 ISO13849-1, IEC61508
 Category 4
 PL e
 SIL 3
 Control the sequence of safe I/O by executing sequence program of ladder language
 Requires Integrated PMC (A05B-2600-J760)
 Optional: PMC change mode (A05B-2600-R652) to display ladder diagram and
sequence program on teach pendant
 FANUC LADDER-III for Robot required to create Safety PMC sequence program
 R-30iB Mate controller requires main board with PMC Function
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Auxiliary Axis Servo Off (Local Stop) Function – J806
 Prevents the unexpected motion of auxiliary axis
by cutting off the servo power of the auxiliary
axis (Safe Torque Off – STO)
 Requires special hardware
 Reference R-30iB Local Stop Function with STO
Maintenance and Order Manual (A-95028E)
 Maximum 8 local stop can be defined in DCS
local stop menu
 STO-OUT – safety output to command servo off
 STO-FB – safety input to monitor servo off status
 Fence – safety input to detect workspace violation
(i.e. light curtain)
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Teach Pendant Hot Swap Function – J647
 Allows the connect / disconnect of teach
pendant without Emergency Stop alarm
 Special hardware for hot swap function required
 Uses safety I/O SFDI1 and SFDI2 on the
emergency stop board
 Cannot be used on R-30iB Mate controller
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Shared Teach Pendant – R844
 The capability use a single pendant among multiple robot controllers connected via Ethernet without
having to change where it is physically attached
 User selects and logs in to a controller, then operates teach pendant as if it were physically attached to
that controller
 Controllers are interconnected via Ethernet and configured as a shared Teach Pendant group
 Defined in all controllers and up to N=16 controllers can be included in a shared Teach Pendant group
 Option includes the following:
 DCS Safe I/O connect (J568)
 FL-net interface (J759)
 Internet Connectivity/Customization (R558)
 Safety function by FL-net (J586)
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I/O Link i Slave Function – R844
 Communicates safety I/O with CNC controller via I/O Link I
 CNC is the Scanner device, and the robot is the Adapter device of I/O Link i
 Maximum 64 safety input and 64 safety output are available
 Safety input signals from CNC are accessed as SLI[1-64]
 Safety output signals to CNC are accessed as SLO[1-64]
 Various hardware requirements based on controller selection
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Safe I/O Consistency Check Function – Standard
 Check the consistency of a pair of safe
I/O
 If the pair of Safe I/O status is not
consistent for the specified time, servo
power is turned off immediately
 Servo power cannot be turned on until
pair of Safe I/O status becomes
consistent
 Maximum 16 pairs of Safe I/O can be
checked
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Functions – Summary
Function name
Emergency Stop Function
‒ Operator panel emergency stop
‒ Teach pendant emergency stop
‒ Deadman switch
‒ External emergency stop (EES)
‒ Fence input (EAS)
‒ SVOFF input (EGS)
‒ NTED input
‒ Robot disable switch
Position/Speed Check Function
‒ Joint Position Check Function
‒ Joint Speed Check Function
‒ Cartesian Position Check Function
‒ Cartesian Speed Check Function
‒ T1 Mode Speed Check Function
ISO13849-1
IEC61508
Standard / Option
Category 4
PL e
SIL 3
Standard
Option
A05B-2600-J567
(Includes Joint Speed check function and
Basic Position check function)
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Category 3
PL d
SIL 2
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Description
Turn off servo motor power according to the
status of emergency stop input. This manual
does not explain this function because it is a
standard function of the controller.
These functions check robot position and speed.
If the robot violates the programmed safety area
or exceeds the programmed speed limit, servo
motor power is turned off.
Functions – Summary
Function name
Joint Speed Check Function
Standard / Option
ISO13849-1
IEC61508
Description
Category 3
PL d
SIL 2
These functions check robot axis speed. If the
axis exceeds the programmed speed limit, servo
motor power is turned off. This function can be
used as Stop check function when the speed
limit is 0.
Category 3
PL d
SIL 2
These functions check robot position. If the axis
exceeds the programmed safety area, servo
motor power is turned off. This function is
restricted function of Cartesian Position Check
function.
Category 4
PL e
SIL 3 4
This function executes logic calculations for safe
I/O. For example, users can control safety
outputs according to the status of
Position/Speed Check functions.
Category 4
PL e
SIL 3
Safe I/O SSO[6] and SSO[7] are used to select
AUTO/T1/T2 operation mode in place of mode
switch on operator panel. To use this option, the
operator panel must be “No mode switch” type.
Option
A05B-2600-J555
(This option is included in Position/Speed check function)
Basic Position Check Function
Option
A05B-2600-J556
