KUKA SafeOperation 2 0 en

KUKA Robot Group
KUKA System Technology (KST)
KUKA.SafeOperation 2.0
For KUKA System Software (KSS) 5.5
Issued: 31.07.2007 Version: 0.6
V0.6 31.07.200
Nullserien-Doku-
KUKA.SafeOperation 2.0 Nullserien-Dokument
© Copyright 2007
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of the KUKA ROBOT GROUP.
Other functions not described in this documentation may be operable in the controller. The user has no
claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software de-
scribed. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guaran-
tee total conformity. The information in this documentation is checked on a regular basis, however, and
necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS4-DOC
V0.4
2 / 167
22.03.200
6 pub de V0.6 31.07.2007 KST-AD-SafeOperation-20 en
Nullserien-Dokument Contents
Contents
1 Introduction ...................................................................................................... 7
1.1 Target group ................................................................................................................... 7
1.2 Robot system documentation ......................................................................................... 7
1.3 Representation of warnings and notes ........................................................................... 7
1.4 Terms used ..................................................................................................................... 8
2 Product description ......................................................................................... 11

2.1 KUKA.SafeOperation overview ....................................................................................... 11
2.2 Functional principle ......................................................................................................... 12
2.3 Monitoring spaces ........................................................................................................... 12
2.3.1 Cell area .................................................................................................................... 13
2.3.2 Cartesian workspaces ............................................................................................... 14
2.3.3 Cartesian protected spaces ....................................................................................... 15
2.3.4 Axis-specific workspaces ........................................................................................... 16
2.3.5 Axis-specific protected spaces .................................................................................. 17
2.3.6 Space-specific velocity .............................................................................................. 18
2.3.7 Stop before reaching boundaries ............................................................................... 19
2.3.8 Reference stop .......................................................................................................... 19
2.4 Tools ............................................................................................................................... 20
2.5 Velocity and acceleration monitoring .............................................................................. 20
2.6 Standstill monitoring ....................................................................................................... 21
2.7 Override reduction .......................................................................................................... 22
2.8 Safe state (output OUT_STATUS) ................................................................................. 24
2.9 Mastering test ................................................................................................................. 25
2.9.1 Reference position ..................................................................................................... 25
2.9.2 Mastering test signal diagram .................................................................................... 26
2.10 Brake test ........................................................................................................................ 27
2.10.1 Parking position ......................................................................................................... 28
2.10.2 Signal diagram of the brake test ................................................................................ 29
2.11 T1 mode (safe robot retraction) ...................................................................................... 30
2.12 Monitoring functions that can be activated ..................................................................... 30
2.13 Components ................................................................................................................... 31
2.13.1 SafeRDC .................................................................................................................... 31
2.13.2 Reference group ........................................................................................................ 33
2.14 Connecting cables .......................................................................................................... 34
2.14.1 Connections on the SafeRDC box ............................................................................. 35
2.14.2 Connections on the SafeRDC box (optional) ............................................................. 35
2.14.3 Connector pin assignment of data cable X21 - X31 .................................................. 36
2.14.4 Connector pin assignment of data cable X21.1 - X41 ............................................... 36
2.14.5 Connector pin assignment of reference cable X42 - XS Ref ..................................... 37
2.14.6 Wiring diagram for 3 reference groups (optional) ...................................................... 37
2.15 Interface X40 .................................................................................................................. 38
2.15.1 Connector pin allocation X40 ..................................................................................... 39
2.15.2 Safe inputs ................................................................................................................. 43
2.15.3 Safe outputs .............................................................................................................. 44
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3 Technical data .................................................................................................. 47

