fanuc R-30iB, R-30iB Mate, R-30iB Plus, R-30iB Mate Plus, R-30iB Compact Plus Operators Manual

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R-30+B/R-30+B Mate/R-30+B Plus/R-30+B Mate Plus/
R-30+B Compact Plus/R-30+B Mini Plus CONTROLLER
Dual Check Safety Function
OPERATOR'S MANUAL
© FANUC CORPORATION, 2012
© MyFANUC 9363E45817F04FCE8821C463B56FA8C1
B-83184EN/13
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All specifications and designs are subject to change without notice.
. The export from Japan may be subject to an export license by the
export to another country may be subject to the license of the government of
Should you wish to export or re-export these products, please contact FANUC for advice.
re, however, a very
and if the manual
that any operations that are not explicitly described as being possible are "not possible".
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Original Instructions
Thank you very much for purchasing FANUC Robot.
Before using the Robot, be sure to read the "FANUC Robot series SAFETY HANDBOOK (B-80687EN)" and understand the content.
No part of this manual may be reproduced in any form.
The products in this manual are controlled based on Japan’s “Foreign Exchange and Foreign Trade Law” government of Japan. Further, re­the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government.
In this manual, we endeavor to include all pertinent matters. There a large number of operations that must not or cannot be performed, contained them all, it would be enormous in volume. It is, therefore, requested to assume
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B-83184EN/13 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

This chapter describes the precautions which must be followed to enable the safe use of the robot. Before using the robot, be sure to read this chapter thoroughly.
For detailed functions of the robot operation, read the relevant operator's manual to understand fully its specification.
For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral equipment installed in a work cell. For safe use of FANUC robots, you must read and follow the instructions in “FANUC Robot series SAFETY HANDBOOK (B-80687EN)”.
1 PERSONNEL
Personnel can be classified as follows.
Operator:
Turns the robot controller power ON/OFF
Starts the robot program from operator panel
Programmer or Teaching operator:
Operates the robot
Teaches the robot inside the safeguarded space
Maintenance technician:
Operates the robot
Teaches the robot inside the safeguarded space
Performs maintenance (repair, adjustment, replacement)
- The operator is not allowed to work in the safeguarded space.
- The programmer or teaching operator and maintenance technician are allowed to work in the safeguarded space. Works carried out in the safeguarded space include transportation, installation, teaching, adjustment, and maintenance.
- To work inside the safeguarded space, the person must be trained on proper robot operation.
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Programmer or
Teaching operator
Maintenance
technician
Turn power ON/OFF to Robot controller
 
Select operating mode (AUTO/T1/T2)
Select remote/local mode
Select robot program with teach pendant
Select robot program with external device
Start robot program with operator’s panel
Start robot program with teach pendant
Reset alarm with operator’s panel
Reset alarm with teach pendant
Set data on teach pendant
Teaching with teach pendant
Emergency stop with operator’s panel
Emergency stop with teach pendant
 
Operator’s panel maintenance
Teach pendant maintenance
Symbol
Definitions
occur if he or she fails to follow the approved procedure.
procedure.
is to be indicated.
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SAFETY PRECAUTIONS B-83184EN/13
Table 1 (a) lists the work outside the safeguarded space. In this table, the symbol “” means the work allowed to be carried out by the specified personnel.
Table 1 (a) List of work outside the Safeguarded Space
Operator
During robot operation, programming and maintenance, the operator, programmer, teaching operator and maintenance technician take care of their safety using at least the following safety protectors.
Use clothes, uniform, overall adequate for the work
Safety shoes
Helmet
2 DEFINITION OF SAFETY NOTATIONS
To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution on safety with "WARNING" or "CAUTION" according to its severity. Supplementary information is indicated by "NOTE". Read the contents of each "WARNING", "CAUTION" and "NOTE" before using the robot.
WARNING
Used if hazard resulting in the death or serious injury of the user will be expected to
Used if a hazard resulting in the minor or moderate injury of the user, or equipment
CAUTION
NOTE
damage may be expected to occur if he or she fails to follow the approved
Used if a supplementary explanation not related to any of WARNING and CAUTION
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B-83184EN/13 TABLE OF CONTENTS

TABLE OF CONTENTS

SAFETY PRECAUTIONS ............................................................................ s-1
1 OVERVIEW ............................................................................................. 1
1.1 DCS FUNCTION COMPONENTS ................................................................. 1
1.2 CAUTIONS AND LIMITATIONS .................................................................... 4
1.2.1 Hardware .................................................................................................................. 4
1.2.2 Software ................................................................................................................... 5
1.3 APPLY TO DCS PARAMETER ..................................................................... 6
1.4 DCS PARAMETER REPORT FILE ............................................................. 11
1.5 BACKUP / RESTORE DCS SETTING PARAMETER ................................. 11
1.6 INITIAL START, IMAGE RESTORE ............................................................ 13
1.7 STOPPING DISTANCE ............................................................................... 14
2 DCS MENU ............................................................................................ 15
2.1 DCS MENU COMPONENTS ....................................................................... 15
2.2 DCS TOP MENU ......................................................................................... 17
2.3 DCS ROBOT SETUP MENU ....................................................................... 20
2.4 DCS MASTERING PARAMETER MENU .................................................... 22
2.5 DCS CODE NUMBER ................................................................................. 23
2.5.1 DCS Code Number Setup Menu ............................................................................ 24
2.6 DCS SIGNATURE NUMBER ....................................................................... 25
2.6.1 DCS Signature Number Menu ............................................................................... 25
2.6.2 DCS Signature Annunciation Menu ....................................................................... 26
2.6.2.1 DCS signature change management utility setup ............................................... 27
2.6.2.2 DCS signature change management utility operation ........................................ 28
2.6.3 DCS Signature Number Output .............................................................................. 28
2.6.4 Code by Password Function ................................................................................... 29
3 LIMITING A ROBOT WORKSPACE ..................................................... 30
3.1 OVERVIEW ................................................................................................. 30
3.2 LIMITING A ROBOT WORKSPACE BY CARTESIAN POSITION CHECK . 31
3.3 ROBOT STOP POSITION PREDICTION .................................................... 34
3.4 SETUP OF USER MODEL .......................................................................... 35
3.5 4D GRAPHICS DCS DISPLAY .................................................................... 39
3.6 RECOVERY FROM ALARM ........................................................................ 41
4 SWITCHING THE WORKSPACE ......................................................... 42
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4.1 OVERVIEW ................................................................................................. 42
4.2 SETUP OF USER MODEL .......................................................................... 43
4.3 CHECKING IF THERE IS AN OPERATOR ON A SAFE MAT..................... 46
4.4 SETUP OF CARTESIAN POSITION CHECK .............................................. 47
4.4.1 Setup of No.1 Zone ................................................................................................ 48
4.4.2 Setup of No.2 Zone ................................................................................................ 52
4.4.3 Setup of No.3 Zone ................................................................................................ 56
5 CHECKING IF AUXILIARY AXES ARE STATIONARY ....................... 60
5.1 OVERVIEW ................................................................................................. 60
5.2 SETUP STOP CHECK FOR AUXILIARY AXIS 1 ........................................ 61
5.3 SETUP OF POSITION CHECK FOR AUXILIARY AXIS 1 ........................... 64
5.4 SETUP OF STOP CHECK FOR AUXILIARY AXES 2 AND 3 ..................... 67
5.5 LIMITING THE MOTION RANGE OF A TURNTABLE ................................ 72
5.6 SETTING UP THE ROBOT WORKSPACE ................................................. 74
6 SET A SLOWDOWN ZONE .................................................................. 77
6.1 OVERVIEW ................................................................................................. 77
6.2 SETUP OF TOOL MODEL .......................................................................... 78
6.3 SETUP OF CARTESIAN POSITION CHECK .............................................. 83
6.3.1 Setup of No.1 Zone ................................................................................................ 84
6.3.2 Setup of No.2 Zone ................................................................................................ 86
6.3.3 Setup of No.3 Zone ................................................................................................ 89
7 POSITION / SPEED CHECK FUNCTION ............................................. 93
7.1 COMPONENTS OF POSITION / SPEED CHECK FUNCTION ................... 94
7.2 JOINT POSITION CHECK FUNCTION ....................................................... 94
7.2.1 Stop Position Prediction ......................................................................................... 96
7.2.2 DCS Joint Position Check List Menu ..................................................................... 97
7.2.3 DCS Joint Position Check Detail Menu ................................................................. 98
7.3 JOINT SPEED CHECK FUNCTION ............................................................ 99
7.3.1 DCS Joint Speed Check List Menu ...................................................................... 100
7.3.2 DCS Joint Speed Check Detail Menu .................................................................. 101
7.4 ZONE CHECK FUNCTION (CARTESIAN POSITION CHECK FUNCTION)
................................................................................................................... 103
7.4.1 Shape Model ......................................................................................................... 103
7.4.2 Safe Zone .............................................................................................................. 105
7.4.2.1 Define the safe zone ......................................................................................... 106
7.4.2.2 Enable and disable zones by disabling input ................................................... 107
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7.4.2.3 Define the target shape model .......................................................................... 108
7.4.2.4 Process time factor ........................................................................................... 109
7.4.2.5 Recovery from alarm ....................................................................................... 110
7.4.2.6 Position check temporary disable function ...................................................... 110
7.4.2.7 Approach warning signal output function ........................................................ 111
7.4.3 Stop Position Prediction ....................................................................................... 112
7.4.4 DCS Cartesian Position Speed Check Function ................................................... 114
7.4.5 DCS Cartesian Position Check List Menu ........................................................... 115
7.4.6 DCS Cartesian Position Check (Diagonal) Menu ................................................ 116
7.4.7 DCS Cartesian Position Speed Check Menu ........................................................ 119
7.4.8 DCS Cartesian Position Check (Lines) Menu ...................................................... 120
7.4.9 DCS User Model List Menu ................................................................................. 122
7.4.10 DCS User Model Element List Menu .................................................................. 123
7.4.11 DCS User Model Detail (Point/Line-Seg) Menu ................................................. 124
7.4.12 DCS User Model Element Detail (2 Spheres) Menu ............................................ 125
7.4.13 DCS User Model Element Detail (Box) Menu ..................................................... 126
7.4.14 DCS Cartesian Position Check (Target Model Collision Check ) Menu ............. 126
7.5 ORIENTATION CHECK FUNCTION
(CARTESIAN POSITION CHECK FUNCTION) ......................................... 128
7.5.1 DCS Cartesian Position Check (Orientation Fix) Menu ...................................... 128
7.6 BASIC POSITION CHECK FUNCTION ..................................................... 130
7.6.1 Restriction of Basic Position function .................................................................. 130
7.7 CARTESIAN SPEED CHECK FUNCTION ................................................ 130
7.7.1 DCS Cartesian Speed Check List Menu ............................................................... 131
7.7.2 DCS Cartesian Speed Check Detail Menu ........................................................... 132
7.7.3 Speed Control function ......................................................................................... 134
7.8 T1 MODE SPEED CHECK FUNCTION ..................................................... 138
7.8.1 DCS T1 Mode Speed Check Menu ...................................................................... 138
7.9 DCS TOOL FRAME ................................................................................... 139
7.9.1 Tool Change Function .......................................................................................... 140
7.9.2 DCS Tool Frame Menu ........................................................................................ 141
7.10 DCS USER FRAME ................................................................................... 142
7.10.1 DCS User Frame Menu ........................................................................................ 143
7.11 SETUP STOP POSITION PREDICTION ................................................... 144
7.11.1 DCS Stop Position Prediction Menu .................................................................... 144
7.12 POS./SPEED CHECK SETUP .................................................................. 146
7.12.1 DCS Pos./Speed Check Setup Menu .................................................................... 146
7.12.2 Target Position Check Function ........................................................................... 148
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8 DCS VISUALIZATION ......................................................................... 149
8.1 VIEWING THE ROBOT MODEL ................................................................ 150
8.1.1 Controlling the Simple View ................................................................................ 153
8.1.1.1 Selecting an orthographic view ........................................................................ 153
8.1.1.2 Panning and zooming ....................................................................................... 153
8.1.1.3 Coordinate displays ......................................................................................... 154
8.1.1.4 Persistence ....................................................................................................... 155
8.1.1.5 Robot group select ........................................................................................... 156
8.1.1.6 Exiting the viewer ............................................................................................ 156
8.2 4D GRAPHICS DCS DISPLAY .................................................................. 156
8.2.1 Operation Procedure ............................................................................................. 157
8.3 VIEWING USER MODELS ........................................................................ 159
8.4 VIEWING CARTESIAN POSITION CHECKS ............................................ 161
8.5 VIEWING JOINT POSITION CHECKS ...................................................... 164
8.5.1 Joint Position Check – Simple Viewer ................................................................. 164
8.5.2 Joint Position Check – 4D Graphics Viewer ........................................................ 165
9 SAFE I/O ............................................................................................. 166
9.1 SAFE I/O ................................................................................................... 166
9.1.1 SFDO Pulse Check ............................................................................................... 174
9.1.2 DCS Safe I/O Status Menu ................................................................................... 175
9.2 SAFE I/O CONNECT FUNCTION ............................................................. 176
9.2.1 DCS Safe I/O Connect Menu ............................................................................... 178
9.3 EXAMPLE OF SAFE ZONE SWITCHING BY USING NSI ........................ 179
9.4 ADDITIONAL SAFETY SIGNALS .............................................................. 182
9.4.1 DCS Safe I/O Device Menu ................................................................................. 184
10 DEVICENET SAFETY ......................................................................... 187
10.1 INTRODUCTION ....................................................................................... 187
10.1.1 Overview .............................................................................................................. 187
10.1.2 CIP Safety Requirements ..................................................................................... 187
10.2 INTEGRATED DEVICENET SAFETY (IDNS) ........................................... 189
10.2.1 Overview .............................................................................................................. 189
10.2.2 Robot Configuration ............................................................................................. 190
10.2.3 Safety PLC Configuration .................................................................................... 192
10.2.3.1 GuardLogix safety PLC example configuration .............................................. 192
10.2.3.2 Omron safety PLC example configuration ...................................................... 196
10.2.4 Troubleshooting .................................................................................................... 200
10.2.4.1 CIP-safety status screen ................................................................................... 200
10.2.4.2 Troubleshooting using LEDs ...........................................................................
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10.3 SAFETY I/O CONNECT IN CIP-SAFETY SYSTEM .................................. 201
10.4 BACKUP/RESTORE OF CIP-SAFETY SETTINGS ................................... 202
10.5 EDS FILE ................................................................................................... 202
11 ETHERNET/IP SAFETY ...................................................................... 203
11.1 INTRODUCTION ....................................................................................... 203
11.1.1 Overview .............................................................................................................. 203
11.1.2 CIP Safety Requirements ..................................................................................... 203
11.2 ETHERNET/IP SAFETY (EIP-SAFE) ........................................................ 205
11.2.1 Overview .............................................................................................................. 205
11.2.2 Robot Configuration ............................................................................................. 206
11.2.3 Safety PLC Configuration .................................................................................... 208
11.2.3.1 GuardLogix safety PLC example configuration using AOP ............................ 208
11.2.3.2 GuardLogix safety PLC example configuration without using AOP ............... 214
11.2.4 Troubleshooting .................................................................................................... 219
11.2.4.1 CIP-safety status screen ................................................................................... 219
11.3 SAFETY I/O CONNECT IN CIP-SAFETY SYSTEM .................................. 219
11.4 BACKUP/RESTORE OF CIP-SAFETY SETTINGS ................................... 220
11.5 EDS FILE ................................................................................................... 220
12 PROFINET SAFETY ........................................................................... 221
12.1 INTRODUCTION ....................................................................................... 221
12.2 PROFINET SAFETY FUNCTION .............................................................. 221
12.2.1 Overview .............................................................................................................. 221
12.2.2 Robot Configuration ............................................................................................. 223
12.2.3 Safety PLC Configuration .................................................................................... 229
12.2.4 Operation without Safety PLC (bypass mode) ..................................................... 234
12.2.5 Troubleshooting .................................................................................................... 235
12.2.5.1 PROFINET safety status screen ....................................................................... 235
12.2.5.2 DIAGSAFETY screen ..................................................................................... 236
12.2.5.3 Error indication ................................................................................................ 237
12.3 BACKUP/RESTORE OF PROFINET SAFETY SETTINGS ....................... 237
12.4 GSDML FILE ............................................................................................. 237
13 SAFETY FUNCTION BY FL-net ......................................................... 238
13.1 INTRODUCTION ....................................................................................... 238
13.2 SAFETY FUNCTION BY FL-net ................................................................ 238
13.2.1 Overview .............................................................................................................. 238
13.2.2 Safety Signal......................................................................................................... 239
13.2.2.1 Sending safety signal area ................................................................................ 239
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13.2.2.2 Receiving safety signal area............................................................................. 239
13.2.3 Robot Configuration ............................................................................................. 242
13.2.4 Alarm .................................................................................................................... 247
13.2.5 Temporarily Detaching Some Nodes from the Safety Function by FL-net .......... 248
13.2.6 Troubleshooting .................................................................................................... 249
13.3 BACKUP/RESTORE OF SAFETY FUNCTION BY FL-NET ...................... 251
14 CC-Link IE FIELD SAFETY SLAVE FUNCTION ................................ 252
14.1 INTRODUCTION ....................................................................................... 252
14.2 FUNCTION ................................................................................................ 252
14.2.1 Overview .............................................................................................................. 252
14.2.2 Robot Configuration ............................................................................................. 253
14.2.3 Safety PLC Configuration .................................................................................... 256
14.2.4 Operation for restart ............................................................................................. 257
14.2.5 Operation without Safety PLC (bypass mode) ..................................................... 257
14.2.6 Troubleshooting .................................................................................................... 258
14.2.6.1 CC-Link IE Field safety status screen.............................................................. 258
14.2.6.2 Error indication ................................................................................................ 259
14.3 BACKUP/RESTORE .................................................................................. 259
14.4 CSP+ FILE ................................................................................................. 259
15 ETHERCAT SAFETY SLAVE ............................................................. 260
15.1 INTRODUCTION ....................................................................................... 260
15.2 FUNCTION ................................................................................................ 260
15.2.1 Overview .............................................................................................................. 260
15.2.2 Robot Configuration ............................................................................................. 261
15.2.3 Safety PLC Configuration .................................................................................... 263
15.2.4 Operation for Restart ............................................................................................ 264
15.2.5 Operation without Safety PLC (bypass mode) ..................................................... 264
15.2.6 Conditions for turning CSO OFF ......................................................................... 264
15.2.7 Troubleshooting .................................................................................................... 265
15.2.7.1 EtherCAT safety slave status screen ................................................................ 265
15.2.7.2 Error indication ................................................................................................ 265
15.3 BACKUP/RESTORE .................................................................................. 266
16 SAFETY PMC FUNCTION .................................................................. 267
16.1 OVERVIEW ............................................................................................... 267
16.2 BASIC SPECIFICATION ........................................................................... 268
16.3 PMC ADDRESSES .................................................................................... 269
16.4 BASIC INSTRUCTIONS ............................................................................ 270
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16.5 FUNCTIONAL INSTRUCTIONS ................................................................ 271
16.6 FANUC LADDER-III PROGRAMMING ...................................................... 271
16.7 TEACH PENDANT OPERATION .............................................................. 272
16.8 SAFETY PMC EXECUTION (APPLY TO DCS PARAMETER) ................. 273
16.9 DCS SAFETY PMC MENU ........................................................................ 274
17 AUXILIARY AXIS SERVO OFF (LOCAL STOP) FUNCTION ............ 275
17.1 DCS LOCAL STOP MENU ........................................................................ 276
18 TEACH PENDANT HOT SWAP .......................................................... 278
18.1 DCS TEACH PENDANT HOT SWAP MENU ............................................ 279
19 SHARED TEACH PENDANT .............................................................. 280
19.1 CONFIGURATION ..................................................................................... 281
19.1.1 Assignment of IP Address .................................................................................... 282
19.1.2 Configuration of Shared Teach Pendant Group ................................................... 283
19.1.3 Configuration of Safety Function by FL-net ........................................................ 285
19.1.4 DCS Configuration of Shared Teach Pendant ...................................................... 287
19.1.5 Creating WEB Page to Switch Robots ................................................................. 289
19.2 OPERATION ............................................................................................. 291
19.2.1 Log into a Robot ................................................................................................... 291
19.2.2 Confirmation of Selected Robot ........................................................................... 293
19.2.3 Operation of Robot ............................................................................................... 294
19.2.4 Bypassing Down Robot ........................................................................................ 294
20 I/O Link i SLAVE FUNCTION ............................................................. 296
20.1 NEEDED HARDWARE CONSTRUCTION ................................................ 297
20.1.1 In Case of using R-30iB or R-30iB Plus .............................................................. 297
20.1.2 In Case of using R-30iB Mate, R-30iB Mate Plus, R-30iB Compact Plus or R-30iB
Mini Plus .............................................................................................................. 299
20.2 I/O LINK i SLAVE MENU ........................................................................... 303
20.3 NUMBER OF SAFETY AND NON-SAFETY SIGNALS ............................. 303
20.3.1 Case with Safety Signals ...................................................................................... 303
20.3.2 Case without Safety Signals ................................................................................. 304
20.4 MAPPING OF SAFETY AND NON-SAFETY SIGNALS ............................ 304
20.5 LOADING OF UNSUPPORTED VERSION BACKUP ............................... 305
20.5.1 Loading of Backup to Unsupported Hardware ..................................................... 305
20.5.2 Loading of Backup that is Unsupported Software................................................ 305
21 SAFE I/O CONSISTENCY CHECK FUNCTION ................................. 306
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21.1 SAFE I/O CONSISTENCY CHECK MENU ................................................ 306
22 OPERATION WITHOUT MODE SWITCH ........................................... 308
22.1 MODE SELECT MENU ............................................................................. 308
23 SAFETY SIGNALS .............................................................................. 310
23.1 SAFETY SIGNAL INTERFACE ................................................................. 311
23.1.1 In Case of A-cabinet ............................................................................................. 311
23.1.2 In Case of B-cabinet ............................................................................................. 312
23.1.3 In Case of Additional Safety I/O Board (mini-slot) ............................................. 313
23.1.4 In case of I/O Unit-MODEL A ............................................................................. 320
23.2 PERIPHERAL EQUIPMENT AND SAFETY SIGNALS CONNECTION ..... 322
23.2.1 In Case of A-cabinet ............................................................................................. 322
23.2.2 In Case of B-cabinet ............................................................................................. 324
23.2.3 In Case of Additional Safety I/O Board (mini-slot) ............................................. 327
23.2.4 In Case of I/O Unit-MODEL A ............................................................................ 332
23.3 SAFETY SIGNAL SPECIFICATIONS ........................................................ 337
23.3.1 Safety Input Specifications ................................................................................... 337
23.3.2 Safety Output Specifications ................................................................................ 339
24 DCS SETTINGS WITH THE TABLET UI ............................................ 340
24.1 DCS SCREEN (TABLET UI) ...................................................................... 341
24.1.1 Screen Layout ....................................................................................................... 342
24.1.2 Layout of the Library Screen ................................................................................ 342
24.1.3 Pos./Speed Check Setting Screen Layout ............................................................. 344
24.1.4 Safe I/O Connect .................................................................................................. 348
24.1.5 Collaborative robot ............................................................................................... 349
24.1.6 Signature screen ................................................................................................... 349
24.1.7 Code number setup ............................................................................................... 351
24.2 SETTING FLOW ........................................................................................ 352
24.2.1 Importing from the Library .................................................................................. 353
24.2.2 Changing the Detailed Settings of the Setting Data ............................................. 354
24.2.3 Applying the Settings to the DCS Parameters ...................................................... 356
24.3 TEMPORARILY RESET ............................................................................ 358
25 ALARM CODES .................................................................................. 360
26 CHECKLIST ........................................................................................ 374
26.1 CHECKLIST OF DCS SYSTEM ................................................................ 374
26.2 CHECKLIST FOR JOINT POSITION CHECK FUNCTION ........................ 376
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26.3 CHECKLIST FOR DCS JOINT SPEED CHECK FUNCTION .................... 376
26.4 CHECKLIST FOR DCS CARTESIAN POSITION CHECK FUNCTION ..... 376
26.5 CHECKLIST FOR DCS CARTESIAN SPEED FUNCTION ....................... 378
26.6 CHECKLIST FOR DCS T1 MODE SPEED CHECK .................................. 378
26.7 CHECKLIST FOR DCS USER MODEL ..................................................... 379
26.8 CHECKLIST FOR DCS TOOL FRAME ..................................................... 379
26.9 CHECKLIST FOR DCS USER FRAME ..................................................... 380
26.10 CHECKLIST FOR DCS STOP POSITION PREDICTION .......................... 381
26.11 CHECKLIST FOR DCS POSITION SPEED CHECK SETUP .................... 382
26.12 CHECKLIST FOR DCS SAFE I/O CONNECT FUNCTION ....................... 382
26.13 CHECKLIST FOR DEVICENET SAFETY .................................................. 383
26.14 CHECKLIST FOR ETHERNET/IP SAFETY .............................................. 383
26.15 CHECKLIST FOR PROFINET SAFETY .................................................... 384
26.16 CHECKLIST FOR DCS SAFETY FUNCTION BY FL-net .......................... 384
26.17 CHECKLIST FOR DCS SAFETY PMC FUNCTION .................................. 385
26.18 CHECKLIST FOR DCS LOCAL STOP FUNCTION ................................... 385
26.19 CHECKLIST FOR DCS TEACH PENDANT HOT SWAP FUNCTION ....... 386
26.20 CHECKLIST FOR DCS SHARED TEACH PENDANT FUNCTION ........... 386
26.21 CHECKLIST FOR DCS I/O Link i Slave FUNCTION ................................. 386
26.22 CHECKLIST FOR DCS SAFE I/O CONSISTENCY CHECK FUNCTION .. 387
26.23 CHECKLIST FOR DCS MODE SELECT FUNCTION ............................... 387
26.24 CHECKLIST FOR DCS I/O DEVICE ......................................................... 388
26.25 CHECKLIST FOR DCS SIGNATURE NUMBER ....................................... 388
c-9
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IEC61508
- Robot disable switch
Turn off servo motor power according to the status of emergency stop input.
- T1 Mode Speed Check function
(Includes Joint Speed
check function)
check.)
speed limit, servo motor
be used as Stop check function when
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B-83184EN/13 1. OVERVIEW

