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FANUC 30iA Dual Check

Safety Fault Recovery

Objectives After completing this lesson and associated exercise, you will:
 Review the FANUC Dual Check Safety Function.
 Learn techniques to avoid DCS Cartesian Position
Check violations.
 Understand DCS alarm codes and faults.
 Use available DCS displays to recover from
violations.

Dual Check Safety (DCS) Position/Speed Check features check the speed and
position data of motors with two independent CPU’s in the robot controller.
These functions can detect position and speed errors immediately and shut down
the motor power by two independent channels.
DCS functions are certified to meet the requirements of International Standard
(ISO) 13849-1.
DCS is a programmable safety system. Changing any parameter of a
programmable safety system needs to be performed and documented per Ford
Global Standard W-EL10.

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DCS FUNCTION COMPONENTS

E-Stop function

Turn off servo motor power according to the status of E-stop input.

Position/Speed Check function

- Joint Position Check function

- Joint Speed Check function
- Cartesian Position Check function
- Cartesian Speed Check function
- T1 Mode Speed check function

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.

Safe I/O Connect function

This function executes logic calculations for safe I/O. Users can control
Ethernet/IP safety outputs according to the status of Position/Speed Check
functions.

DCS Visualization

This function allows users to view a graphical representation of the DCS Model
and Position Check settings from within the DCS menus on the teach pendant.

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Avoiding DCS Cartesian Position Limit violations

Most DCS Cartesian Position limit faults (SRVO-402) occur when the robot
programmer/electrician is jogging the robot after a program has been aborted, or
has determined that jogging is the safest way to move the robot in a particular set
of circumstances.

DCS Cartesian Position boundaries are not obvious and can easily be violated
when jogging or changing the programmed path of the robot.

The easiest way to avoid Cartesian Position faults is to drive the robot through
existing programmed positions.

For example:

The cell is in automatic operation.

The robot is at the maintenance position running the maintenance program.

A problem occurs that drops automatic operation and requires the electrician to
move the robot back to the home position.

Enable the teach pendant and select T1 and STEP mode.

Cursor to the next programmed position that moves away from the maintenance
position and run that line using the FWD button and shift key on the teach
pendant. Repeat these steps for the next programmed position until the home
position is reached.

If a program is aborted, using the teach pendant you can select the aborted
program, cursor to the appropriate programmed position, i.e. drop or pick
positions, run that line using the FWD button while pressing and holding the
shift key on the teach pendant. Repeat these steps for the next programmed
position until you are clear of any DCS boundaries.

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Common DCS Alarm Codes

Listed are common DCS Alarm codes that are displayed on the teach pendant
display in the Status area or Alarm screens.

A full listing of DCS alarm codes can be found in the FANUC Dual Check
Safety Function Operators Manual.

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The SRVO-408 SERVO DCS SSO Ext Emergency Stop alarm is commonly
mistaken for a Cartesian Position limit alarm.

When you see this alarm there is an Emergency Stop condition! Correct the Estop
condition before proceeding.

Safety Chain Reset

Safety chain faults occur when the robot detects a problem with the circuitry
connected to the dual input safety signals (OPSFTY).
Safety Chain Fault Alarm Codes and Description for R-30iA
SRVO-378 SERVO OPSFTY11 status abnormal
SRVO-385 SERVO OPSFTY42 status abnormal
[Cause] A Chain alarm was detected with the OPSFTY signal.
[Remedy] Check whether the circuitry connected to the dual input signal (OPSFTY)
is faulty.
Check whether the timing of the dual input signal (OPSFTY) satisfies the timing
specification.
Replace the panel board.
NOTE: To recover from this alarm, follow the chain alarm reset operation below. See
appendix 1 of this document.
NOTE: If this alarm is issued, do not reset the chain error alarm until the failure is
checked and corrected. If robot use is continued with one of the double circuits being
faulty, safety may not be guaranteed when the other circuit fails.

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Recovering from DCS Cartesian Position Check Faults

General Rule for DCS Cartesian Position Check(SRVO-402) Recovery

To recover from a DCS limit fault, you must press and hold the SHIFT key and
then RESET.

Jog away from the DCS boundary in the opposite direction of the approach.

Knowing the direction of entry is key to a quick recovery.

Aborted Program DCS Cartesian Position Check (SRVO-402) Recovery

When running the GO TO HOME POS macro program, the robot is programmed
to go to the Home position from the current position in one unpredictable Joint
move. The Joint move synchronously positions all axis to the home position
without regard for the path of the tool center point.

When you violate a DCS boundary while moving the robot in this fashion, the
direction of entry may be hard to determine.

Examine the status of the Cartesian Position Check on line five of the DCS
menu.

MENU >0 NEXT >6 SYSTEM >8 DCS Top page

If there is a violation the status will indicate UNSF .

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Press the NEXT button and then press [F5]VIEW button to enter

DCS Visualization to view all the Cartesian Position Checks or

Cursor to line 5 and press the [F3]DETAIL function button to enter a specific
Cartesian Position Check.

Cursor to the Cartesian positon check that indicates UNSF .

Press the [F3]DETAIL then press the NEXT button.

Press [F5]VIEW button to enter the DCS Visualization of that Cartesian Position
Check zone.

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The violated boundary will be displayed in red.

Toggle through the views to determine the direction to exit the zone.

X
Y
F1 Toggle the X-Y view

F2 Toggle the X-Z view

F3 Toggle the Y-Z view

Z+

Y+

0
X+
World Coordinate System

Right Hand Rule

When you have determined what direction the robot was moving when the boundary
was violated:

Press and hold the SHIFT key and then RESET.

Jog away from the DCS boundary in the opposite direction of the approach.

WARNING: Repeated resetting of the alarm might indicate the robot is driving
further into the boundary.

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