3.1 Technical data of the SafeRDC ...................................................................................... 47
3.2 Reference switch ............................................................................................................ 47
3.3 Reference switch hole pattern ........................................................................................ 48
3.4 Hole pattern for actuating plate ....................................................................................... 49
4 Safety ................................................................................................................ 51
5 Installation ....................................................................................................... 55
5.1 System requirements ...................................................................................................... 55
5.2 Installing or updating KUKA.SafeOperation .................................................................... 55
5.3 Uninstalling KUKA.SafeOperation .................................................................................. 55
6 Start-up ............................................................................................................. 57
6.1 Start-up overview ............................................................................................................ 57
6.2 Installing the reference switch and actuating plate ......................................................... 58
6.3 Exchanging the lid of the SafeRDC box ......................................................................... 59
6.4 Connecting the connecting cables .................................................................................. 60
6.5 Connecting the Safety PLC ............................................................................................ 61
6.6 Assigning input and output signals ................................................................................. 61
6.7 Defining monitoring spaces ............................................................................................ 62
6.7.1 Defining a cell area .................................................................................................... 64
6.7.2 Defining axis-specific monitoring spaces ................................................................... 65
6.7.3 Defining Cartesian monitoring spaces ....................................................................... 67
6.8 Defining tools .................................................................................................................. 69
6.9 Defining the reference position ....................................................................................... 72
6.10 Safety parameters .......................................................................................................... 74
6.10.1 Setting safety parameters .......................................................................................... 75
6.10.2 Parameters – General information ............................................................................. 76
6.10.3 Parameters – Monitored axes .................................................................................... 76
6.10.4 Parameters – Reduced axis velocity ......................................................................... 76
6.10.5 Parameters – Cartesian velocity ................................................................................ 77
6.10.6 Parameters – Reduced axis acceleration .................................................................. 77
6.10.7 Parameters – Monitoring Spaces .............................................................................. 78
6.10.8 Parameters – Tools ................................................................................................... 82
6.10.9 Parameters – Monitoring of mastering ....................................................................... 83
6.10.10 Parameters – Standstill monitoring ............................................................................ 84
6.10.11 Parameters – Interfaces ............................................................................................ 84
6.10.12 Parameters – Machine data ($ROBCOR.DAT) ........................................................ 84
6.10.13 Parameters – Machine data ($MACHINE.DAT) ........................................................ 85
6.11 Assigning external axes to the reference group ............................................................. 85
6.12 Programming the mastering test ..................................................................................... 86
6.13 Checking the reference position (actuation with tool) ..................................................... 87
6.14 Performing a mastering test manually ............................................................................ 87
6.15 Defining the brake test .................................................................................................... 88
6.15.1 Defining robot axes for the brake test ........................................................................ 90
6.15.2 Defining external axes for the brake test ................................................................... 91
6.16 Programming the brake test ........................................................................................... 92
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Nullserien-Dokument Contents
6.17 Performing a manual brake test ...................................................................................... 93

6.18 Safety acceptance of KUKA.SafeOperation ................................................................... 93
7 Programming .................................................................................................... 95
7.1 Programs for the mastering test ..................................................................................... 95
7.2 Programs for the brake test ............................................................................................ 95
8 Operation .......................................................................................................... 97
8.1 Displaying safety parameters ......................................................................................... 97
8.2 Verifying safety parameters ............................................................................................ 97
8.3 Reading the operating hours meter ................................................................................ 98
8.4 Archiving safety parameters ........................................................................................... 98
8.5 Importing safety parameters ........................................................................................... 98
8.6 Restoring safety parameters ........................................................................................... 99
9 System variables .............................................................................................. 101

9.1 Signal declarations ......................................................................................................... 101
9.2 Signals for the mastering test ......................................................................................... 101
9.3 Signals for diagnosis ....................................................................................................... 102
9.4 Robot status signals ....................................................................................................... 103
9.5 Signals for the brake test ................................................................................................ 104
9.6 Variables for override reduction ...................................................................................... 105
10 Messages .......................................................................................................... 107

10.1 Messages during operation ............................................................................................ 107
10.2 Messages during verification of the safety parameters .................................................. 113
10.3 Messages for the brake test ........................................................................................... 115
11 Diagnosis .......................................................................................................... 117