1 OVERVIEW

Dual Check Safety (DCS) Position/Speed Check features check the speed and position data of motors with two independent CPUs in the robot controller. These functions can 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.
DCS Position/Speed Check features do not need additional external sensors to monitor speed and position. Only the built-in servo motor sensors are used for this function. (To use safety inputs or safety outputs, external electrical circuits are required.)
DCS functions are certified to meet the requirements of International Standard ISO13849-1 and IEC61508 by an internationally accredited certification body.

1.1 DCS FUNCTION COMPONENTS

The DCS system consists of the following standard and optional functions. Safety Category, PL(Performance Level), SIL(Safety Integrity Level) are specified in the column of "ISO 13849-1 / IEC61508" in the following table.
DCS function components
Function name Standard / Option
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
Position/Speed Check function
- Joint Position Check function
- Joint Speed Check function
- Cartesian Position Check function
- Cartesian Speed Check function
ISO13849-1
Standard Category 4
PL e SIL 3
Option A05B-2600-J567
check function and Basic Position
Category 3 PL d SIL 2
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.
Description
Joint Speed Check function Option
These functions check robot axis speed. If the axis exceeds the programmed power is turned off. This function can
the speed limit is 0.
A05B-2600-J555 (This is the part of Joint Speed Check in the DCS Speed/Position
Category 3 PL d SIL 2
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IEC61508
Basic Position Check function
- Cartesian Position Check function
Option
Category 3
These functions check robot position
Position/Speed Check functions.
External mode select function
Option A05B-2600-
Category 4
Safe I/O SSO[6] and SSO[7] are used to select AUTO/T1/T2 operation
the operator panel
must be “No mode switch” type.
device.
EtherNet/IP Safety function
Option (*2, *3)
Category 4
The robot controller works as an
scanner device.
Connect function)
external F-Host.
Safety function by FL-net
Option (*11)
Connect function)
Category 4
The robot controller communicates
Connect function)
language.
Auxiliary axis servo off (local stop)
Option (*7)
Category 4
This function prevents the
hardware.
Safety I/O by additional safety I/O board
SIL 3
This function is able to add safety I/O
Safety I/O by I/O Unit-MODEL A (*10)
Option (*8)
Category 3
SIL 2
This function is able to add safety I/O
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1. OVERVIEW B-83184EN/13
Function name Standard / Option
7DF4 series or earlier :
- Cartesian Speed Check function
7DF5 series or later :
- Joint Position Check function
- Joint Speed Check function
Safe I/O Connect function Option
DeviceNet Safety function Option (*1, *3)
A05B-2600-J556 (This is the simplified option of Position/Speed check function.)
A05B-2600-J568
J569 (Includes Safe I/O Connect function)
A05B-2600-J974 (Includes Safe I/O Connect function)
ISO13849-1
PL d SIL 2
Category 4 PL e SIL 3 (*4)
PL e SIL 3
Category 4 PL e SIL 3
Description
and speed. If the robot violates the programmed safety area or exceeds the programmed speed limit, servo motor power is turned off. This function is restricted function of Position/Speed Check function.
This function executes logic calculations for safe I/O. For example, users can control safety outputs according to the status of
mode in place of mode switch on operator panel. To use this option,
The robot controller works as a slave device of a DeviceNet Safety network and communicates safety signals with an external safety master
A05B-2600-R713 (Includes Safe I/O Connect function)
PROFINET Safety function (*9) Option (*3, *5)
A05B-2600-J931 (Includes Safe I/O
A05B-2600-J586 (Includes Safe I/O
Safety PMC function (*10) Option (*6)
A05B-2600-J764 (Includes Safe I/O
function
(*10)
A05B-2600-J806
Option A05B-2600-J131
PL e SIL 3
Category 4 PL e SIL 3
PL e SIL 3
Category 4 PL e SIL 3
PL e SIL 3
Category 4 PL e
adapter device of an EtherNet/IP Safety network and communicates safety signals with an external safety
The robot controller works as a F­device of PROFIsafe and communicates safety signals with an
safety signals with the other robot controller or CNC controller.
The robot controller controls the sequence of safe I/O by executing sequence program of ladder
unexpected motion of auxiliary axis by cutting off the servo power of the auxiliary axis. This function needs the special
signals.
PL d
signals.
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IEC61508
Teach Pendant Hot Swap function
Option
Category 4
This function allows to connect /
Pendant Hot Swap.
This function requires
exclusive hardware.
I/O Link i Slave function
Standard
(*12))
Category 3
The robot controller communicates
SIL 3
ower is
turned off on inconsistency status.
CC-Link IE Field Safety slave function
Option (*3, *13)
Category 4
The robot controller works as a safety
signals with an external safety master station.
Connect function)
works as a safety
external safety master station.
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B-83184EN/13 1. OVERVIEW
Function name Standard / Option
A05B-2600-J647
Shared Teach Pendant function Option
A05B-2600-R844
(But the exclusive hardware is needed
Safe I/O consistency check function Standard Category 4
A05B-2600-S524 (Includes Safe I/O Connect function)
EtherCAT safety slave Option (*3, *14)
A05B-2600-S532 (Includes Safe I/O
ISO13849-1
PL e SIL 3
Category 4 PL e SIL 3
PL d SIL 2
PL e
PL e SIL 3
Category 4 PL e SIL 3
Description
disconnect teach pendant without Emergency Stop alarm. This function requires special hardware for Teach
Teach Pendant is able to operate other controllers in Shared Teach Pendant group.
safety signals with CNC controller by I/O Link i.
This function check consistency of a pair of safe I/O. Servo motor p
slave station of CC-Link IE Field Safety and communicates safety
The robot controller slave of Safety over EtherCAT® and communicates safety signals with an
*1: To use DeviceNet Safety function, one of the following options is needed.
A05B-2600-J753 DeviceNet Master&Slave A05B-2600-J754 DeviceNet Slave *2: To use 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) *3: A05B-2600-J974, A05B-2600-R713, A05B-2600-J931, A05B-2600-S524 and A05B-2600-S532are
exclusive. Only one of DeviceNet Safety, EtherNet/IP Safety, PROFINET Safety, CC-Link IE Field Safety slave or EtherCAT safety slave can be installed.
*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.
*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.
For R-30iB Plus controller, one of the following options is needed.
A05B-2600-J709 PROFINET I-device A05B-2600-R834 Dual-Channel PROFINET A05B-2600-S523 PROFINET FANUC board (7DF4 series is required) These options are exclusive. Either A05B-2600-J709 or A05B-2600-R834 or A05B-2600-S523 can
be ordered.
A05B-2600-J930 cannot be ordered. *6: To use Safety PMC function, the following option is needed. A05B-2600-J760 Integrated PMC
*7: The complex system such as 3 axes positioner needs Safe I/O connect (A05B-2600-J568) option. *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).
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Item
Value
SFF
Greater than 99.0%
PFH/h
Less than 8.76x10-8 1/h
WARNING
PL d, SIL 2 safety function is adequate.
WARNING
cable duct.
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1. OVERVIEW B-83184EN/13
*9: For R-30iB Mate controller, 7DC3 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.
*10: 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.
*11: To use Safety function by FL-net, the following option is needed. A05B-2600-J759 FL-net function *12: To use I/O Link i Slave function, the special Main board and CPU card are needed. Please refer to
Section 14.1 in this manual
*13: To use CC-Link IE Field Safety slave function, the following function is needed. A05B-2600-J779 CC-Link IE Field slave function Please refer to Table 14.2.1(a) for the controller type and the software version where CC-Link IE Field
Safety slave function is supported.
*14: To use EtherCAT safety slave, the following function is needed. A05B-2600-J743 EtherCAT slave function Please refer to Table 26.2.1(a) for the controller type and the software version where EtherCAT safety
slave is supported.
Safety index

1.2 CAUTIONS AND LIMITATIONS

1.2.1 Hardware

1 When Position/Speed Check function is used, adequate risk assessment for the
whole robot system is necessary to verify that a Category 3, PL d, SIL 2 safety function is adequate.
2 When SFDO pulse check is disabled, adequate risk assessment for the whole
robot system is necessary to verify that a Category 3, PL d, SIL 2 safety function is adequate. The external device connected to SFDO needs to check the discrepancy of redundant output signals when SFDO pulse check is disabled. If the external device detects the discrepancy in a given time, the system should be turned to the safe state like emergency stop condition.
3 When additional Safety I/O by I/O Unit-MODEL A is used, adequate risk
assessment for the whole robot system is necessary to verify that a Category 3,
At the initial start-up, the operation check and validation of the wiring for safety
signals should be carried out, and then the wiring should be protected by the
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CAUTION
more in a year.