(This option is included in Position/Speed check function)
Safe I/O Connect Function
External Mode Select Function
Option
A05B-2600-J568
Option
A05B-2600-J569
(Includes Safe I/O Connect function)
4 When
SFDO pulse check is enabled, SFDO output is safety function of Category 4, PL e, SIL 3. When it is disabled, SFDO output is
safety function of Category 3, PL d, SIL 2.
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Functions – Summary
Standard / Option
ISO13849-1
IEC61508
Description
Option 3
A05B-2600-J974
(Includes Safe I/O Connect function)
Category 4
PL e
SIL 3
The robot controller works as a slave device of a
DeviceNet Safety network and communicates
safety signals with an external safety master
device.
Option 3
A05B-2600-R713
(Includes Safe I/O Connect function)
Category 4
PL e
SIL 3
The robot controller works as an adapter device
of an EtherNet/IP Safety network and
communicates safety signals with an external
safety scanner device.
Option 3, 5
A05B-2600-J931
(Includes Safe I/O Connect function)
Category 4
PL e
SIL 3
Option
A05B-2600-J586
(Includes Safe I/O Connect function)
Category 4
PL e
SIL 3
Function name
DeviceNet Safety Function
One of the following options is needed
A05B-2600-J753 DeviceNet Master & Slave
A05B-2600-J754 DeviceNet Slave
EtherNet/IP Safety Function
One of the following options is needed
A05B-2600-R784 EtherNet/IP Adapter
A05B-2600-R785 EtherNet/IP Scanner
(EtherNet/IP Scanner option includes EtherNet/IP Adapter function)
ProfiNet Safety Function
For R-30iB Mate controller, V8.30 series is
required for PROFINET Safety function. Order
A05B-2600-J930 for open air type controller.
Order A05B-2600-R834 if it is not open air type
controller.
Safety Function by FL-net
To use Safety function by FL-net, the following
option is needed. A05B-2600-J759 FL-net
function
3 A05B-2600-J974, A05B-2600-R713 and
A05B-2600-J931 are exclusive. Only one of
DeviceNet Safety, EtherNet/IP Safety or
PROFINET Safety can be installed.
5 For R-30iB controller, one of the following options is
needed to use PROFINET Safety function.
A05B-2600-J930 PROFINET I/O
A05B-2600-R834 Dual-Channel PROFINET (7DC3 series
is required)
These options are exclusive. Either A05B-2600-J930 or
A05B-2600-R834 can be ordered.
The robot controller works as a F-device of
PROFIsafe and communicates safety signals
with an external F-Host.
The robot controller communicates safety
signals with the other robot controller or CNC
controller.
For R-30iB Plus controller, one of the following options is
needed.
A05B-2600-J709 PROFINET I-device
A05B-2600-R834 Dual-Channel PROFINET
These options are exclusive. Either A05B-2600-J709 or
A05B-2600-R834 can be ordered.
A05B-2600-J930 cannot be ordered.
5
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Functions – Summary
Standard / Option
ISO13849-1
IEC61508
Option 6
A05B-2600-J764
(Includes Safe I/O Connect function)
Category 4
PL e
SIL 3
The robot controller controls the sequence of
safe I/O by executing sequence program of
ladder language.
Option 7
A05B-2600-J806
Category 4
PL e
SIL 3
This function prevents the unexpected motion of
auxiliary axis by cutting off the servo power of
the auxiliary axis. This function needs the
special hardware.
Option
A05B-2600-J131
Category 4
PL e
SIL 3
This function is able to add safety I/O
signals.
Option 8
Category 3
PL d
SIL 2
This function is able to add safety I/O
signals.
Option
A05B-2600-J647
Category 4
PL e
SIL 3
Function name
Safety PMC Function 10
Auxiliary Axis Servo Off (local stop)
Function
Safety I/O by Additional Safety I/O
Board 10
Safety I/O by I/O Unit-MODEL A 10
Teach Pendant Hot Swap Function
6 To
use Safety PMC function, the following
option is needed. A05B-2600-J760
Integrated PMC
8 To
use Safety I/O by I/O Unit-MODEL A,
please refer to the connection and
maintenance manual of I/O Unit-MODEL
A(B-61813EN).
Description
This function allows to connect / disconnect
teach pendant without Emergency Stop alarm.
This function requires special hardware for
Teach Pendant Hot Swap.
To use Safety PMC function, Safety I/O by
additional safety I/O board or Safety I/O by
I/O Unit-MODEL A in R-30iB Mate/R-30iB
Mate Plus controller, the main board that
has PMC function is necessary.
10
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Functions – Summary
Function name
Shared Teach Pendant Function
I/O Link i Slave function
To use I/O Link i Slave function, the special Main
board and CPU card are needed.
Safe I/O Consistency Check Function
Standard / Option
ISO13849-1
IEC61508
Description
Option
A05B-2600-R844
Category 4
PL e
SIL 3
Teach Pendant is able to operate other
controllers in Shared Teach Pendant group. This
function requires exclusive hardware.
Standard
(But the exclusive hardware is needed)
Category 3
PL d
SIL 2
The robot controller communicates
safety signals with CNC controller by
I/O Link i.
Standard
Category 4
PL e
SIL 3
This function check consistency of a
pair of safe I/O. Servo motor power is
turned off on inconsistency status.
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Tips and Tricks