11.1 Opening diagnosis .......................................................................................................... 117
11.2 Overview of diagnosis ..................................................................................................... 117
11.3 Detailed information about the monitoring spaces .......................................................... 118
11.3.1 Detailed information about the cell area .................................................................... 119
11.3.2 Detailed information about the axis-specific monitoring space .................................. 120
11.3.3 Detailed information about the Cartesian monitoring space ...................................... 121
11.4 Detailed information about the safe inputs ..................................................................... 122
11.5 Detailed information about the safe outputs ................................................................... 123
12 Troubleshooting ............................................................................................... 125

12.1 LEDs on the SafeRDC board .......................................................................................... 125
12.2 LEDs on the I/O Print board ............................................................................................ 128
12.3 Results of the brake test ................................................................................................. 128
13 Repair ................................................................................................................ 131

13.1 Connections on the SafeRDC board .............................................................................. 131
13.2 Connections on the I/O Print board ................................................................................ 132
13.3 Removing the SafeRDC board ....................................................................................... 132
13.4 Removing the I/O Print board ......................................................................................... 134
13.5 Installing the I/O Print board ........................................................................................... 134
13.6 Installing the SafeRDC board ......................................................................................... 135

14 Appendix ........................................................................................................... 137

14.1 Interface X40 circuit example 1 ...................................................................................... 137
14.4 Checklists ....................................................................................................................... 140
14.4.1 Checklist for robot and system .................................................................................. 140
14.4.2 Checklist for safe functions ........................................................................................ 141
14.4.3 Checklist for velocity limits ......................................................................................... 143
14.4.4 Checklist for reduced accelerations ........................................................................... 145
14.4.5 Checklist for standstill monitoring .............................................................................. 146
14.4.6 Checklist for configuration of the cell area ................................................................. 148
14.4.7 Checklist for configuration of axis-specific monitoring spaces ................................... 149
14.4.8 Checklist for configuration of Cartesian monitoring spaces ....................................... 152
14.4.9 Checklist for configuration of the tools ....................................................................... 154
14.5 Applied norms and directives .......................................................................................... 155
15 KUKA Service ................................................................................................... 157

15.1 Requesting support ......................................................................................................... 157
15.2 KUKA Customer Support ................................................................................................ 157
Index .................................................................................................................. 163

Nullserien-Dokument 1. Introduction
1 Introduction
1.1 Target group
This documentation is aimed at users with the following knowledge and skills:
KUKA.SafeOperation training
Advanced KRL programming skills
Advanced knowledge of the robot controller system
For optimal use of our products, we recommend that our customers take part
in a course of training at KUKA College. Information about the training pro-
gram can be found at www.kuka.com or can be obtained directly from our
subsidiaries.
1.2 Robot system documentation
The robot system documentation consists of the following parts:

Operating instructions for the robot
Operating instructions for the robot controller
Operating and programming instructions for the KUKA System Software
Documentation relating to options and accessories
Each of these sets of instructions is a separate document.
1.3 Representation of warnings and notes
Safety Warnings marked with this pictogram are relevant to safety and must be ob-
served.
Danger!
This warning means that death, severe physical injury or substantial material
damage will occur, if no precautions are taken.
Warning!
This warning means that death, severe physical injury or substantial material
damage may occur, if no precautions are taken.
Caution!
This warning means that minor physical injuries or minor material damage
may occur, if no precautions are taken.
Notes Notes marked with this pictogram contain tips to make your work easier or ref-
erences to further information.
Tips to make your work easier or references to further information.