1.2.2 Software

* Limitations for DCS Position/Speed Check functions is applied to DCS Joint Speed Check function
Robot model
DCS Position/Speed Check functions are supported on most, but not all, robot models. Contact your FANUC representative for a list of supported robot models. If DCS Position/Speed Check is loaded into the system of an unsupported robot model, " SYST-218 DCS Unavailable robot model" or "SRVO-364 DCS PRMCRC alarm" occurs. This alarm cannot be cleared until the software option configuration is changed.
Servo gun axis, Independent axis
Servo gun axis and Independent axis cannot be used with DCS Position/Speed Check functions. These axes are regarded as EXCLUDED axes.
Positioner axis
To use DCS Position/Speed Check functions for a positioner axis of customer make, the positioner (A05B­2600-H896) must be a Basic Positioner with Known Kinematics. If another positioner type is used, the alarm "SYS-218 DOS Unavailable robot model" occurs.
Continuous turn
Continuous turn axes are regarded as Speed Only axes, and the axis can be used only for Joint Speed Check function. The continuous turn axis cannot be used for Joint Position Check function. When a motion group includes a continuous turn axis, except when it is an Auxiliary Extended Axis, the motion group cannot be used with the Cartesian Position Check and Cartesian Speed Check functions. The T1 Mode Speed Check function for the motion group checks regards the position of the continuous turn axis is always 0, and checks the DCS TCP speed and the wrist flange center speed. * When the last robot axis (For 6 axis robot, J6) of M-2iA or M-3iA is continuous turn axis, the axis is
* In 7DC1 series or 7DD0 series software, the continuous turn axis is regarded as EXCLUDE axis. The
Extended Axis Control
Axes configured using the Extended Axis Control option are supported in the Position Check and Speed Check functions. In the case where the Extended Axis is being used as a robot transfer unit (RTU) and is configured as an Integrated Extended Axis, the safe zone of the Cartesian Position Check will remain stationary as the robot moves along the transfer unit. If the Extended Axis is configured as an Auxiliary Extended Axis, the safe zone will travel along the transfer unit with the robot.
RAIL Unit
If the robot transfer unit (RTU) is configured as an independent group it should be setup as a Rail Unit (H894). In this case the safe zone will travel along the transfer unit with the robot
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R-30iB/R-30iB Plus, R-30iB Mate/R-30iB Mate Plus, R-30iB Compact Plus and
R-30iB Mini Plus are evaluated as a system with the high demand mode of operation defined in IEC61508. To confirm that the safety function can work correctly, please check the alarm detection by inputting emergency stop twice or more in a year, or please check the system operation by cycling power twice or
and DCS Basic Position Check function. Please read "also cannot be used with DCS Joint Speed Check function and DCS Basic Position Check function" as "cannot be used with DCS Position/Speed Check function."
regarded as EXCLUDE axis. The continuous turn axis cannot be used for Joint Speed Check function.
continuous turn axis cannot be used for Joint Speed Check function.
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CAUTION
group with the robot.
Setting parameter
DCS parameter
DCS function
DCS menu
Apply
(Copy)
Set / Read
Read
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1. OVERVIEW B-83184EN/13
When the robot is mounted on rail axis, the safe zone is moved if the world
frame of the robot is moved according to the move of the rail axis. To fix the safe zone, the rail axis should be defined as Integrated Rail axis of the same motion
Stopping method of multi group
In multi group robot system, when the robot of a group is stopped, the robots of the other groups also stop by the same stop type.

1.3 APPLY TO DCS PARAMETER

The parameters for DCS functions (DCS parameters) are stored in a different memory area from the parameters for other functions, and the data integrity is checked. Users cannot change DCS parameters directly. To change DCS parameters, users must change the normal parameters (setting parameters) first, and then copy the parameters from the setting parameters to the DCS parameters. This operation is called "Apply to DCS parameter".
When an item in a DCS menu is changed, the setting parameter is changed. When the value of setting parameters and the value of DCS parameters are different, the alarm "SYST-212 Need to apply to DCS param" occurs. This alarm cannot be reset until the "Apply to DCS parameter" procedure is done.
Normally, the DCS menu is protected because an alarm occurs if a DCS menu item is changed unintentionally. When a numeric key or function key is pressed while in a DCS menu, the message "Do you want to change setting?" is displayed. If [F4(YES)] is pressed, the protection is released, and users can change items in the DCS menu. When the Teach Pendant enable switch is turned off, the DCS menu is also protected. The protection cannot be released when Teach Pendant enable switch is off.
Robot setup data and mastering parameters are also referenced by DCS Position/Speed Check functions. These parameters are used for normal motion control as well as setting parameters for the DCS Position/Speed Check functions. These parameters are set by other areas of the controller software and are not changed in the DCS menu. However, if these parameters are changed, they will need to be applied to DCS parameters by using the “Apply to DCS parameter” procedure. When the DCS Position/Speed Check option is loaded, and the mastering data or robot setup data is changed, for example when robot mastering is changed, the alarm "SYST-212 Need to apply to DCS param" occurs. This alarm cannot be reset until the "Apply to DCS parameter" procedure is done.
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CAUTION
releases the [SHIFT] key, the alarm will be occurs again.
NOTE
please disable the Joint/Cartesian position check to do mastering operation.
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B-83184EN/13 1. OVERVIEW
When a backup file (for example SYSVARS.SV or SYSMAST.SV) is loaded, and the setting parameters (including mastering parameters and robot setup data) are changed, the alarm "SYST-212 Need to apply to DCS param" occurs. This alarm cannot be reset until the "Apply to DCS parameter" procedure is done.
1 If an operator who does not know the code number changes Setting parameters,
Mastering parameters or robot setup data by loading a backup file, the alarm "SYST-212 Need to apply DCS param" occurs, and the system will not work. An operator who knows the code number must change setting parameters, mastering parameters or robot setup data.
2 The "SYST-212 Need to apply to DCS param" alarm is not a safety function. It is
intended to guide the operator to apply the modified parameters. There are situations that the alarm can be cleared, but the modified parameters do not take affect until the apply process is complete and the power is cycled on the controller.
3 When user setting the safe area in the DCS position / speed check function,
check the safety setting while jogging the robot. If the alarm "SYST-212 Need to apply to DCS param" occurs, the robot can not jog. Operator will be asked to apply and restart to reset the alarm every time operator changes the setting. To avoid such situation, this alarm can be temporarily reset only when the mode switch is T1 and press and hold the [SHIFT] and [RESET] key. If operator
The operation to apply DCS parameters is the following.
If you removed a battery cable from a motor on a robot, you need to change
mastering parameter. Before the correct mastering data is set and applied to DCS parameter, DCS uses the previous mastering parameter. So, DCS Joint/Cartesian position check function may cause alarm. In this case,
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DCS 1/15 1 Safe I/O Status: 2 Safe I/O connect: OK 3 Joint position check: ---- OK 4 Joint speed check: ---- OK 5 Cart. position check: ---- CHGD 6 Cart. speed check: ---- OK 7 T1 mode speed check: OK 8 User\model: CHGD 9 Tool frame: OK 10 User frame: OK 11 Stop position prediction: OK 12 Robot setup: OK 13 Mastering parameter: OK 14 Pos./Speed check setup: OK 15 Signature number: 16 Code number setup:
[ TYPE ] APPLY DETAIL UNDO
CAUTION
DCS parameters from being changed by unauthorized personnel.
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1. OVERVIEW B-83184EN/13
Operation to apply DCS parameter
1 "MENU""SYSTEM"[F1([TYPE])] →"DCS" shows the DCS top menu. When the DCS top menu
is not displayed, press PREV until it is displayed.
2 Press [F2(APPLY)] in the DCS top menu.
Note: If there is invalid setting (for example, invalid user frame number is used in Cartesian Position
check), the menu page of the invalid parameter is displayed, and message is displayed on prompt line. In this case, please check the setting in the displayed page.
3 The message "Code number(Master):" is displayed. Please enter the 4 digit code number. (Default
code number is "1111".) Apply to DCS parameter is not done until the correct code number is entered. When "Master" is displayed in parenthesis, the master code number must be entered. If “Base” or “Position/Speed Check” or “I/O Connect” is displayed in parenthesis, the corresponding local code number or master code number must be entered. (Refer to 2.5 DCS CODE NUMBER)
* At this time, the message " Enter previous code number:" may be displayed. Please refer to 2.5 DCS
CODE NUMBER for detail.
Make sure to change the code number from the default “1111” setting to prevent
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DCS Verify (diff) 1/163 F Number: F00000 VERSION : HandlingTool $VERSION: V9.0044 11/08/2016 DATE: 08-DEC-16 10:14 DCS Version: V4.0.1
--- Cartesian Position Check ----------- Process time factor (Max.1000): 32 No. G M Status Comment 1 ENABLE 1 WD CHGD [ ] 2 DISABLE 1 WD ---- [ ] : : 32 DISABLE 1 WD ---- [ ]
No. 1 Status:CHGD 1 Comment: [ ] 2 Enable/Disable: ENABLE 3 Method: Working zone(Diagonal) 4 Group: 1 5 Target model 1: Robot model 6 Target model 2: DISABLE 7 Target model 3: DISABLE 8 User frame: 0 Position(mm): Current Point 1 Point 2 9 X 1827.0 3000.0 -3000.0 10 Y 0.0 3000.0 -3000.0 11 Z 1300.0 2000.0 0.0 12 Stop type: StopCategory 1 13 Speed check <DETAIL> 14 Disabling input: ---[ 0: ] 15 Use Stop Position Prediction: Yes
ALL OK QUIT
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WARNING
must be tested again.
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1. OVERVIEW B-83184EN/13
4 DCS Verify menu is displayed. The contents of the DCS menus are displayed in the DCS verify menu.
Verify the setting values at this time. Pressing [F3] toggles the display between the "DIFF" and "ALL" menu. The “DIFF“ menu only shows the items that were changed after the last verify was performed. The “ALL” menu shows all DCS parameters that are being applied by this operation including unchanged parameters.
5 When the DCS verify menu is displayed, the copy from setting parameter to DCS parameter is
completed. The displayed values are read from the copied DCS parameters. The displayed values can be checked to verify that the copy to DCS parameters was achieved correctly. After verifying the displayed values, press [F4(OK)] if the displayed values are correct. If the displayed value are not correct, press [F5(QUIT)], change the settings and do apply operation again. When [F4(OK)] is pressed, it is recorded that the displayed DCS parameters are verified by the operator. If [F5(QUIT)] is pressed, the DCS parameters are updated but the values are not verified yet. In this situation, the alarm "SYST-219 Need to apply to DCS param" is displayed. To clear the alarm, perform the apply to DCS parameter procedure again.
6 After [F4(OK)] is pressed, cycle power on robot controller.
Changed parameter values will be used after the cycle power. Until a cycle power is performed, the alarm "SYST-290 Cycle power to use new DCS parameter" will occur.
7 Perform the actual DCS function to verify that the changed parameters are set correctly.
If a robot is used with an incorrect DCS parameter setting, the safety function
does not work correctly and serious personal injury could result. When the DCS parameter is changed, the value must be verified, and the related DCS functions
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File name
Description
DCSVRFY.DG
Current "ALL" contents of DCS parameters are written.
DCSDIFF.DG
Current "DIFF" contents of DCS parameters are written.
Only DCSCHGD1 - 3.DG correspond in R-30iB and R-30iB Mate.
File
Included DCS setting parameters
(Includes user setting of Stop Position Prediction)
DCSIOC.SV
Safe I/O Connect function and user comments of the Safe I/O signals.
NOTE - DCS parameters set by an external configuration tool are not included.
SYSPASS.SV
Code numbers
NOTE - F-Parameter is not included.
SYSMAST.SV
Mastering parameters
Auxiliary axis servo off (local stop).
LADDERS.PMC
Safety PMC program.
SYSFLSF.SV
Safety function by FL-net (Items in DCS Safety function by FL-net menu)
SYSCCSF.SV
CC-Link IE Field Safety (Items in DCS CC-Link IE Field Safety menu)
SYSFSOE.SV
EtherCAT safety slave (Items in DCS EtherCAT Safety menu)
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B-83184EN/13 1. OVERVIEW

1.4 DCS PARAMETER REPORT FILE

The DCS parameter values are recorded when DCS parameters are verified. DCS parameter reports for the latest 3 times DCS parameters are verified can be output as a DCS parameter report file. DCS parameter values are recorded when [F4(OK)] is pressed in the DCS verify menu. The current DCS parameters can also be output as a DCS parameter report file.
DCS parameter report files are output by selecting "Diagnostic" or "All of above" from the [F4(BACKUP)] key in the file menu. They can also be read from MD: via FTP.
The DCS parameter report file is a text file containing the same information as displayed on the DCS verify menu. There are 2 types of DCS parameter report files, one contains the same contents as the DCS verify(ALL) menu and the other contains the same contents as the DCS verify(DIFF) menu.
DCS parameter report files
DCSCHGD01 - 21.DG Verified "DIFF" contents of DCS parameters are written. 01 is last verified "DIFF". Each
time the number gets bigger it will be old data. Normally it will be saved up to 03. You can select the number of files to save with the system variable $DCS_CFG->$NUM_CHDG.