DCS Tool Change Setup
Safe IO Connect Logic
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DCS Tool Change Setup – Setting up Tooling Frames


Setting up Frames
Two tool frames set up
 Tool 1
 Tool 2

Example
 Tool 1 and 2 with two identical tool
frames
 They do not have to be identical

First step in the process in setting up
DCS Tool Change
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DCS Tool Change Setup – Setting up User Models


User Model List
Create user models for each tool
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DCS Tool Change Setup – Setting up User Models



User Model 1: Tool 1
Create the DCS Model
Example
 Box
 X, Y, Z := 200
 No offset

Tool 1 is enabled
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DCS Tool Change Setup – Setting up User Models



User Model 2: Tool 2
Create the DCS Model
Example
 Point
 Size:= 100
 Pos1, Pos2 Z := 100

Tool 2 is enabled
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DCS Tool Change Setup – Setting up Tool Select Mode


Tool Select: -1 (Tool Change)
Assignment of CSI signals from Safety
PLC to Robot Controller
 CSI[21]: Tool 1
 CSI[22]: Tool 2

Note: @ for No. 1, indicates Safety
PLC is selecting Tool 1
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DCS Tool Change Setup – Configuring CPC for Tool Select



Target Model 2: Tool Change
Cartesian Position Check monitors Tool
1 and Tool 2
PLC Safety Signals select tool
configuration
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DCS Tool Change Setup – Configuring CPC for Tool Select


CSI[21] and CSI[22] from Safety PLC used for DCS Tool Mode Select
Only one tool can be selected: SRVO-416 DCS Tool Mismatch (G1) 1,1
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DCS Safe IO Connect



Internal Logic to monitor and control
safety logic
Minimal logic for zone control
Example
 Disabling Input SIR[23]
 Safe IO Connect Logic configured to
monitor CSI[23] AND !CSI[24]
 CPC 8 monitors SIR[23] as disabling
unit

Zone 8 disabled, no fault, orange
display
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DCS Safe IO Connect

Example,
 Light Screen violation by operator
 CPC 8 Becomes Active
 SRVO-402 DCS Cart. Pos. Limit (no.8,
G1, M0) faults
 Zone 8 enabled, violated, red display
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DCS Tool Mode Select and Safe IO Connect

Tool Mode Selection
 Allows different models to be selected
based on tool changing
 Multiple tool interfaces can be
configured
 Only a single tool can be selected using
safety signals
 Single Tool selection monitored actively

DCS Safe IO Connect
 Perform simple safety logic within
controller
 Activate and deactivate speed and
position checks
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DCS Latest Feature – CRX Tablet TP DCS Interface Screens
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CRX Tablet TP DCS User Interface Screens


CRX Robot Controller Latest (V9.40P/12)
Latest DCS Interface Screens







Robot Move Zone
Robot Restricted Zone
Hand / Vacuum
Hand / Welding Torch
Hand / Gripper
Select a Different Robot Move Zone
System Specific Libraries for Ease of Use
 Quick setup
 Adjustment of few parameters
 Dynamic visualization of changes
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Robot Move Zone
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Robot Move Zone


Import configuration for a Robot Move Zone
Example: Cartesian Position No. 8
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Robot Move Zone
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Robot Move Zone

Templates for ease of configuration
 Quick integration
 Ease of use setup
 Dynamically adjust and apply


All screens interactive
Ability to temporarily reset DCS violations to move
robot into safe position
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DCS Setup Screens



Alternative to the template approach
DCS setup as in previous version
Limited to the following






Joint Position
Joint Speed
Cartesian Position
Cartesian Speed
User Model
Safe IO Connect
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DCS Speed Check




Displays DCS
Configured Zones
Displays unused
zones
Parameters
configurable
Disabling Input
programmable
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DCS User Model




Configure user
models, up to 16
Set up specific
shapes
Configure
boundaries of
shape
Configure link
(i.e. FacePlate)
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DCS Tablet TP Interface Screens

DCS Tablet TP Interface screens introduce the
concept of templates to easily setup and configure
zones
 Move Zones
 Restricted Zones
 EOAT
 Hand / Vacuum
 Hand / Welding Torch
 Hand Gripper
 Selecting Move Zones

Easy interactive screens assist in setup and improve
the ease of use
Friday Webinar Series
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Questions
We will now be taking questions using the Q&A panel that can be found at the bottom of
your screen by selecting the icon.
Use the Q&A to Ask Questions
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FANUC ASI Network Benefits
ASI Network Benefits give you access to a lot of great features including the FANUC
Sales Toolbox, the FANUC Advantage Marketing Program, and many other marketing
programs.
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Access to Webinar Files
To access, please visit crc.frc.com, click on the ASI Network tab, and select the Friday
Webinar Series link from the toolbar on the left side of your screen.
ASI Network Tab at crc.frc.com
Friday Webinar Series Link
Access to over 100 Webinars!
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Today’s Speakers
Haresh Moradia
Senior Electrical Engineer
General Industry and Automotive Segment
Email: haresh.moradia@fanucamerica.com
FANUC America Corporation
3900 W. Hamlin Rd.
Rochester Hills, Michigan 48309
www.fanucamerica.com
Friday Webinar Series
CONFIDENTIAL - Not To Be Re-Distributed In Any Form