1.4 Terms used
Term Description
Axis range Range, in degrees or millimeters, which can be
defined for each axis to be monitored.
Axis limit An axis has 2 axis limits which define the axis
range. There is an upper axis limit and a lower
axis limit.
Stopping distance The stopping distance consists of the reaction
distance and the braking distance.
Reaction distance = distance traveled between
detection of the fault and application of the
brakes.
Braking distance = distance traveled between
the brakes being applied and the robot coming to
a standstill.
Workspace If a workspace is defined, the axis or tool must
stay within the parameterized limits and must not
leave the workspace.
(>>> 2.3.4 "Axis-specific workspaces" page 16)
(>>> 2.3.2 "Cartesian workspaces" page 14)
Brake test In the brake test, the robot controller checks the
functionality and wear of the brakes.
(>>> 2.10 "Brake test" page 27)
Brake test cycle time The brake test cycle time is a parameterizable
value. When this time has elapsed, the robot
controller initiates a brake test.
Input test pulse The input test pulse must be activated in the
configuration window for testing the dual-chan-
nel operation of the safe inputs.
Monitoring time Within the monitoring time, the system must
check whether a brake test or mastering test is
requested.
Parking position If a brake is identified as being defective, the
robot can be moved to the parking position. The
parking position must be selected in a position
where the robot can sag safely.
(>>> 2.10.1 "Parking position" page 28)
Mastering test The mastering test is used to check whether the
current position of the robot and the external
axes corresponds to a reference position.
(>>> 2.9 "Mastering test" page 25)
Polygon, convex A convex polygon is a polygon consisting of at
least 3 different corners. The individual line seg-
ments of the vertices must not be outside the
polygon. Triangles and squares are examples of
convex polygons.
(>>> 2.3.1 "Cell area" page 13)

Nullserien-Dokument 1. Introduction
Term Description
Reference group The axes required for moving to a reference
position are listed in a reference group. Each
configured axis must be assigned to a reference
group.
All robot axes are assigned to reference group 1.
External axes can be assigned to other refer-
ence groups.
A maximum of 3 reference groups can be cre-
ated.
Reference position In the mastering test, the robot moves to the ref-
erence position and compares the actual posi-
tion of the monitored axes with the stored
reference position.
(>>> 2.9.1 "Reference position" page 25)
Reference stop If a reference stop is set for one of the Cartesian
monitoring spaces 2 to 8 and the following pre-
conditions are met, the robot stops with a STOP
1.
Monitoring space is activated.
Mastering test is requested.
Operating mode T2, AUT or AUT EXT
(>>> 2.3.8 "Reference stop" page 19)
Reference switch A reference switch is necessary for carrying out
the mastering test. The reference switch con-
firms the reference position.
(>>> 3.2 "Reference switch" page 47)
Protected space The axis or tool must move outside the parame-
terized protected space limits and must not
enter the protected space.
(>>> 2.3.5 "Axis-specific protected spaces"
page 17)
(>>> 2.3.3 "Cartesian protected spaces"
page 15)
Standstill monitoring The robot is at a monitored standstill, but may
nonetheless move within the parameterized axis
angle or distance tolerances. If the limit is
exceeded or the velocity is increased minimally,
the robot is stopped by the SafeRDC.
(>>> 2.6 "Standstill monitoring" page 21)
STOP 0 In the case of a STOP 0, the drives are deacti-
vated immediately and the brakes are applied.
The robot deviates from the path.
STOP 0 corresponds to the category 0 stop
function in DIN EN 60204-1.
STOP 1 In the case of a STOP 1, the robot is braked on
the programmed path for 1 second with a
dynamic braking ramp. The drives are then
deactivated and the brakes are applied.

Term Description
STOP 2 In the case of a STOP 2, the drives are not
deactivated and the brakes are not applied. The
robot is braked with a dynamic braking ramp.
Monitoring space A monitoring space can be Cartesian or axis-
specific and can be defined as a workspace or
safeguarded zone.
(>>> 2.3 "Monitoring spaces" page 12)
Cell area If a cell area is defined, the tool must stay within
the parameterized limits and must not leave the
cell area. The cell area is defined as a convex
polygon.
(>>> 2.3.1 "Cell area" page 13)