1.5 BACKUP / RESTORE DCS SETTING PARAMETER

Backup DCS setting parameters
DCS setting parameters are backed up in the following files.
Backup files for DCS setting parameters
DCSPOS.SV Position/Speed Check function
SYSCIPS.SV DeviceNet Safety or EtherNet/IP Safety (Items in DCS CIP safety menu)
SYSPNSF.SV PROFINET Safety (Items in DCS PROFINET safety menu)
SYSVARS.SV Robot setup data, Robot model, Defaults for Stop Position Prediction, Safe I/O device,
Restore DCS setting parameters
A code number is not required to restore DCS setting parameters, but the alarm "SYST-212 Need to apply to DCS param" occurs if the DCS setting parameters restored are different than the current DCS parameters. To reset the alarm, the operation to apply the DCS parameter is needed, including the need to enter the appropriate code number, for this operation.
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CAUTION
DCS setting parameters.
NOTE
1 When DeviceNet Safety function is used, basic devicenet settings (such as Mac
PMIOG2.SV or PNFB.SV with SYSPNSF.SV if required.
5 In PROFIsafe, F-Host is supposed to send F-Parameter to F-Device. F-
ETHERCAT.SV. Backup/restore ETHERCAT.SV with SYSFSOE.SV if required.
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1. OVERVIEW B-83184EN/13
If an operator who does not know the code number restores DCS Setting
parameters and the alarm "SYST-212 Need to apply DCS param" occurs, the system will not work. An operator who knows the code number must restore
Id, baud rate) are held in SYSDNET.SV. Backup/restore SYSDNET.SV with SYSCIPS.SV if required.
2 If EtherNet/IP Safety is used, standard settings such as IP address and subnet
mask will be saved in SYSHOSV.SV. If necessary, SYSHOSV.SV must also be saved with SYSCIPS.SV.
3 In both DeviceNet Safety and EtherNet/IP Safety function, the Safety PLC data
set in the robot (eg. SNN) is not included in any application backup. It must be explicitly set on a robot from the Safety PLC configuration software.
4 When PROFINET Safety function is used, basic PROFINET settings (such as
I/O Device configuration) are held in PNIO.SV in A05B-2600-J930, or in PMIO.SV in A05B-2600-R834, or in PMIOG2.SV in A05B-2600-J709, or in PNFB.SV in A05B-2600-S523. Backup/restore PNIO.SV or PMIO.SV or
Parameter is not stored in any application backup.
6 When Safety function by FL-net is used, basic FL-net settings (such as area 1/2
configuration) are held in FLNET.SV. Backup/restore FLNET.SV with SYSFLSF.SV if required.
7 When CC-Link IE Field Safety is used, basic CC-Link IE Field slave settings are
held in CCIEDEF.SV. Backup/restore CCIEDEF.SV with SYSCCSF.SV if required.
8 When EtherCAT safety slave is used, basic EtherCAT slave settings are held in
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*** BOOT MONITOR ***
Initialize DCS parameters? Yes:All DCS parameters are initialized. You must enter code number to apply settings if DCS options are used. No :DCS parameters are kept. You must enter code number to apply settings if DCS settings in backup are different than current settings. Parity error will occur if the FROM/SRAM module has been changed or lost battery power. (Yes=1, No = [else]):
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B-83184EN/13 1. OVERVIEW

1.6 INITIAL START, IMAGE RESTORE

In a system where the DCS Position/Speed Check option, Safe I/O Connect option, External mode select option, Safety PMC, DeviceNet Safety, EtherNet/IP Safety PROFINET Safety or Safety function by FL­net option is loaded, the following message is displayed at initial start or image restore. This question decides whether DCS parameters are initialized or not.
And in a system where those options are not loaded, if the safety I/O device is connected and the initialization of the safety I/O device is done, the following message is displayed at initial start or image restore too.
Yes: All DCS parameters are initialized.
You must enter code number to apply DCS settings if any DCS options are used.
No: DCS parameters are kept.
You must enter code number to apply DCS settings if the DCS settings in the backup are different than the current settings. Parity error will occur if the FROM/SRAM module has been changed or lost battery power.
- Normally, "No" is selected. Users do not need to enter code numbers when "No" is selected as long as the DCS parameters are not changed as follows. 1 Backup files are loaded after initial start, and the DCS setting parameters are the same as the
DCS setting parameters before the initial start.
2 DCS setting parameters stored in the restored image file are the same as the DCS setting
parameters before the image restore.
- If FROM/SRAM module has been changed or lost battery power, please select "Yes". If "No" is selected, SRAM parity error will occur, and system cannot be used.
- If "Yes" is selected when DeviceNet Safety or EtherNet/IP Safety is used, the parameters that are set by the external configuration tool via the safety network are cleared and the parameters must set by the configuration tool again. These parameter are not set by the apply to DCS parameter.
- In an image restore case, when the current DCS parameters and the DCS parameters in the image file are the same, the above question is not displayed and the DCS parameters are kept.
- In an image restore case, when the software in current FROM/SRAM module has no DCS related options, the above question is not displayed and the DCS parameters are initialized.
- In an image restore case, when "No" is selected, the alarm "SYST-219 Need to apply DCS param" and "SRVO-337 DCS PRMCHK alarm" occurs if the current DCS parameters and the DCS parameters in the image file are different. In this case, please perform the “Apply to DCS parameter” procedure.
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1. OVERVIEW B-83184EN/13
WARNING
necessary, including the additional delay of 8 ms.

1.7 STOPPING DISTANCE

Dual Check Safety (DCS) stops the robot by shutting down the motor power. When the motor power is shut down while the robot is moving, the robot’s momentum causes it to move some distance before it completely stops. This distance depends on the type of robot, payload, and speed.
The default scan time of the Position/Speed Check functions is 8 msec. This scan time might change according to your system configuration. The actual scan time is displayed in the DCS robot SETUP menu (Refer to Section 2.3 DCS Robot Setup Menu). DCS Position/Speed Check functions will detect an alarm within a maximum of one scan time.
The stop distance is calculated as follows: (Speed x Scan time) + moving distance through momentum
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1 The robot stopping distance must be considered when DCS Position/Speed
Check is used. A risk assessment for the whole robot system is necessary.
2 If StopCategory 1 is set as a stop type, motor power shutdown is delayed for a
maximum of 2 seconds. In this case, a risk assessment for the whole robot system is necessary, including the 2 seconds delay.
3 If Safe I/O Connect feature is used, safety signal status could be delayed by a
maximum of 2 ms. In this case, a risk assessment for the whole robot system is necessary, including the additional 2 ms delay.
4 If DeviceNet Safety or Ethernet/IP Safety feature is used, safety signal status
could be delayed by a maximum of 2 ms. In this case, a risk assessment for the whole robot system is necessary, including the additional 2 ms delay.
5 If PROFINET Safety feature is used, safety signal status could be delayed by a
maximum of 4 ms. In this case, a risk assessment for the whole robot system is necessary, including the additional 4 ms delay.
6 If Safety function by FL-net feature is used, safety signal status could be
delayed by a maximum of "Timer for receive data + 4" ms. In this case, a risk assessment for the whole robot system is necessary, including the additional "Timer for receive data + 4" ms delay. See item "Timer for receive data" in "Table13.2.3 (b) Parameters in Safety function by FL-net screen" for "Timer for receive data".
7 If Safety PMC feature is used, safety signal status that is output by the Level 1
sequence program could be delayed by a maximum of 2ms. And safety signal status that is output by the Level 2 sequence program could be delayed by a maximum of the execution period of Level 2. The execution period of Level 2 is displayed in DCS Safety PMC menu. In this case, a risk assessment for the whole robot system is necessary, including the additional signal status delay.
8 If CC-Link IE Field Safety feature is used, safety signal status could be delayed
by maximum of “Max. trans Interval +8” ms. In this case, a risk assessment for the whole robot system is necessary, including the additional delay of “Max. trans Interval + 8” ms. See item “Max. Trans Interval (128μs)” in Table 14.2.2(a) for more detail.
9 If EtherCAT safety slave is used, safety signal status could be delayed by a
maximum of 8 ms. In this case, a risk assessment for the whole robot system is
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B-83184EN/13 2. DCS MENU

2 DCS MENU

In the DCS menu, users can change DCS setting parameters and apply these parameters to DCS parameters.
DCS menu is displayed if the option related to DCS function is loaded. In Multi-Arm system, DCS menu is displayed even though no option related to DCS function is loaded, because DCS parameter may need to be changed according to the robot configuration. And DCS menu is displayed even though no option related to DCS function is loaded when new safety I/O device is connected too.

2.1 DCS MENU COMPONENTS

Display DCS menu
DCS menu is displayed by the following operation. [MENU] "SYSTEM" [F1(TYPE)] "DCS"
DCS menu components
DCS menu consists of the following menus.
DCS Top menu
DCS Safe I/O status menu DCS Safe I/O connect menu or DCS Safety PMC menu DCS Joint position check menu DCS Joint speed check menu DCS Cartesian position check menu DCS Cartesian speed check menu DCS T1 mode speed check menu DCS User model menu DCS Tool frame menu DCS User frame menu DCS Stop position prediction menu DCS Robot setup DCS Mastering parameter menu DCS Pos./Speed check setup menu DCS CIP Safety menu DCS PROFINET Safety menu DCS Safety function by FL-net menu DCS Local stop menu DCS Teach Pendant Hot Swap menu DCS Shared Teach Pendant menu DCS I/O Link i Slave menu DCS Mode Select menu DCS Safe I/O Consistency Check menu DCS Safe I/O device menu DCS Signature number menu DCS Code number setup menu
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2. DCS MENU B-83184EN/13
In this Chapter, the following menus related to general DCS functions are described.
- DCS Top menu
- DCS Robot setup menu
- DCS Mastering parameter menu
- DCS Signature number menu
- DCS Code number setup menu
The following menus are described in "7 POSITION / SPEED CHECK FUNCTION".
- DCS Joint position check menu
- DCS Joint speed check menu
- DCS Cartesian position check
- DCS Cartesian speed check
- DCS T1 mode speed check menu
- DCS User Model menu
- DCS Tool frame menu
- DCS User frame menu
- DCS Stop position prediction menu
- DCS speed check
The following menus are described in "9 SAFE I/O"
- DCS Safe I/O status menu
- DCS Safe I/O connect menu
- DCS Safe I/O device menu
The following menu is described in "10 DEVICENET SAFETY" and "11 ETHERNET/IP SAFETY"
- DCS CIP Safety menu
The following menu is described in "12 PROFINET SAFETY"
- DCS PROFINET Safety menu
The following menu is described in "13 SAFETY FUNCTION BY FL-net".
- DCS Safety function by FL-net menu
The following menu is described in "15 SAFETY PMC FUNCTION".
- DCS Safety PMC function menu
The following menu is described in "16 AUXILIARY AXIS SERVO OFF (LOCAL STOP) FUNCTION".
- DCS Local stop menu
The following menu is described in "17 TEACH PENDANT HOT SWAP".
- DCS Teach Pendant Hot Swap menu
The following menu is described in "18 SHARED TEACH PENDANT".
- DCS Shared Teach Pendant menu
The following menu is described in "19 I/O LINK i SLAVE FUNCTION".
- DCS I/O Link i Slave menu
The following menu is described in "20 SAFE I/O CONSISTENCY CHECK FUNCTION".
- DCS Safe I/O Consistency Check menu
The following menu is described in "21 OPERATION WITHOUT MODE SWITCH".
- DCS Mode Select menu
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DCS 1/24 1 Safe I/O Status: 2 Safe I/O connect: OK 3 Joint position check: ---- OK 4 Joint speed check: ---- OK 5 Cart. position check: ---- OK 6 Cart. speed check: ---- OK 7 T1 mode speed check: OK 8 User model: OK 9 Tool frame: OK 10 User frame: OK 11 Stop position prediction: OK 12 Robot setup: OK 13 Mastering parameter: OK 14 Pos./Speed check setup OK
15 CIP safety: OK 16 Safety function by FL-net: OK 17 Local Stop Setup: OK 18 Teach Pendant Hot Swap: OK 19 Shared Teach Pendant: OK 20 I/O Link i Slave: OK 21 Mode Select OK 22 Safe I/O consistency check: OK 23 Safe I/O device: OK 24 Signature number: 25 Code number setup:
[ TYPE ] APPLY DETAIL UNDO
Item
Description
This line is displayed when "Safe I/O Connect" or the option that includes it are loaded.
Safe I/O connect
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Safe I/O
replaced by "Safety PMC".
device menu is set to "Safety PMC".
Joint position check
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Joint
Check" option is loaded. (*1)
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B-83184EN/13 2. DCS MENU

2.2 DCS TOP MENU

This is the top level DCS menu and includes the operation to “Apply to DCS parameter”. Each DETAIL menu can be displayed from this menu. The DCS top menu can be displayed by pressing PREV from each DETAIL menu.
DCS Top menu
Items in DCS Top menu
Safe I/O status When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Safe I/O
Status menu is displayed.
Connect menu is displayed. This line is displayed when "Safe I/O Connect" or the option that includes it are loaded. When "Safe I/O process" in Safe I/O device menu is set to "Safety PMC", this item is
Safety PMC When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the Safety PMC
menu is displayed. This line is displayed when "Safety PMC" is loaded and "Safe I/O process" in Safe I/O
Position Check menu is displayed. This line is displayed when "DCS Position/Speed Check" option or "DCS Basic Position
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Item
Description
Joint speed check
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Joint
Check" option or "DCS Joint Speed check" option is loaded. (*1)
option is loaded.
Cart. speed check
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Cartesian
This line is displayed when "DCS Position/Speed Check" option is loaded.
This line is displayed when "DCS Position/Speed Check" option is loaded.
User model
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS User
Check" option is loaded.
Check" option is loaded. (*1)
User frame
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS User
This line is displayed when "DCS Position/Speed Check" option is loaded.
Check" option is loaded.
Robot setup
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Robot
option or "DCS Basic Position Check" option is loaded.
option is or "DCS Basic Position Check" option loaded.
Pos./Speed check
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCSPos./Speed
This function does not correspond in R-30iB and R-30iB Mate.
This line is displayed when "DeviceNet Safety", or “EtherNet/IP Safety” option is loaded.
PROFINET Safety
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS
This line is displayed when "PROFINET Safety" option is loaded.
This line is displayed when "Safety function by FL-net" option is loaded.
Local Stop Setup
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Local stop
This line is displayed when "Axiliary axis servo off (local stop) function" option is loaded.
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2. DCS MENU B-83184EN/13
Speed Check menu is displayed. This line is displayed when "DCS Position/Speed Check" option or "DCS Basic Position
Cart. position check When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Cartesian
Position Check menu is displayed. This line is displayed when "Position/Speed Check" option or "DCS Basic Position Check"
Speed Check menu is displayed.
T1 mode speed check
Tool frame When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Tool
Stop position prediction
Mastering parameter
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS T1 Mode Speed Check menu is displayed.
Model menu is displayed. This line is displayed when "DCS Position/Speed Check" option or "DCS Basic Position
Frame menu is displayed. This line is displayed when "DCS Position/Speed Check" option or "DCS Basic Position
Frame menu is displayed.
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Stop Position Prediction menu is displayed. This line is displayed when "DCS Position/Speed Check" option or "DCS Basic Position
Setup menu is displayed. This line is displayed when "DCS Position/Speed Check" option or "DCS Joint Speed check"
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Mastering Parameter menu is displayed. This line is displayed when "DCS Position/Speed Check" option or "DCS Joint Speed check"
setup
CIP Safety When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS CIP Safety
Safety function by FL-net
check setup menu is displayed.
This line is displayed when "DCS Position/Speed Check" option or "DCS Basic Position Check" option is loaded.
menu is displayed.
PROFINET Safety menu is displayed.
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Safety function by FL-net menu is displayed.
setup menu is displayed.
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Item
Description
Teach Pendant Hot
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Teach
This line is displayed when "Teach Pendant Hot Swap function" option is loaded.
This line is displayed when "Shard Teach Pendant function" option is loaded.
I/O Link i Slave
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS I/O Link i
This line is displayed when the special hardware for I/O Link i Slave is used.
R-30iB Compact Plus or R-30iB Mini Plus.
Safe I/O
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Safe I/O
This line is always displayed.
This line is always displayed.
Signature number
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Signature
This line is always displayed.
This line is always displayed.
OK / CHGD /
For menus that allow setting parameters to be changed in the detail menu, OK/CHGD/PEND
has not been cycled.
DISABLE. See "7.12 Pos./Speed check setup".
---- / SAFE / OVER
On Joint Speed Check and Cartesian Speed Check lines, ----/SAFE/OVER/DSBL is
DSBL: Disabled by disabling input now.
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B-83184EN/13 2. DCS MENU
Swap
Shared Teach Pendant
Mode Select When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Mode
consistency check
Safe I/O device When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Safe I/O
Code number setup When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Code
Pendant Hot Swap menu is displayed.
When the [ENTER] key or the [F3(DETAIL)] key is pressed on this item, the DCS Shared Teach Pendant menu is displayed.
Slave menu is displayed.
Select menu is displayed. This line is displayed when "TP mode select ” function" option is loaded or controller type is
consistency check menu is displayed.
device menu is displayed.
Number menu is displayed.
Number Setup menu is displayed.
PEND
---- / SAFE / UNSF / DSBL
/ DSBL
is displayed in the right column. OK: Setting parameter and DCS parameter are the same.
CHGD: Setting parameter is changed, but not applied to DCS parameter. PEND: Setting parameter is changed and applied to DCS parameter, but controller power
On Joint Position Check and Cartesian Position Check lines, ----/SAFE/UNSF/DSBL is
displayed in the second column from the right.
----: Disabled by settings. SAFE: Enabled, and in the safe zone now. UNSF: Enabled, and out of the safe zone now. DSBL: Disabled by disabling input now. DSSF: Disabled by disabling input in the safe zone now. DSUN: Disabled by disabling input out of the safe zone now. DSSF, DSUN are displayed when Disabled CPC Position Check in Pos./Speed check is
displayed in the second column from the right.
----: Disabled by settings. SAFE: Enabled, and speed is less than the limit now. OVER: Enabled, and speed is over the limit now.
*1: In case of "DCS Basic Position Check", item line is not displayed if the software version is 7DF4
series or earlier. Item line is always displayed if the software version is 7DF5 series or later.
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Operation
Description
[F2(APPLY)]
Apply to DCS parameters.
[ENTER]
[F5(UNDO)]
UNDO all items in the DCS menu except robot setup data, mastering parameters and Safety
parameters.
[NEXT→] [F3(4D)]
See "8.2 4D GRAPHICS DCS DISPLAY ".
[NEXT→] [F5(View)]
Display robot model in the Simple view. See "8.1. Viewing the robot model".
DCS Robot setup 1/11 Status 1 Number of groups: 1 OK 2 Scan time: 8 msec OK 3 ---------- Group 1 ---------- 4 Robot: R-2000iB/210F OK 5 Number of axes: 6 OK 6 J1: Servo card - Axis 1 OK 7 J2: Servo card - Axis 2 OK 8 J3: Servo card - Axis 3 OK 9 J4: Servo card - Axis 4 OK 10 J5: Servo card - Axis 5 OK 11 J6: Servo card - Axis 6 OK
[ TYPE ]
Item
Description
Number of groups
This item indicates the number of DCS motion groups.
Scan time
This item indicates the scan time of position / speed checking process.
used for this action group.
Number of axes
This item indicates the number of axes in this motion group.
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2. DCS MENU B-83184EN/13
Operation in DCS Top menu
[F3(DETAIL)] or
Display the detail menu of the highlighted item.
PMC program, all DCS setting parameters are reset to be the same as the current DCS
Display the 4D graphics DCS screen.

2.3 DCS ROBOT SETUP MENU

This menu is available when the "DCS Position/Speed Check" option or "DCS Basic Joint Speed check" option or "DCS Basic Position check" option is loaded. This menu displays the robot setup data related to DCS Position/Speed Check functions. When robot setup data is changed in the Maintenance menu at Control Start, CHGD is displayed on the status column of the changed item in this menu. In this situation, "SYST-212 Need to apply to DCS param" occurs and cannot be reset until "Apply to DCS parameter" is done.
DCS Robot setup menu
DCS Robot setup menu is displayed by pressing the [ENTER] key or the [F3(DETAIL)] key while on the "Robot setup" item in the DCS Top menu.
Items in DCS Robot setup menu
Robot This item indicates the robot model name of the group assigned to this DCS motion group.
If it is described as "Excluded!", the motion group is excluded by DCS Position/Speed functions. Since the number of axes is considered to be 0, Cartesian Position Check function and Cartesian Speed Check function and T1 mode Speed Check function can't be
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Item
Description
J1 - J9
This item indicates the hardware configuration of each axis.
osition
is always 0, and checks the DCS TCP speed and the wrist flange center speed.
+X : +Z direction, -Z : -Z direction
Arm length
This item indicates the arm length of the extended axis
Offset
This item indicates the offset of the extended axis
Offset X
Offset Z
This item indicates the offset of the positioner axis
Linear axis or Rotary axis.
Motor direction
This item indicates the motor direction of extended axis, positioner axis or independent axis
Gear ratio
This item indicates the gear ratio of extended axis, positioner axis or independent axis
Pos. tolerance
This item indicates the position tolerance of the extended axis, positioner axis or
the alarm "SRVO-365 DCS FB_CMP alarm" occurs.
not cycled yet, and the new setting is not used. Power must be cycled.
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B-83184EN/13 2. DCS MENU
Servo card : This axis is connected to axis control card on main board. Axis board This axis is connected to auxiliary axis board. The slot name that the
auxiliary axis board is inserted is displayed in the parenthesis.
Excluded! This axis is excluded by DCS Position/Speed Check functions. Joint P
Check and Joint Speed Check cannot be enabled for this axis. When a motion group includes an excluded axis, except when it is an Auxiliary Extended Axis, the motion group cannot be used with the Cartesian Position Check, Cartesian Speed Check and T1 Mode Speed Check functions.
Speed only! This axis can be used only for Joint Speed Check. Joint Position Check
cannot be enabled for this axis. When a motion group includes an speed only axis, except when it is an Auxiliary Extended Axis, the motion group cannot be used with the Cartesian Position Check and Cartesian Speed Check functions. The T1 Mode Speed Check function regards the position of the speed only axis
Direction This item indicates the direction of the Extended axis or Positioner.
[Extended axis] Auxiliary axes No direction
X : X direction, Y : Y direction, Z : Z direction [Positioner axis] +X : +X direction, -X : -X direction +Y : +Y direction, -Y : -Y direction
Offset Y
Axis type This item indicates the axis type of extended axis, positioner axis or independent axis.
independent axis. If the difference between the command position and feedback position exceeds this value,
Status This item indicates the status of each item displayed.
OK : Robot setting is the same as DCS parameter
CHGD : Robot setting is changed but not applied to DCS parameter. The alarm "SYST-
212 Need to apply to DCS param" occurs.
PEND : Robot setting is changed and applied to DCS parameter, but controller power is
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DCS Mastering parameter 1/7 Axis Position Master count Status 1 ---------- Group 1 ---------- 2 J1 0.000 deg 0 OK 3 J2 0.000 deg 0 OK 4 J3 0.000 deg 0 OK 5 J4 0.000 deg 0 OK 6 J5 0.000 deg 0 OK 7 J6 0.000 deg 0 OK
[ TYPE ]
Item
Description
Axis
This item indicates the axis number.
parameters are applied to DCS parameters.
Master count
This item indicates the value of the standard mastering parameters.
parameters of this axis are not copied to DCS parameters.
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2. DCS MENU B-83184EN/13

2.4 DCS MASTERING PARAMETER MENU

This menu is available when the "DCS Position/Speed Check" option or "DCS Basic Joint Speed check" option or "DCS Basic Position check" option is loaded. The mastering parameters of the setting parameters are displayed in this menu, they are not set from this menu. The mastering parameters are changed by the normal mastering procedure.
When the standard mastering parameters are changed by mastering procedure, CHGD is displayed on the status column of the changed item in this menu. "SYST-212 Need to apply to DCS param" occurs and cannot be reset until "Apply to DCS parameter" is done.
DCS Mastering Parameter menu
DCS Mastering Parameter menu is displayed by pressing the [ENTER] key or the [F3(DETAIL)] key while on the "Mastering Parameter" item in the DCS Top menu.
Items in DCS Mastering parameter menu
Position This item indicates the current position calculated from the applied mastering parameters.
Verify that the displayed position shows the correct robot position when mastering
Status This item indicates the status of each axes’ mastering parameters.
OK : Mastering parameters are the same as DCS parameters CHGD : Mastering parameters are changed but not applied to DCS parameters. The alarm "SYST-212 Need to apply to DCS param" occurs. PEND : Mastering parameters are changed and applied to DCS parameter, but controller power is not cycled yet, and the new setting is not used. Power must be cycled
Not displayed: This axis is excluded by DCS Position/Speed Check functions. Mastering
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CAUTION
prevent DCS parameters from being changed by an unauthorized personnel.
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2.5 DCS CODE NUMBER

The menu is used to change the DCS code number. DCS parameter must be entered when "Applying to DCS parameter". DCS code number is a 4 digit number.
There are 2 types of code numbers, a master code number and local code numbers.
Master code number
The master code number can be used to apply any changed parameters.
Local code number
There are 3 local code numbers, Base, Position/Speed Check and Safe I/O Connect. Each of these local code numbers only allow changes in each specified area to be applied. When multiple setting parameters are changed, the master code number or all local code numbers corresponding to the changed setting parameters need to be entered to apply to DCS parameter. For example, if setting parameters for Position/Speed Check and setting parameters for Safe I/O Connect are changed, master code number or the local code numbers for both Position/Speed Check and Safe I/O Connect must be entered.
Local code numbers are not defined by default. When the local code number for a changed setting parameter is not defined, the master code number must be used. The default master code number is "1111". In the message to apply to DCS parameter, the name of the required code number is displayed (i.e. "Code number(pos./speed):"). The “Apply to DCS parameter” is not performed until the specified local code number or master code number is entered.
To change a code number, the current local code number or master code number must be entered. To clear a local code number, the current master code number must be entered.
Code numbers are saved as part of the robot backup in SYSPASS.SV. When code numbers are changed by loading the SYSPASS.SV file, the alarm "SYST-219 Need to apply DCS param" occurs. To clear the alarm, the “Apply to DCS parameter” operation must be performed. In this operation, the previous master code number must be entered as follows.
- The message "Previous code number(master):" is displayed, please enter the master code number that was used before SYSPASS.SV is loaded.
- Then the message "Code number(Master)" is displayed, please enter the master code number that is loaded from the SYSPASS.SV.
When code numbers are changed by loading the image file, the alarm "SYST-219 Need to apply DCS param" occurs. To clear the alarm, the “Apply to DCS parameter” operation must be performed. In this operation, the previous master code number must be entered as follows.
- The message "Previous code number(master):" is displayed, please enter the master code number that was used before the image file is loaded. (If Yes was selected for "Initialize DCS parameters?" at image restore, please enter "1111".)
- Then the message "Code number(Master)" is displayed, please enter the master code number that is loaded from the image file.
Make sure to change the master code number from the default “1111” setting to
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DCS Code number setup 1/6
1 Master code number Local code number 2 Base UNDEFINED 3 Position/Speed check UNDEFINED 4 I/O connect UNDEFINED Code number by Pass. func. 5 Master code by Pass. ENABLE 6 TP mode select by Pass. ENABLE
Item
Description
Master code number
When the [ENTER] key is pressed on this item, the master code number can be changed. The current master code number must be entered.
If the Base code number is defined, "DEFINED" is displayed.
Position/Speed
The code number to change the DCS parameters for the Position/Speed Check function.
If the Position/Speed Check code number is defined, "DEFINED" is displayed.
If the Safe I/O Connect code number is defined, "DEFINED" is displayed.
Master code by Pass.
If this function is enabled, user can skip to input Master code for DCS apply by using Password Function. For more detail, please refer to “2.6.4 Code by Password Function”.
Pass.
Password Function. For more detail, please refer to “2.6.4 Code by Password Function”.
Operation
Description
The Master code number must be entered.
PREV
DCS Top menu is displayed.
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2.5.1 DCS Code Number Setup Menu

The DCS Code Number Setup menu is displayed by pressing the [ENTER] key or the [F3(DETAIL)] key while on the "Code number setup" item in the DCS Top menu.
Items in DCS code number setup menu
Base The code number to change the DCS parameters for robot setup date, mastering parameter,
CIP Safety, PROFINET Safety, Safety function by FL-net and Auxiliary axis servo off (local stop) function. When the [ENTER] key is pressed on this item, the local code number for Base DCS parameters can be changed. The current Base code number or Master code number must be entered. If the Base code number is not defined, "UNDEFINED" is displayed.
check
I/O connect The code number to change the DCS parameters for the Safe I/O Connect function, Safe I/O
TP mode select by
When the [ENTER] key is pressed on this item, the local code number for Position/Speed Check DCS parameters can be changed. The current Position/Speed Check code number or Master code number must be entered. If the Position/Speed Check code number is not defined, "UNDEFINED" is displayed.
device, Safety PMC program, Teach Pendant Hot Swap and Shared Teach Pendant. When the [ENTER] key is pressed on this item, the local code number for Safe I/O Connect DCS parameters can be changed. The current Safe I/O Connect code number or Master code number must be entered. If the Safe I/O Connect code number is not defined, "UNDEFINED" is displayed.
If this function is enabled, user can skip to input Master code for TP mode select by using
Operation in DCS code number setup menu
F2(CLEAR) When F2 is pressed on a local code number, the local code number becomes undefined.
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DCS Signature number (Dec) Current Latch 1 Total: 357145112 0 Time:27-MAY-09 14:49 None 2 Base: 2084717660 0 Time:26
-MAY
-09 15:50 None 3 Pos./Speed: 998197839 0 Time:27-MAY-09 14:49 None 4 I/O connect: 273305809 0 Time:26
-MAY
-09 15:48 None
[ TYPE ] Dec/Hex Annun
Item
Description
Current
This column displays the Current signature numbers.
OFF.
Time
The Time setting for "Current" signatures is the time that the signature number was changed to
In DCS parameter verify menu or in report file, "Changed" is displayed on the "Current"
signature that is changed by this APPLY operation. The "Current" time will be set to
the time when the new DCS parameter setting is enabled at next power up.
Total
Displays the signature number of all DCS parameters.
Base
Displays the signature number of the DCS parameters for robot setup date, mastering
off (local stop) function.
Pos./Speed
Displays the signature number of the DCS parameters for the Position/Speed Check function.
I/O connect
Displays the signature number of the DCS parameters for the Safe I/O Connect function, Safe I/O device, Safety PMC program, Teach Pendant Hot Swap and Shared Teach Pendant.
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2.6 DCS SIGNATURE NUMBER

The DCS Signature Number menu displays the signature numbers of the various types of DCS parameters. A signature number is a CRC of the DCS parameter values. When DCS parameters are changed, the corresponding signature number is also changed. These signature numbers can be used to indicate that DCS parameters have been changed. DCS code numbers are not included as part of the signature numbers. Changing the DCS code numbers will not change the DCS signature numbers.

2.6.1 DCS Signature Number Menu

The DCS Signature Number menu is displayed by pressing the [ENTER] key or the [F3(DETAIL)] key while on the "Signature number" item in the DCS Top menu.
Items in DCS Signature number menu
Latch When one of the CCR[1-4] signals are changed from OFF to ON using the Safe I/O Connect
function, the current signature number is copied to the latched signature number. When a current signature number matches its latched signature number, the corresponding CCL[1-4] signal is set ON. When they are different, the corresponding CCL[1-4] signal is set
this value. The Time setting for "Latch" signatures is the time that the current signature was copied to the latched signature number by using the Safe I/O Connect function. NOTE­time of the
parameter, CIP Safety, PROFINET Safety, Safety function by FL-net and Auxiliary axis servo
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Operation
Description
[F3(Dec/Hex)]
Toggles the display of the signature numbers between decimal and hexadecimal format.
[F5 (Annun)]
Displays the DCS Signature number annunciation setup menu
[PREV]
DCS Top menu is displayed.
DCS
Signature Annunciation
Parameter Signature
Curr: [11-DEC-09 18:25] -20554788
Prev: [10-DEC-09 12:23] -19745529
1 Signature change annunc: RO[ 1]
[ TYPE ] [CHOICE] CNF SIG
WARNING
not use Signature Change Annunciation output for safety purposes.
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Operation in DCS Signature number menu

2.6.2 DCS Signature Annunciation Menu

The Dual Check Safety (DCS) Signature Annunciation menu provides a means to see at a glance that DCS settings have been changed. It displays two Parameter Signature numbers with dates, and a Signature Change Annunciation output.
The Parameter Signature numbers represent a summary of all DCS parameter values and are equal to the Total signature number on the Signature Number menu. There are two Parameter Signature numbers: a Current number and a Previous number. On initial load of the DCS Position and Speed Check option, the Signature is calculated and displayed as the Current (Curr:) value. The Previous (Prev:) value is uninitialized. After initial load, a new Signature is calculated each power up. If changes have been made to any of the DCS setup parameters, a new value and date are displayed as the Current item. Otherwise, the value and date will remain the same. The Previous value is set by confirming the signature using the CNF SIG function key. See "Procedure 2­6-2 Confirming Changes to the Parameter Signature" for instructions on confirming the current signature. Once confirmed, the Previous signature and date are set equal to the Current values. In addition to the Signatures indicating changes to DCS setup parameters, this feature also indicates changes with a digital output called the Signature Change Annunciation output. Either a Digital output or a Robot output can be selected along with specifying the output index. After this output has been set up, it will turn on and stay on as long as the Current and Previous Signatures are the same. If they are different, the output will turn off. This output can be connected to an annunciating lamp or to a PLC to provide status of the Signatures.
Signature Change Annunciation output is not a safety function. If the output of
this function is used where a safety function is required, the safety function will not work under some fault conditions and serious personal injury could result. Do
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WARNING
not use Signature Change Annunciation output for safety purposes.
DCS
Signature Annunciation
Parameter Signature
Curr: [11-DEC-09 18:25] -20554788
Prev: [10-DEC-09 12:23] -19745529
1 Signature change annunc: RO[ 1]
[ TYPE ] [CHOICE] CNF SIG
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2.6.2.1 DCS signature change management utility setup
It outputs to the Robot or Digital output whether the DCS parameter has been changed. The Current and Previous Signature values will still indicate changes to DCS parameters whether or not you set up a digital output. The only setup required for this function is the selection of a Robot or Digital output that will be used to annunciate changes to the Signature value. If you set up the digital output, and the Current and Previous Signature values change, the digital output will turn on and stay on as long as the values are the same. As soon as the Current and Previous values are different, the output will turn off. Use the following procedure to set up a digital output that will annunciate Signature changes.
Signature Change Annunciation output is not a safety function. If the output of
this function is used where a safety function is required, the safety function will not work under some fault conditions and serious personal injury could result. Do
Procedure 2-6-1 Setting up the DCS Signature Change Management Utility
Steps :
1 Press the [MENU] key. 2 Select SYSTEM. 3 Press the F1, [TYPE] key. 4 Select DCS. 5 Press the [ENTER] key or the [F3(DETAIL)] key while on the “Signature Number” item. 6 Press the [F5(Annun)] key. You will see a screen similar to the following:
7 Move the cursor to the output field of Signature change annunc which should display DO or RO, and
press [F4(CHOICE)]. Select the output type desired. 8 Move the cursor to the index number in the brackets, and set the desired index number. 9 Cycle power to finalize the setup.
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2.6.2.2 DCS signature change management utility operation
The Parameter Signature numbers represent a summary of all DCS parameter values and are equal to the Total signature number on the Signature Number menu. There are two Parameter Signature numbers: a Current number and a Previous number. On initial load of the DCS Position and Speed Check option, the Signature is calculated and displayed on the Signature Annunciation menu as the Current (Curr:) value. The Previous (Prev:) value is uninitialized. After initial load, a new Signature is calculated each power up. If changes have been made to any of the DCS setup parameters, a new value and date are displayed as the Current item. Otherwise, the value and date will remain the same. The Previous value is set by confirming the signature using the CNF SIG function key. See "Procedure 2­6-2 Confirming Changes to the Parameter Signature" for instructions on confirming the current signature. Once confirmed, the Previous signature and date are set equal to the Current values.
Procedure 2-6-2 Confirming Changes to the Parameter Signature
Steps :
1 On the DCS Signature Annunciation menu, the CNF SIG function key should be displayed when the
cursor is on any item. 2 Press the [F5(CNF SIG)] key. You will be prompted to enter the DCS Code number (master). The
correct code number must be provided to confirm the Signature. You will be prompted to “Confirm
new parameter signature?” 3 Press the [F4(YES)] key. The message “New parameter signature saved” will be displayed and the
Previous value of the Parameter Signature and date will be changed to equal the value and date of the
Current signature. If the annunciating output has been set up, the output will turn on to indicate that
the Current and Previous Signature values are the same.
If the Current and Previous Signature values are the same and a Signature Change Annunciator output has been set up, the output will be on. If the Current and Previous Signature values are different, the output will turn off.