Nullserien-Dokument 2. Product description
2 Product description
2.1 KUKA.SafeOperation overview
KUKA.SafeOperation is an option with software and hardware components.
This option may only be retrofitted after consultation with the KUKA Robot
Group.
Functions Connection to an external safety logic

Monitoring that can be activated using safe inputs
Safe outputs that can be activated for status messages of the monitoring
functions
Monitoring of up to 8 user-defined monitoring spaces
Monitoring space 1: cell area
Monitoring spaces 2 to 8: axis-specific or Cartesian monitoring spaces
Safe monitoring of axis-specific velocities and accelerations
Safe monitoring of space-specific velocities
Safe monitoring of Cartesian velocities at the activated tool
Modeling of up to 3 tools with special TCPs
Safe standstill monitoring
Safe stop via Electronic Safety Circuit (ESC) with safe disconnection of the
drives
Monitoring of the mastering
Brake test
Areas of application Human-robot cooperation

Direct loading of workpieces without an intermediate support
Replacement of conventional axis range monitoring systems
Fig. 2-1: Example of a cell with KUKA.SafeOperation

1 Installed reference switch 5 System control panel

2 Robot 6 Robot controller
3 Loading station 7 Bending machine
4 Safety mat
Communication The safety functions are activated via safe inputs of interface X40. The safe
outputs of interface X40 can be wired externally.
2.2 Functional principle
Description The robot moves within the limits that have been configured and activated.
The actual position is continuously calculated and monitored against the safe-
ty parameters that have been set.
The SafeRDC monitors the robot system by means of the safety parameters
that have been set. If the robot violates a monitoring limit or a safety parame-
ter, it is stopped.
The safe inputs and outputs of the SafeRDC are of a redundant design and
LOW active.
2.3 Monitoring spaces
Description Up to 8 freely definable monitoring spaces are available.
Caution!
In order to allow safe retraction of the robot, the monitoring spaces are not
subjected to safe monitoring in T1 mode. If a limit is exceeded in T1 mode,
the robot is not stopped safely and there is a risk of personal injury and ma-
terial damage.
(>>> 2.11 "T1 mode (safe robot retraction)" page 30)
Monitoring space 1: The cell area is a Cartesian workspace in the form of a convex polygon with 3
cell area to 6 corners.
(>>> 2.3.1 "Cell area" page 13)
“Stop before reaching boundaries” can be activated or deactivated.
(>>> 2.3.7 "Stop before reaching boundaries" page 19)
It is permanently monitored and always active. The corners can be configured,
activated and deactivated individually.
A stop is triggered at the limit.
Monitoring spaces 2 Monitoring spaces 2 to 8 can be defined as Cartesian cuboids or by means of

to 8 individual axis ranges. They can be set as workspaces or safety zones.
(>>> 2.3.2 "Cartesian workspaces" page 14)
(>>> 2.3.3 "Cartesian protected spaces" page 15)
(>>> 2.3.4 "Axis-specific workspaces" page 16)
(>>> 2.3.5 "Axis-specific protected spaces" page 17)
Space-specific Cartesian velocities can be defined inside or outside monitor-
ing spaces 2 to 8.
(>>> 2.3.6 "Space-specific velocity" page 18)
“Stop before reaching boundaries” can be activated or deactivated.

(>>> 2.3.7 "Stop before reaching boundaries" page 19)