2.6.3 DCS Signature Number Output

The DCS Signature numbers can be output through normal (non-safe) group outputs. Each 32-bit signature output requires two 16-bit groups.
This is configured by setting $DCS_CRC_OUT[x].$START_GRP to the starting group number. There are eight values accessible :
- Current Total CRC : $DCS_CRC_OUT[1].$START_GRP
- Current Base CRC : $DCS_CRC_OUT[2].$START_GRP
- Current Pos/Speed CRC : $DCS_CRC_OUT[3].$START_GRP
- Current I/O Connect CRC : $DCS_CRC_OUT[4].$START_GRP
- Latch Total CRC : $DCS_CRC_OUT[5].$START_GRP
- Latch Base CRC : $DCS_CRC_OUT[6].$START_GRP
- Latch Pos/Speed CRC : $DCS_CRC_OUT[7].$START_GRP
- Latch I/O Connect CRC : $DCS_CRC_OUT[8].$START_GRP
For example, if $DCS_CRC_OUT[1].$START_GRP is set to 1 then GO[1] and GO[2] are set to the lower and upper 16-bits of the Current Total CRC. If the Total Current CRC is 0x46A61511 (hex value) then GO[1] will be set to 0x1511 and GO[2] will be set to 0x46A6.
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Tag
Description
const=”25”
Permit user to skip inputting master code for DCS apply.
Tag
Description
to select T2)
const=”27”
Permit user to skip inputting Master code for TP mode select to AUTO/T1/T2
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2.6.4 Code by Password Function

By using this function, the specified user by password function can skip to input the master code for DCS apply and TP mode select.
When “Master code by Pass.” in Code number setup page is enabled, the specified level user can skip to input the master code which is necessary for DCS apply. Every operation level setting is specified by the XML file of password function. A following features tag is used in the XML file.
Features tag for DCS apply
When “TP mode select by Pass.” in Code number setup page is enabled, specified level user can skip to input the master code which is necessary for TP mode select. The setting of every operation level is specified by the XML file of password function. Following features tags are used in the XML file.
Features tag for TP mode select
const=”26” Permit user to skip inputting Master code for TP mode select of AUTO/T1 (Need Master code
Example) An example of XML file under the following conditions is shown below.
Permit Level 2 user to skip inputting the master code for DCS apply. Permit Level 3 user to skip inputting the master code for DCS apply. Permit Level 3 user to skip inputting the master code for TP mode select to AUTO/T1.
<?xml version="1.0"?> <PASSWORD> <PWD level="2" const="25" access="1"/> <!-- DCS apply permission --> <PWD level="3" const="25" access="1"/> <!-- DCS apply permission --> <PWD level="3" const="26" access="1"/> <!-- AUTO/T1 permission --> </PASSWORD>
For more details about password function, please refer to “R-30iB/R-30iB Mate/R-30iB Plus/R-30iB Mate Plus/R-30iB Compact Plus/R-30iB Mini Plus CONTROLLER OPERATOR’S MANUAL (Basic Function) (B-83284) 9.11 PASSWORD FUNCTION”.
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Type
Item
Description
workspace limit
function
Setup of Stop Position Prediction
Set a robot to stop within the programmed workspace. attached by users, such as hands.
Check
Check the DCS zone using 4D graphics
Check the robot shape and robot workspace specified in the DCS function using a three-dimensional display.
Troubleshooting
Recovery from alarm
Recovering from an alarm when a robot moves out of the workspace.
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3 LIMITING A ROBOT WORKSPACE

3.1 OVERVIEW

This chapter describes the method for limiting the workspace of a robot with Dual Check Safety (DCS) functions. The robot stops when it performs an operation which goes beyond the specified workspace. The following picture shows the restricted workspace of the robot.
Setup of robot workspace limit → 3.2
Setup of user model → 3.4
This chapter describes the setup procedure to limit the robot workspace.
Settings Setup of robot
Setup of user model Set user models in order to limit the workspace of equipment
Set the limits of the robot workspace with Cartesian Position Check
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WARNING
values must be verified and the function must be tested again.
CAUTION
same motion group as the robot.
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3.2 LIMITING A ROBOT WORKSPACE BY CARTESIAN
POSITION CHECK
This section describes the procedure to set a robot workspace as shown in the following figure using the DCS Cartesian Position Check function.
See Subsection " 7.4.2.1 Define the safe zone" for detailed information.
If a robot workspace is set up incorrectly, the safety function will not work, and
serious personal injury could result. When a robot workspace is changed, the
If the robot is mounted on a rail axis, the robot workspace moves when the world
frame of the robot moves along with the movement of the rail axis. To fix the robot workspace, the rail axis should be defined as Integrated Rail axis of the
Point 1
Zone No.1
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1 Press the [MENU] key on Teach Pendant to display MENU pop up screen. 2 Select "0 -- NEXT --" → "6 SYSTEM" → "DCS", and press the [Enter] key to display DCS top menu.
3 Select "Cart. position check" and press the [Enter] key to display Cartesian Position Check list menu.
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Number
Item
Setting
Description
displayed No.
Mate)
9
X Point 1 Point 2
Values for the
diagonal of a box
Defines the coordinates of the two ends of the
10
Y Point 1 Point 2
down and the robot stops.
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4 Select any "No." and press the [Enter] key to display Cartesian Position Check menu.
5 Perform the following settings in Cartesian Position Check menu.
2 Enable/Disable "ENABLE" Enable Cartesian Position Check function of the
3 Method "Working zone
(Diagonal)" ("Diagonal IN" In R-30iB, R-30iB
coordinates of the
11 Z Point 1 Point 2
12 Stop type "Stop Category 0" Configure so that if a robot goes beyond the
two ends of the
Define the robot workspace to be the inside of a box using the Cartesian Position Check function. The setting "Working zone(Diagonal)" defines the coordinates of the two ends of the diagonal of a box.
diagonal of the box for which "Diagonal (IN)" is the robot workspace.
workspace, robot motor power immediately shuts
See Subsection 7.4.5 for detailed information about " DCS Cartesian Position Check List Menu ".
6 Press the [PREV] key two times to display DCS top menu.
Setup of a robot workspace is now complete. If a robot arm goes beyond a specified workspace, DCS
Cartesian Position Check function limits the robot.
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WARNING
mechanical brake.
NOTE
Go to "3.4 SETUP OF USER MODEL."
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3.3 ROBOT STOP POSITION PREDICTION

If only the workspace is set using Cartesian Position Check, the robot stops after it goes beyond the workspace. When the motor power is shut down, the robot’s momentum causes it to move some distance
before it completely stops. The actual "Robot Stop Position" will be beyond the workspace.
To stop the robot within the robot workspace, use the DCS Stop Position Prediction function. The setup procedure for the Stop Position Prediction function is as follows. See Subsection 7.4.3 for detailed
information.
1 If Stop Position Prediction is set up incorrectly, the robot will leave the safety
zone, and serious personal injury could result. When Stop Position Prediction is changed, the values must be verified and the function must be tested again.
2 If an axis does not have a mechanical brake, the axis can move freely when the
motor power is shut down, and Stop Position Prediction does not work correctly for the axis. In this case, a risk assessment for the whole robot system is necessary, including the free movement of the axis that does not have a
If a robot does not need to stop inside a robot restriction zone, the settings in this
section are not required.
1. Select "Stop position prediction" in DCS top menu and press the [Enter] key to display Stop Position
Prediction Menu.
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Number
Item
Setting
Description
"speed."
Z
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2. Perform the following settings in the Stop Position Prediction Menu.
1 Mode "DEFAULT" Configure using the setting type for the Stop Position
Prediction function, so that default values according to robot type are automatically set to "stop distance" and
See Subsection 7.11.1 for detailed information about "DCS Stop Position Prediction Menu".
Setup of the Stop Position Prediction function is now complete. The robot will stop within the robot workspace when servo power is shut down.

3.4 SETUP OF USER MODEL

Since DCS function check is not set for hands, etc. attached to the robot, they are not subject to checking by the DCS function.
To limit the workspace of hands, etc. attached to the robot like the ones shown in the following picture,
user models must be set. The setup procedure for a user model is as follows. See Subsection 7.4.1 for detailed information about "Shape Model".
X
Flange frame
Point 1
(-120.0, 0.0, 250.0)
Y
Radius 280mm
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1 Select "User Model" in DCS top menu and press the [Enter] key to display User Model List Menu.
2 Select any "No." and press the [Enter] key to display User Model Detail (Element List) Menu.
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Number
Item
Setting
Description
1
Enable/Disable
"ENABLE"
Enable the user model elements of the displayed No.
2
Link Number
"99"
Configure to mount the user model element on a flange.
flange frame.
5
Shape
"Point"
Configure so that the shape of a user model element is a sphere.
280 mm.
7
Pos1 X Y Z
X: "-120.000"
Configure the center point of the sphere of a user
Point 2 is not used.
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3 Select any "No." and press the [Enter] key to display User Model Element Detail Menu.
4 Perform the following settings in the User Model Element Detail Menu.
4 Tool frame "0" Configure so that the base frame of the element is the
6 Size (mm) "280.0" Configure so that the radius of a user model element is
Y: "0.000" Z: "250.000"
model element to be the base frame of the flange frame.
See Subsection 7.4.11 for detailed information about "DCS User Model Detail (Point/Line-Seg) Menu".
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3. LIMITING A ROBOT WORKSPACE B-83184EN/13
Next, to enable the specified user models, set the number of the user model to be the target model for
Cartesian Position Check.
5 Press the [Prev] key 3 times to display DCS top menu.
6 Select "Cart. position check" and press the [Enter] key to display Cartesian Position Check list menu.
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Number
Item
Setting
Description
Menu in step 4.
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7 Select the number selected in step 4 of "3.2 LIMITING A ROBOT WORKSPACE BY CARTESIAN
POSITION CHECK" and press the [Enter] key to display Cartesian Position Check Menu.
8 Perform the following settings in Cartesian Position Check menu.
6 Target model 2. "No." selected in the
User Model List
Set the specified user models to be the target for Cartesian Position Check.
Setup of a user model is now complete. Perform the applying operation after user model setup is complete. Please refer to "1.3 APPLY TO DCS PARAMETER".

3.5 4D GRAPHICS DCS DISPLAY

In the 4D Graphics DCS Display Menu, you can check robot shapes and robot workspaces specified in DCS functions using a three-dimensional display. The procedure to display 4D graphic DCS is as follows. See Subsection 8.2 for detailed information about "4D Graphics DCS DISPLAY".
1 Press the [MENU] key on Teach Pendant to display MENU pop up screen. 2 Select "0 -- NEXT --" → "6 SYSTEM" → "DCS", and press the [Enter] key to display DCS top menu. 3 Press the [F8] key or press the [FCTN] key while pressing the [i] key to display related menu. 4 Select "4D DCS Display" to display 4D graphic DCS Display Menu.
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Display
Key input
Touch panel operation
Enlarge the display
Press the [↑] (enlarge) key.
Touch the upper half of the screen.
Reduce the display
Press the [↓] (reduce) key.
Touch the lower half of the screen.
Display
Key input
Touch panel operation
Pan the display
Press the [↑] / [↓] / [←] / [→] key.
Touch the screen and drag your finger up, down, left or right.
Display
Key input
Touch panel operation
or right.
CAUTION
Display" Menu.
Robot model
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Workspace
User model
5 Operate the display.
There are two ways to operate the display. One is key input and the other is touch panel operation.
Enlarge / Reduce
Press [F3 [ZOOM]] and perform the following operations.
Pan operation
Press [F4 [PAN]] and perform the following operation.
Rotation
Press the [F5 [ROTATE] ]and perform the following operation.
Rotate the display Press the [↑] / [↓] / [←] / [→] key. Touch the screen and drag it up, down, left
Please refer to "4D Graphic Function" in "Optional Function OPERATOR'S
MANUAL" (B-83284EN-2) for detailed operation of the "4D Graphics DCS
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CAUTION
the alarm occurs again and the robot stops.
CAUTION
alarm occurs, the alarm occurs again and the robot stops.
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3.6 RECOVERY FROM ALARM

When a robot moves out of its robot workspace, "SRVO-402 DCS Cart. pos. limit (%d,%s:G%d,M%d) %02x" alarm occurs and the robot stops.
Cartesian Position Check number, Comment (If comment was input), Group number, and User Model number (0: robot model) are displayed in order from the left in the alarm.
If the Stop Position Prediction function is enabled, the stop position of the robot will be within the robot workspace, and the alarm can be cleared.
The alarm cannot be cleared when the robot is outside the robot workspace. The procedure to recover from an alarm is as follows:
1 Set mode switch to [T1] to enable teach pendant. 2 Press the [SHIFT] + [RESET] key to clear the alarm.
Keep pressing the [SHIFT] key until the robot has returned to the robot
workspace. If the [SHIFT] key is released while the robot is still outside the robot workspace,
3 Press and hold the [SHIFT] key and jog the robot to move the robot to the robot workspace.
As the robot workspace is set in Cartesian Position Check, the position and
orientation of the flange just before the alarm occurs are recorded. The robot can be jogged toward the position and orientation just before where the alarm occurs. If the robot is jogged away from the position and orientation where the
In the following cases, robots cannot be recovered from alarm with procedure above, since the data for the frame position and orientation just before the alarm occurs are lost. Disable the Cartesian Position Check function settings, recover from the alarm, then enable the settings again.
- The motor or Pulse coder is replaced, and the robot position exits the robot workspace.
- The Zone or shape model is changed and applied to DCS parameters, power to the controller is cycled,
and the current position exits the robot workspace.
- The controller power is turned off while the robot is moving, and the robot exits the robot workspace
by momentum movement.
- The mastering parameters or robot setup data are changed and applied to DCS parameters, power to
the controller is cycled, and the robot exits the robot workspace. See Subsection 7.4.2.5 for detailed information about "Recovery from alarm".
Operation of recovery from alarm is now complete.
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Type
Item
Description
attached by users, such as hands.
Setup of safety signal connections
Safety I/O checks if there is an operator is on a safe mat. Connect a safe mat to the safety signals.
Setup of Cartesian Position Check
Set the Cartesian Position Check zone.
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4. SWITCHING THE WORKSPACE B-83184EN/13

4 SWITCHING THE WORKSPACE

4.1 OVERVIEW

This chapter describes the method for enabling and disabling the robot workspace using safety I/O. For an arc welding robot system as shown below, set the robot to weld a workpiece which is not being worked on by the operator when the operator is on a safe mat. When the robot approaches the workpiece which is being worked on by the operator, the robot stops, ensuring the safety of the operator. Safety I/Os are safe signals that can be used in DCS. For example, to switch the zone of the Zone Check Function, the safety input is set to a disabling input for the Zone Check Function. Please refer to "7.4.2.2 Enable and disable zones by disabling input".
In this chapter, a safe zone that is not a box shape will be set (a maximum of 8 vertexes from P1 to P8, and upper / lower limits). The Zone Check Function checks if the shape model is within the safe zone.
Setup of user model → 4.2
Setup of Cartesian Position Check → 4.4
This chapter describes the setup procedure to change a robot workspace.
Settings Setup of user model Set user models to limit the motion range of equipment
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WARNING
values must be verified and the function must be tested again.
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4.2 SETUP OF USER MODEL

The setup procedure for the user model for an arc welding torch is as follows. The user model of the torch is set using two "Line_seg" shape elements. Please refer to "7.4.1 Shape Model".
If a robot workspace is set up incorrectly, the safety function will not work, and
serious personal injury could result. When a robot workspace is changed, the
1 Press the [MENU] key on Teach Pendant to display MENU pop up screen. 2 Select "0 -- NEXT --" → "6 SYSTEM" → "DCS", and press the [Enter] key to display DCS top menu.
3 Select "User model" and press the [Enter] key to display User Model List Menu.
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No.
Item
Setting
Description
1
Enable/Disable
"ENABLE"
Enable the user model elements of the displayed No.
segment.
6
Size (mm)
"60.0"
Configure so that the radius of a user model element is 60 mm.
Z: "0.000"
8
Pos2 X Y Z
X: "0.000"
Z: "280.000"
Specify the position of the other end on the center line of a
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4 Select any "No." and press the [Enter] key to display User Model Detail (Element List) Menu.
5 Select any "No." and press the [Enter] key to display User Model Element Detail Menu.
5 Shape "Line_seg" Configure so that the shape of a user model element is line
7 Pos1 X Y Z X: "0.000"
Y: "0.000"
Y: "0.000"
Please refer to "7.4.11 DCS User Model Detail (Point/Line-Seg) Menu".
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Set the position of one end on the center line of a user model element.
user model element.
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No.
Item
Setting
Description
1
Enable/Disable
"ENABLE"
Enable the user model elements of the displayed No.
5
Shape
"Line_seg"
Configure so that the shape of a user model element is line segment.
mm.
7
Pos1 X Y Z
X: "0.000"
Z: "280.000"
Specify the position of one end on the center line of a user
Z: "400.000"
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6 Press the [Prev] key to return to "User Model Detail (Element List) Menu", select another shape
element ("No.2" in the example), and perform the following settings.
6 Size (mm) "50.0" Configure so that the radius of a user model element is 50
Y: "0.000"
8 Pos2 X Y Z X: "-90.000"
Y: "0.000"
model element.
Specify the position of the other end on the center line of a user model element.
7 Press the [Prev] key 3 times to display DCS top menu.
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CAUTION
connection .
Z direction 280 mm
Position (0, 0,280)
Z direction 400 mm
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DCS check can now be added to a welding torch.
X
Y
Z
X direction -90 mm
Flange frame

4.3 CHECKING IF THERE IS AN OPERATOR ON A SAFE MAT

As a precondition, two safe mats are connected to the emergency stop board as redundant contacts. The left safe mat is connected to SFDI11 and SFDI21, and the state can be referenced by Safety I/O SPI [1]. The right safe mat is connected to SFDI12 and SFDI22, and the state can be referenced by Safety I/O SPI [2]. When there is no operator on a safe mat, both redundant signals (SFDI11 and SFDI21 in case of the left safe mat) are closed and Safety I/O (SFDI [1]) is ON. If either of the redundant signals is open, Safety I/O (SFDI [1]) is turned OFF.
Please refer to "9.2 SAFE I/O CONNECT FUNCTION".
Refer to "Safety signal connection" in this manual for details on safety signal
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Type
Setting
No.1
A zone that surrounds the whole workspace of the robot. Always active. Disabling input is not set.
No.2
A zone that is enabled when an operator is on the left safe mat. If this zone is enabled, the robot
SPI [1], which shows the status of the left safe mat, is set to the disabling input.
SPI [2], which shows the status of the right safe mat, is set to the disabling input.
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4.4 SETUP OF CARTESIAN POSITION CHECK

In Cartesian Position Check setup, three zones, from No. 1 to No. 3, are set up.
cannot move to the left side.
No.3 A zone that is enabled when an operator is on the right safe mat. If this zone is enabled, the
robot cannot move to the right side.
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4.4.1 Setup of No.1 Zone

This section describes the setup method for No.1 zone. No.1 zone is always active, so disabling input is not set. An alarm occurs if the robot exits the zone when there is no operator on a safe mat.
P3
P2
P4
P1
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1 Select "Cart. position check" in DCS screen and press the [Enter] key to display Cartesian Position
Check menu.
2 Select any "No." and press the [Enter] key to display Cartesian Position Check detail menu.
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No.
Item
Setting
Description
1
Enable/Disable
"ENABLE"
Enable Cartesian Position Check for the displayed No.
3
Method
"Working zone (Lines)"
The Working zone is defined to be inside the vertexes of a polygon in the X-Y plane in "Lines."
OF USER MODEL"
9
Number of
"4"
Set the number of vertexes for the polygon in the X-Y
vertexes P1 to P4.
Y: "-1800.0"
11
P2
X: "1500.0" Y: "1800.0"
Specify the X-Y coordinates of vertex P2. Y: "1800.0"
13
P4
X: "-1500.0" Y: "-1800.0"
Specify the X-Y coordinates of vertex P4.
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3 Perform the following settings in Cartesian Position Check detail menu.
6 Target model 2 The "No." of the user
model set in "4.2 SETUP
vertexes
10 P1 X: "1500.0"
12 P3 X: "-1500.0"
Specify the set user model to be the target for Cartesian Position Check.
plane. Here, we specify it to be "4", the number of
Specify the X-Y coordinates of vertex P1.
Specify the X-Y coordinates of vertex P3.
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No.
Item
Setting
Description
14
P5
X: "0.0"
Specify the X-Y coordinates of vertex P5.
both X and Y.
both X and Y.
16
P7
X: "0.0"
Specify the X-Y coordinates of vertex P7.
both X and Y.
both X and Y.
18 Z Z1:”-500.0”
Z2:”2000.0”
Specify the Z coordinates of upper and lower limit. motor power.
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Y: "0.0"
15 P6 X: "0.0"
Y: "0.0"
Y: "0.0"
17 P8 X: "0.0"
Y: "0.0"
19 Stop type "Stop Category 0" Specify "Stop Category 0", to immediately shut down the
As vertex P5 is not used for No.1, "0.0" is specified for
Specify the X-Y coordinates of vertex P6. As vertex P6 is not used for No.1, "0.0" is specified for
As vertex P7 is not used for No.1, "0.0" is specified for
Specify the X-Y coordinates of vertex P8. As vertex P8 is not used for No.1, "0.0" is specified for
Please refer to "7.4.8 DCS Cartesian Position Check (Lines) Menu".
4 Press the [Prev] key 3 times to display DCS top menu.
Setup of No.1 zone is now complete.
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enabled.
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4.4.2 Setup of No.2 Zone

This section describes the setup method for No.2 zone. SPI [1], which shows the status of the left safe mat, is set to the disabling input. When there is no operator on the left safe mat, SPI [1] is ON and this zone is disabled. When there is no operator on the left safe mat, this zone is enabled. When the robot is about to exit this zone, it stops.
P4
P5
When an operator is on the left safe mat, this zone is
P3
P1
P2
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1 Select "Cart. position check" in DCS screen and press the [Enter] key to display Cartesian Position
Check menu.
2 Select any "No." and press the [Enter] key to display Cartesian Position Check detail menu.
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No.
Item
Setting
Description
1
Enable/Disable
"ENABLE"
Enable Cartesian Position Check for the displayed No.
(Safe side)
a polygon in the X-Y plane in "Lines."
OF USER MODEL"
9
Number of
"5"
Set the number of vertexes for the polygon in the X-Y
vertexes P1 to P5.
Y: "500.0"
11
P2
X: "1500.0" Y: "1800.0"
Specify the X-Y coordinates of vertex P2. Y: "1800.0"
Y: "-750.0"
Y: "-750.0"
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3 Perform the following settings in Cartesian Position Check detail menu.
3 Method
6 Target model 2 The "No." of the user
vertexes
10 P1 X: "1500.0"
12 P3 X: "-1500.0"
13 P4 X: "-1500.0"
14 P5 X: "500.0"
"Lines (IN) " The Working zone is defined to be inside the vertexes of
model set in "4.2 SETUP
Specify the set user model to be the target for Cartesian Position Check.
plane. Here, we specify it to be "5", the number of
Specify the X-Y coordinates of vertex P1.
Specify the X-Y coordinates of vertex P3.
Specify the X-Y coordinates of vertex P4.
Specify the X-Y coordinates of vertex P5.
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No.
Item
Setting
Description
15
P6
X: "0.0"
Specify the X-Y coordinates of vertex P6.
both X and Y.
both X and Y.
17
P8
X: "0.0"
Specify the X-Y coordinates of vertex P8.
both X and Y.
Z2: “2000.0”
19
Stop type
"Stop Category 0"
Specify "Stop Category 0", to immediately shut down the motor power.
disabled.
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Y: "0.0"
16 P7 X: "0.0"
Y: "0.0"
Y: "0.0"
18 Z Z1: ”-500.0”
21 disabling input "SPI[1]" Specify the Safety I/O that indicates the state of the left
As vertex P6 is not used for No.2, "0.0" is specified for
Specify the X-Y coordinates of vertex P7. As vertex P7 is not used for No.2, "0.0" is specified for
As vertex P8 is not used for No.2, "0.0" is specified for
Specify the Z coordinates of upper and lower limit.
safe mat. If the specified Safety I/O is ON, this zone is
4 Press the [Prev] key 3 times to display DCS top menu.
Setup of No.2 zone is now complete.
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When an operator is on
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4.4.3 Setup of No.3 Zone

This section describes the setup method for No.3 zone. SPI [2], which shows the status of the right safe mat, is set to the disabling input. When an operator is not on the right safe mat, SPI [2] is turned ON and this zone is disabled. When an operator is on the right safe mat, this zone is enabled. When the robot is about to exit this zone, it stops.
P3
P4
P2
P1
P5
the right safe mat, this zone is enabled.
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1 Select "Cart. position check" in DCS screen and press the [Enter] key to display Cartesian Position
Check menu.
2 Select any "No." and press the [Enter] key to display Cartesian Position Check detail menu.
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No.
Item
Setting
Description
1
Enable/Disable
"ENABLE"
Enable Cartesian Position Check for the displayed No.
zone(Lines )"
polygon in the X-Y plane in "Lines.".
6
Target model 2
The "No." of the
USER MODEL"
Specify the set user model to be the target for Cartesian
vertexes
Here, we specify it to be "5", the number of vertexes P1 to P5.
10
P1
X: "1500.0" Y: "-500.0"
Specify the X-Y coordinates of vertex P1. Y: "-1800.0"
12
P3
X: "-1500.0" Y: "-1800.0"
Specify the X-Y coordinates of vertex P3. Y: "750.0"
14
P5
X: "500.0" Y: "750.0"
Specify the X-Y coordinates of vertex P5.
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3 Perform the following settings in Cartesian Position Check detail menu.
3 Method "Working
user model set in "4.2 SETUP OF
9 Number of
11 P2 X: "1500.0"
13 P4 X: "-1500.0"
"5" Set the number of vertexes for the polygon in the X-Y plane.
The Working zone is defined to be inside the vertexes of a
Position Check.
Specify the X-Y coordinates of vertex P2.
Specify the X-Y coordinates of vertex P4.
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No.
Item
Setting
Description
15
P6
X: "0.0"
Specify the X-Y coordinates of vertex P6.
and Y.
and Y.
17
P8
X: "0.0"
Specify the X-Y coordinates of vertex P8.
and Y.
Z2: “2000.0”
20
Stop type
"Power-Off stop"
Specify [Power-off stop], to immediately shut down the motor power.
If the specified Safety I/O is ON, this zone is disabled.
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Y: "0.0"
16 P7 X: "0.0"
Y: "0.0"
Y: "0.0"
18 Z Z1: ”-500.0”
21 disabling input "SPI[2]" Set the Safety I/O that indicates the state of the right safe mat.
As vertex P6 is not used for No.3, "0.0" is specified for both X
Specify the X-Y coordinates of vertex P7. As vertex P7 is not used for No. 3, "0.0" is specified for both X
As vertex P8 is not used for No. 3, "0.0" is specified for both X
Specify the Z coordinates of upper and lower limit.
4 Press the [Prev] key 3 times to display DCS top menu.
Setup of No.3 zone is now complete. Perform an apply operation after setup for zones No.1 to No.3 is complete. Please refer to "1.3 APPLY TO DCS PARAMETER".
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5. CHECKING IF AUXILIARY AXES ARE STATIONARY B-83184EN/13

5 CHECKING IF AUXILIARY AXES ARE
STATIONARY

5.1 OVERVIEW

This chapter describes the system that checks if auxiliary axes are stationary. In the case of the arc welding robot shown in the picture below, an operator steps onto the safe mat and replaces Workpiece 2. The robot welds Workpiece 1 while the operator is replacing the workpiece. The robot performs the welding in coordination with auxiliary axis 2. When the operator finishes replacing the workpiece and leaves the safe mat, and the robot finishes welding Workpiece 1, auxiliary axis 1 rotates 180 degrees and Workpiece 1 and Workpiece 2 switch places. After that, the robot welds Workpiece 2 in coordination with auxiliary axis 3, and the operator replaces Workpiece 1. When an operator is on the safe mat, the system checks if auxiliary axis 1 and the auxiliary axis on the side of the safe mat (2 or 3) are stationary. If an auxiliary axis moves while the system is checking for stop, an alarm occurs and the robot and all auxiliary axes stop.
See Subsection 7.2 for detailed information about " 7.2 Joint Position Check function.
Workpiece 1
Auxiliary axis 2
Auxiliary axis 1
Workpiece 2
Auxiliary axis 3
Safe mat
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Type
Item
Description
Setup of stop check for auxiliary axis 1
Set the input signal from a safe mat to be disabling input.
2 and 3 are able to move (stop check is disabled).
2 and 3
Check (JPC) to be disabling input.
Setup of robot workspace
Set up the robot workspace.
WARNING
values must be verified and the function must be tested again.
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In this chapter, the following settings are performed.
Settings
Zone setup for auxiliary axis 1 Set the positions of auxiliary axis 1 where both auxiliary axes
Setup of stop check for auxiliary axes
Set the signal that represents the status of Joint Position

5.2 SETUP STOP CHECK FOR AUXILIARY AXIS 1

Specify the following settings in the Joint Speed Check function of the DCS function, to monitor to ensure that auxiliary axis 1 does not rotate when an operator is on a safe mat (plate).
If a robot workspace is set up incorrectly, the safety function will not work, and
serious personal injury could result. When a robot workspace is changed, the
1 Press the [MENU] key on Teach Pendant to display MENU pop up screen. 2 Select "0 -- NEXT --" → "6 SYSTEM" → "DCS", and press the [Enter] key to display DCS top menu.
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3 Select "Joint speed check" and press the [Enter] key to display Joint Speed Check menu.
4 Select any "No." and press the [Enter] key to display Joint Speed Check detail menu.
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No.
Item
Setting
Description
2
Enable/Disable
"ENABLE"
Enable the displayed No.
4
Group
"2"
Select auxiliary axis 1's group.
5
Axis
"1"
Select the axis for which auxiliary axis 1 is set.
limit is set to "0."
Category 0"
check is enabled.
12
Permissible
"0.2"
Set the permissible movement distance for when checking if the
system through risk assessment.
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5 Perform the following settings in Joint Speed Check menu.
6 Limit "0" This function can be used as a stop check function when the speed
7 Stop type "Stop
11 disabling input "SPI[1]" To enable / disable the Joint Position Check dynamically, a Safety
distance
Select "Stop Category 0" to instantly shut off power.
I/O can be set as a disabling input. When the specified Safety I/O is ON, this function disabled. When the specified Safety I/O is OFF, this function is enabled. Here, the condition is connecting so that input signals from safe mats are sent to SPI[1]. When an operator is on a safe mat, SPI[1] is turned OFF and stop
axis is stationary. Set 0.2 deg for the permissible distance here, to permit subtle movements when the servo is ON. An alarm does not occur if the movement is less than the permissible distance, even when the function is checking if the axis is stationary. Decide a suitable permissible distance value for your
Please refer to "7.2.3 DCS Joint Position Check Detail Menu".
6 Press the [Prev] key 2 times to display DCS top menu.
After these steps, the DCS Joint Speed Check function is enabled when an operator is on a safe mat, and emergency stop occurs when auxiliary axis 1 moves.
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WARNING
values must be verified and the function must be tested again.
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5.3 SETUP OF POSITION CHECK FOR AUXILIARY AXIS 1