For each of the monitoring spaces 2 to 8, a reference stop can be set that
stops the robot if no mastering test has been carried out.
(>>> 2.3.8 "Reference stop" page 19)
Monitoring can be activated, deactivated or assigned to a safe input for acti-
vation or deactivation for each of the individual monitoring spaces 2 to 8.
Safe outputs that can be switched externally can be assigned to monitoring
spaces 2 to 8.
Whether or not a stop is triggered at the limit is a function that can be activated.
Stop reactions
Stop reaction Description Example
The stop is triggered if a moni- Robot exceeds the
toring function is already acti- limit of an activated
STOP 0
vated and the robot then workspace in Auto-
exceeds the monitoring limit. matic mode.
The stop is triggered if a moni- A safeguarded zone in
toring function is just being which the robot is cur-
STOP 1 activated and the robot has rently situated is acti-
already exceeded the monitor- vated by a safety mat.
ing limit.
Robot exceeds the
The stop is triggered by the limit of an activated
STOP 2
KUKA System Software. workspace in T1
mode.
2.3.1 Cell area
Description The cell area is a Cartesian monitoring space. 2 user-configured spheres are
modeled around the tool on the mounting flange of the robot; when the robot
moves, these spheres move with it. These spheres are monitored against the
cell area and must only move within this cell area. If a sphere touches the limits
of the cell area, the robot stops with a STOP 0.
Caution!
When configuring and programming, it must be remembered that the Carte-
sian monitoring spaces are only monitored against the modeled spheres on
the mounting flange of the robot. If robot components are situated outside the
modeled spheres, they are not monitored and a violation of the limit is not de-
tected. This can result in personal injury and material damage.
The cell area is configured in the ROBROOT coordinate system as a convex

polygon with 3 to 6 corners.
Convex polygon:
A convex polygon is a polygon consisting of at least 3 different corners. The
individual line segments of the vertices must not be outside the polygon. Tri-
angles and squares are examples of convex polygons.

1 Example of a convex polygon with 6 corners

2 Example of a non-convex polygon with 6 corners
Example The diagram (>>> Fig. 2-2) shows an example of a configured cell area.
Fig. 2-2: Example of a cell area
1 Cell area
2 Spheres on tool
3 Robot
2.3.2 Cartesian workspaces
Description 2 user-configured spheres are modeled around the tool on the mounting
flange of the robot; when the robot moves, these spheres move with it. These
spheres are monitored against the Cartesian workspace and must only move
within the defined and activated workspace.
If a sphere touches the limit of the workspace, the following reactions can be
configured:
Set safe output
Stop robot
No reaction

Caution!
The Cartesian workspace is configured in the ROBROOT coordinate system

as a cuboid with 2 auxiliary points.
Example The diagram (>>> Fig. 2-3) shows an example of a configured Cartesian
workspace.
Fig. 2-3: Example of a Cartesian workspace
1 Workspace
2 Spheres on tool
3 Robot
2.3.3 Cartesian protected spaces
Description 2 user-configured spheres are modeled around the tool on the mounting
flange of the robot; when the robot moves, these spheres move with it. These
spheres are monitored against the Cartesian protected space and must only
move outside the defined and activated protected space.
If a sphere touches the limit of the protected space, the following reactions can
be configured:
Set safe output
Stop robot
No reaction

Caution!
The Cartesian protected space is configured in the ROBROOT coordinate

system as a cuboid with 2 auxiliary points.
Example The diagram (>>> Fig. 2-4) shows an example of a configured Cartesian pro-
tected space.
Fig. 2-4: Example of a Cartesian safeguarded zone
1 Protected space
2 Spheres on tool
3 Robot
2.3.4 Axis-specific workspaces
Description The axis limits can be set and monitored individually for each axis via the soft-
ware. The resulting axis range is the permissible range of an axis within which
the robot may move. The individual axis ranges together make up the overall
workspace, which may consist of up to 8 axis ranges. The 6 robot axes and 2
external axes can be defined in a workspace.
If the robot touches the axis limit, the following reactions can be configured:
Set safe output
Stop robot
No reaction

Example The diagram (>>> Fig. 2-5) shows an example of an axis-specific workspace.
The workspace of axis 1 is configured from –110° to +130° and corresponds
to the permissible motion range of the robot.
Fig. 2-5: Example of an axis-specific workspace
1 Workspace 3 Stopping distance

2 Robot 4 Protected space
2.3.5 Axis-specific protected spaces
Description The axis limits can be set and monitored individually for each axis via the soft-
ware. The resulting axis range is the range of an axis within which the robot
may not move. The individual axis ranges together make up the overall pro-
tected space, which may consist of up to 8 axes ranges. The 6 robot axes and
2 external axes can be defined in a protected space.
If the robot touches the axis limit, the following reactions can be configured:
Set safe output
Stop robot
No reaction
Example The diagram (>>> Fig. 2-6) shows an example of an axis-specific protected
space. The safeguarded space and the stopping distances correspond to the
configured protected space. The motion range of axis 1 is limited to –185° to
+185° by means of software limit switches. The protected space is configured
from –110° to –10°. This results in 2 permissible motion ranges for the robot,
separated by the configured protected space.

Fig. 2-6: Example of an axis-specific protected space
1 Permissible motion range 1 4 Protected space

2 Robot 5 Permissible motion range 2
3 Stopping distance
2.3.6 Space-specific velocity
Description A Cartesian velocity, that is active inside or outside the monitoring space, can
be defined for monitoring spaces 2 to 8. A TCP is defined for the tool. This TCP
is monitored against a configured velocity limit. If the TCP on the tool exceeds
the velocity limit, the robot is stopped.
Example The diagram (>>> Fig. 2-3) shows an example of a configured Cartesian
workspace. If the TCP on the tool exceeds the velocity limit inside the work-
space, the robot is stopped.

Fig. 2-7: Space-specific velocity example
1 Workspace
2 Spheres on tool
3 Robot
2.3.7 Stop before reaching boundaries
Description The function “Stop before reaching boundaries” can be activated or deactivat-
ed for monitoring spaces 1 to 8. If the function is activated, the robot stops be-
fore it reaches the limit of the workspace.
The minimum distance from the workspace limit depends on the global Carte-
sian velocity:
Minimum distance from

Global Cartesian velocity
workspace limit
10 m/s 40 mm
5 m/s 20 mm
1 m/s 4 mm
This function is not available for all robot types. More detailed information
about the availability of robots with this function can be obtained from the
KUKA Robot Group.
2.3.8 Reference stop
Description If a reference stop is set for one of the Cartesian monitoring spaces 2 to 8 and
the following preconditions are met, the robot stops with a STOP 1.
Monitoring space is activated.
“Mastering test required” message is active.

Operating mode T2, AUT or AUT EXT

In order to be able to move the robot, deactivate all monitoring spaces and per-
form a mastering test.
2.4 Tools
Description 3 tools can be defined. Tool 1 is set by default. 2 spheres are defined about
each tool; these are monitored against the configured limits of the monitoring
spaces. A TCP is defined for each of the tools 1 to 3 and monitored against
the configured velocity limits.
The TCP of the tools can be freely configured in the configuration window. It
is independent of the current TCP in the KUKA System Software with the var-
iable $TOOL.
Depending on the inputs E4 and E5, the following tool is activated.
Input E5 = LOW E5 = HIGH

The most recently activat-
E4 = LOW Tool 2 is active.
ed tool is active.
E4 = HIGH Tool 3 is active. Default tool 1 is active.
If there is a LOW level signal at inputs E4 and E5, the most recently activated
tool remains active and the robot stops with a STOP 1. The robot can be
moved free in T1 mode.
Example 2 spheres and a TCP are defined on tool 1 of the robot by means of the
FLANGE coordinate system.
Fig. 2-8: Tool
2.5 Velocity and acceleration monitoring
Description The following velocity and acceleration monitoring functions can be set in the
configuration window:
Reduced axis velocity