Set the position of auxiliary axis 1 where both the auxiliary axes 2 and 3 are able to move (stop check is disabled) to Joint Position Check No. 1 and No. 2, respectively.
If a robot workspace is set up incorrectly, the safety function will not work, and
serious personal injury could result. When a robot workspace is changed, the
1 Select "Joint position check" in DCS screen and press the [Enter] key to display Joint Position Check
list menu.
2 Select "No. 1" and press the [Enter] key to display Joint Position Check detail menu.
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No.
Item
Setting
Description
2
Enable/Disable
"ENABLE"
Enable the displayed No.
3
Group
"2"
Select auxiliary axis 1's group.
4
Axis
"1"
Select the axis for which auxiliary axis 1 is set.
axis 2 becomes available within this range of values.
2 becomes available within this range of values.
enable / disable stop check for auxiliary axis 2.
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3 Perform the following settings in Joint Position Check detail menu.
6 Upper limit "5" Set the upper limit of auxiliary axis 1. Motion of auxiliary
7 Lower limit "-5" Set the lower limit of auxiliary axis 1. Motion of auxiliary axis
8 Stop type "Not stop" By selecting "Not stop", an alarm does not occur even when
auxiliary axis 1 exits this motion range. As Safety I/O JPC[1] is ON when the axis is in this zone, this signal is used to
With this setting, the zone of auxiliary axis 1 where auxiliary axis 2 is able to move is set to Joint Position Check No. 1. Next, set the zone of auxiliary axis 1 where auxiliary axis 3 is able to move to Joint Position Check No. 2.
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4 Press the [Prev] key to display Joint Position Check list menu.
5 Select "No. 2" and press the [Enter] key to display Joint Position Check detail menu.
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No.
Item
Setting
Description
2
Enable/Disable
"ENABLE"
Enable the displayed No.
3
Group
"2"
Select auxiliary axis 1's group.
4
Axis
"1"
Select the axis for which auxiliary axis 1 is set.
6
Upper limit
"185"
Set the upper limit of auxiliary axis 1. Motion of auxiliary axis 3 becomes available within this range of values.
3 becomes available within this range of values.
8
Stop type
"Not stop"
By selecting "Not stop", an alarm does not occur even when
enable / disable stop check for auxiliary axis 2.
WARNING
values must be verified and the function must be tested again.
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6 Perform the following settings in Joint Position Check detail menu.
7 Lower limit "175" Set the lower limit of auxiliary axis 1. Motion of auxiliary axis
auxiliary axis 1 exits this motion range. As Safety I/O JPC[1] is ON when the axis is in this zone, this signal is used to
7 Press the [Prev] key 2 times to display DCS top menu.

5.4 SETUP OF STOP CHECK FOR AUXILIARY AXES 2 AND 3

Set up stop check for auxiliary axes 2 and 3. Set auxiliary axis 2 (Group 3, Axis 1) to Joint Speed Check No. 2. Set the speed limit to 0 and check if the axis is stationary. Set JPC[1], which indicates the state of Joint Position Check No. 1, as disabling input. Set the permissible distance to 0.2 deg. Next, set auxiliary axis 3 (Group 4, Axis 1) to Joint Speed Check No. 3. Set the speed limit to 0 and check if the axis is stationary. Set JPC[2], which indicates the state of Joint Position Check No. 2, as disabling input. Set the permissible distance to 0.2 deg. The workpiece can be rotated only when it is in front of the robot. Whether or not the workpiece is in front of the robot is determined by the position of auxiliary axis 1. The position check of auxiliary axis 1 is already set in No. 1 and 2 of Joint Position Check. Using the result, the stop check for auxiliary axis 2 and 3 is enabled / disabled.
If a robot workspace is set up incorrectly, the safety function will not work, and
serious personal injury could result. When a robot workspace is changed, the
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1 Select "Joint speed check" in DCS screen and press the [Enter] key to display Joint Speed Check list
menu.
2 Select "No. 2" and press the [Enter] key to display Joint Speed Check detail menu.
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No.
Item
Setting
Description
2
Enable/Disable
"ENABLE"
Enable the displayed No.
4
Group
"3"
Select auxiliary axis 2's group.
5
Axis
"1"
Select the axis for which auxiliary axis 2 is set.
6
Limit
"0"
This function can be used as a stop check function when the speed limit is set to 0.
power.
11
disabling input
"JPC[1] "
The result of Joint Position Check No. 1 is reflected in this
when the stop check for auxiliary axis 2 is disabled.
value for your system through risk assessment.
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3 Perform the following settings in Joint Speed Check detail menu.
7 Stop type "Stop Category 0" Select "Stop Category 0" to immediately shut down the
signal. JPC[1] is ON when auxiliary axis 1 is between -5 deg and 5 deg, and motion of auxiliary axis 2 becomes available
12 Permissible
distance
"0.2" Set the permissible movement distance for when checking if
the axis is stationary. Set 0.2 deg for the permissible distance here, to permit subtle movements when the servo is ON. An alarm does not occur if the movement is less than the permissible distance, even when the function is checking if the axis is stationary. Decide a suitable permissible distance
Next, set up stop check of axis 2 in Joint Speed Check No. 3. Set up Group 4, Axis 1. Set JPC[2] as disabling input. Other items are the same as for No. 2.
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4 Press the [Prev] key to display Joint Speed Check list menu.
5 Select "No. 3" and press the [Enter] key to display Joint Speed Check detail menu.
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No.
Item
Setting
Description
2
Enable/Disable
"ENABLE"
Enable the displayed No.
4
Group
"4"
Select auxiliary axis 3's group.
5
Axis
"1"
Select the axis for which auxiliary axis 3 is set.
the speed limit is set to 0.
power.
disabled.
12
Permissible
"0.2"
Set the permissible movement distance for when checking if
value for your system through risk assessment.
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6 Perform the following settings in Joint Speed Check detail menu.
6 Limit "0" This function can be used as a stop check function when
7 Stop type "Stop Category 0" Select "Stop Category 0" to immediately shut down the
11 disabling input "JPC[2] " The result of Joint Position Check No. 2 is reflected to this
signal. JPC[1] is ON when auxiliary axis 1 is between 175 deg to 185 deg, and motion of auxiliary axis 3 becomes available when the stop check for auxiliary axis 3 is
distance
the axis is stationary. Set 0.2 deg for the permissible distance here, to permit subtle movements when the servo is ON. An alarm does not occur if the movement is less than the permissible distance, even when the function is checking if the axis is stationary. Decide a suitable permissible distance
7 Press the [Prev] key 2 times to display DCS top menu.
The above setting will prevent the workpiece on the side of a safe mat from rotating when an operator is on the safe mat.
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WARNING
values must be verified and the function must be tested again.
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5.5 LIMITING THE MOTION RANGE OF A TURNTABLE

If the motion range of an axis is +-720 or similar degrees, the unsafe side may come to the front even outside the set range. Configure settings to limit the motion range for such cases.
If a robot workspace is set up incorrectly, the safety function will not work, and
serious personal injury could result. When a robot workspace is changed, the
1 Select "Joint position check" in DCS screen and press the [Enter] key to display Joint Speed Check
list menu.
2 Select any "No." and press the [Enter] key to display Joint Position Check detail menu.
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No.
Item
Setting
Description
2
Enable/Disable
"ENABLE"
Enable the displayed No.
3
Group
"2"
Select auxiliary axis 1's group.
4
Axis
"1"
Select the axis for which auxiliary axis 1 is set.
6
Upper limit
"180"
Set the upper limit of auxiliary axis 1.
7
Lower limit
"-180"
Set the lower limit of auxiliary axis 1.
power.
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3 Perform the following settings in Joint Position Check detail menu.
8 Stop type "Stop Category 0" Select "Stop Category 0" to immediately shut down the
4 Press the [Prev] key 2 times to display DCS top menu.
The above settings will allow limiting the motion range of the turntable.
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5.6 SETTING UP THE ROBOT WORKSPACE

Set up Cartesian Position Check and limit the robot workspace, so that the robot does not enter a safe mat side. Set a welding torch model to user model No. 1. Refer to "4. SWITCHING THE WORKSPACE" for details on the setup method.
Point 2
Point 1
Set up Cartesian Position Check as follows.
1 Select "Cart. position check" in DCS screen and press the [Enter] key to display Cartesian Position
Check list menu.
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2 Select any "No." and press the [Enter] key to display Cartesian Position Check detail menu.
3 Perform the following settings in Cartesian Position Check detail menu.
Enter the user model No. of welding torch, for "Target model 2."
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No.
Item
Setting
Description
2
Enable/Disable
"ENABLE"
Enable the displayed No.
Mate)
9
X Point 1 Point 2
Values for the
diagonal of a box
Defines the coordinates of the two ends of the diagonal of
10
Y Point 1 Point 2
11
Z Point 1 Point 2 stops.
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3 Method "Working
zone(Diagonal )" ("Diagonal (IN)" in R-30iB, R-30iB
coordinates of the two ends of the
12 Stop type "Stop Category 0" Configure so that if a robot goes beyond the workspace,
Define the robot workspace to be the inside of a box using the Cartesian Position Check function. The setting "Working zone (Diagonal)" defines the coordinates of the two ends of the diagonal of a box.
the box for which "Working zone (Diagonal)" is the robot workspace.
robot motor power immediately shuts down and the robot
Perform an applying operation once the settings up to here are complete. Please refer to "1.3 APPLY TO DCS PARAMETER".
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Type
Item
Description
Settings
Setup of tool model
Set the user model in each the case of tool
Setup of Cartesian Position Check
Set the Cartesian Position Check zone
Setup of Cartesian Position Speed Check
Set the stop zone
Setup of Cartesian Position Speed Check
Set the slowdown zone
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6 SET A SLOWDOWN ZONE

6.1 OVERVIEW

This chapter describes the method to set a slowdown zone. In a Handling robot system as shown below, the robot take a work of this side to a back stand. A danger area is increased by gripping works. For that reason, the robot must set user models in each the case of tool. And only if an operator is in collaborate zone, the robot slowdown to ensure safety of an operator. If the robot exits the working zone where a speed check function enable at a high speed, the robot stops, and work efficiency becomes worse. When Speed Check function becomes to enable, delay that turn enable at time before slowing down. See Subsection 7.4.4 for detailed information about “DCS Cartesian Position Speed Check Function”. This setting is not used in R-30iB, R-30iB Mate.
Setup of CPC → 6.3.1
Setup of CPC → 6.3.2
Setup of CPSC 6.3.3
Setup of tool model → 6.2
This chapter describes the setup procedure to change a robot workspace.
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values must be verified and the function must be tested again.
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6.2 SETUP OF TOOL MODEL

This section describes method that set the user models in each tool states. There are two states that work exists or not. The user model of the tool is set using "box" shape elements.
If a robot workspace is set up incorrectly, the safety function will not work, and
serious personal injury could result. When a robot workspace is changed, the
1 Press the [MENU] key on Teach Pendant to display MENU pop up screen. 2 Select "0 -- NEXT --" → "6 SYSTEM" → "DCS", and press the [Enter] key to display DCS top menu.
3 Select "User model" and press the [Enter] key to display User Model List Menu.
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4 Select any "No." and press the [Enter] key to display User Model Detail (Element List) Menu.
5 Select any "No." and press the [Enter] key to display User Model Element Detail Menu.
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No.
Item
Setting
Description
1
Enable/Disable
"ENABLE"
Enable the user model elements of the displayed No.
segment.
6
Width (X) (mm)
X: "450.0"
Set the Width of the box element.
7
Height (Y) (mm)
Y: "420.0"
Set the Height of the box element.
8
Thick (Z) (mm)
Z: "800.0"
Set the Thick of the box element.
Z: “0.0”
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6 Press the item of "5 Shape" and select "Box". Perform following settings in User Element Detail (Box)
menu.
5 Shape "Box" Configure so that the shape of a user model element is line
9 Offset X: “-100.0”
Y: “90.0”
Set the position at the center of Width(X) and Height(Y) on the plane of Thick(Z)=0.
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No.
Item
Setting
Description
1
Enable/Disable
"ENABLE"
Enable the user model elements of the displayed No.
segment.
6
Width (X) (mm)
X: "750.0"
Set the Width of the box element.
7
Height (Y) (mm)
Y: "600.0"
Set the Height of the box element.
8
Thick (Z) (mm)
Z: "1400.0"
Set the Thick of the box element.
Z: “-200.0”
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7 Press the [Prev] key 2 times to display User model list. Select other item and perform following setting
in User Element Detail (Box) menu.
5 Shape "Box" Configure so that the shape of a user model element is line
9 Offset X: “-50.0”
Y: “100.0”
Set the position at the center of Width(X) and Height(Y) on the plane of Thick(Z)=0.
8 Press the [Prev] key 3 times to DCS top menu. Select Tool frame.
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Item
Setting
Description
Tool select
Set to Tool Change. Please refer to "7.9.1 Tool Change Function"
No.
Set "Tool frame" corresponding to the model.
Model
Set "User model" corresponding to the tool.
Verify I/O
SPI[1]」
Set safety I / O to be used as switching tool model.
No.
Set "Tool frame" corresponding to the model.
Model
Set "User model" corresponding to the tool.
Verify I/O
SPI[2]」
Set safety I / O to be used as switching tool model.
User model 1
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9 Perform following settings in DCS Tool frame menu
「-1」 「1」 「1」 「 「3」 「2」 「
DCS check can now be added to a tool and a work.
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Type
Setting
No.1
A zone that surrounds the whole workspace of the robot. Always active. Disabling input is not set.
entry in the zone, the robot immediately stops.
SPI [3], which shows the status of the safe mat, is set to the disabling input.
User model 2
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6.3 SETUP OF CARTESIAN POSITION CHECK

In Cartesian Position Check setup, set up 2 zones of No.1 - 3.
No.1
No.3
No.2
No.2 A zone that is enabled when an operator is on the safe mat. In this zone is enabled, if the robot
No.3 A zone that is enabled when an operator is on the safe mat. In this zone is enabled, if the robot
goes out of the zone, Speed Check Function become to enable.
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6.3.1 Setup of No.1 Zone

This section describes the setup method for No.1 zone. No.1 zone is always active, so disabling input is not set.
P2
P1
1 Select "Cart. position check" in DCS screen and press the [Enter] key to display Cartesian Position
Check menu.
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No.
Item
Setting
Description
1
Enable/Disable
"ENABLE"
Enable Cartesian Position Check for the displayed No.
Diagonal zone(Inside).)
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2 Select any "No." and press the [Enter] key to display Cartesian Position Check detail menu.
3 Perform the following settings in Cartesian Position Check detail menu.
3 Method
"Working zone (Diagonal)" (In R-30iB, R-30iB Mate,
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No.
Item
Setting
Description
5
Target model 1
"Robot model" ("-1" In R­30iB, R-30iB Mate)
Specify the set tool model to be the target for Cartesian Position Check.
30iB, R-30iB Mate)
Position Check.
9 X Point1: "-2000.0"
Point2: "3000.0"
Specify the X coordinates of vertex P1, P2. Point2: "6000.0"
11 Z Point1: "-500.0"
Point2: "2000.0"
Specify the upper and lower . motor power.
When an operator is on the safe mat, The Area of No2 becomes enable.
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6 Target model 2 “Tool change” ("-2" In R-
10 Y Point1: "-3200.0"
12 Stop type "Stop Category 0" Specify "Stop Category 0" to immediately shut down the
Specify the set tool model to be the target for Cartesian
Specify the Y coordinates of vertex P1, P2.
4 Press the [Prev] key 3 times to display DCS top menu.
Setup of No.1 zone is now complete.

6.3.2 Setup of No.2 Zone

This section describes the setup method for No.2 zone. This zone is defined to stop the robot for safe when there is an operator on the safe mat. SPI [3], which shows the status of the safe mat, is set to the disabling input. When there is no operator on the safe mat, SPI [3] is ON and this zone is disabled. When there is no operator on the safe mat, this zone is enabled. When the robot enters this zone, it stops.
P2
P1
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