The velocity of every robot axis can be monitored against a limit value.
Axis velocity limit value that can be activated by means of the safe input
“Safe reduced velocity”.
Axis velocity limit value for T1 mode
Cartesian velocity
The Cartesian velocity at the TCP of the current tool can be monitored.
Global velocity
Limit value that can be activated for the velocity at the TCP of the tool by
means of the safe input “Safe reduced velocity”
Limit value for the velocity at the TCP of the tool for T1 mode
Space-specific velocity
(>>> 2.3.6 "Space-specific velocity" page 18)
Reduced axis acceleration
The acceleration of every robot axis can be monitored against a limit value.
The axis acceleration can be activated in the configuration window.
Axis acceleration limit value that can be activated by means of the safe in-
put “Safe reduced velocity”
Axis acceleration limit value for T1 mode
Stop reactions
Robot exceeds the
The stop is triggered if a moni-
configured and acti-
toring function is already acti-
STOP 0 vated limit value for
vated and the robot then
reduced axis accelera-
exceeds the monitoring limit.
tion.
The “Safe reduced
velocity” for which the
toring function is just being
limit value has already
STOP 1 activated and the robot has
been exceeded by the
already exceeded the monitor-
robot is activated by a
ing limit.
safety mat.
2.6 Standstill monitoring
Description The robot is at a monitored standstill, but may nonetheless move within the pa-
rameterized axis angle or distance tolerances. If the limit is exceeded or the
velocity is increased minimally, the robot is stopped by the SafeRDC.
The axis angle or distance tolerance can be activated and configured individ-
ually for axes 1 to 8. The axes that are activated in the case of standstill mon-
itoring are independent of the axes that are activated in the safety parameter
Monitored axes.
All activated axes must be mastered and there must be no active encoder er-
rors. Following loss of mastering or an encoder error, the robot can only be
moved free in T1 mode. In all other operating modes, the robot stops with a
STOP 0.
A limit value can be set for standstill monitoring; this limit value is activated via
the safe input “Standstill monitoring”.

Caution!
In order to allow safe retraction of the robot, standstill monitoring is not sub-
jected to safe monitoring in T1 mode. The robot is not safely stopped and
there is a risk of personal injury and material damage.
Stop reactions
Standstill monitoring is
activated and the
SafeRDC detects a
toring function is already acti-
STOP 0 change of position in
vated and the robot then
Automatic mode that is
exceeds the monitoring limit.
greater than the
resolver noise.
The stop is triggered if a moni- While the robot is mov-
toring function is just being ing, standstill monitor-
STOP 1 activated and the robot has ing is activated by
already exceeded the monitor- means of a safety mat.
ing limit.
Robot exceeds the
The stop is triggered by the axis limit configured for
STOP 2
KUKA System Software. standstill monitoring in
T1 mode.
2.7 Override reduction
Description Override reduction is not subjected to safe monitoring.

The variables for override reduction can be modified in the $CUSTOM.DAT file
in the directory C:\KRC\ROBOTER\KRC\STEU\MADA, in a KRL program or
via the menu sequence Monitor > Variable > Single. If a variable is modified,
an advance run stop is triggered.
(>>> 9.6 "Variables for override reduction" page 105)
If the velocity is reduced by means of override reduction, the message “Safe
robot override reduction active” appears in T1 and T2 mode. Message output
in Automatic mode can be activated via the variable $SR_OV_MSG_SHOW =
TRUE.
$SR_VEL_RED The variable $SR_VEL_RED is used to activate override reduction for the ve-
locity. The Cartesian velocity at the TCP of the current tool is automatically re-
duced if the programmed velocity is greater than the value of the lowest
velocity limit that is activated and currently monitored by the SafeRDC. This
prevents the robot from being stopped when the Cartesian velocity limit is ex-
ceeded.
The variable $SR_OV_RED specifies the percentage of the lowest velocity
limit that is activated and currently monitored by the SafeRDC. The Cartesian
velocity of the TCP of the current tool is reduced to this value.
Example:
The lowest velocity limit 1,000 mm/s is active on the SafeRDC. If
$SR_VEL_RED = TRUE and $SR_OV_RED = 95 are set, the Cartesian ve-
locity of the TCP of the current tool is reduced to 950 mm/s.

Fig. 2-9: Example: Override reduction with $SR_VEL_RED
v3 Global Cartesian velocity; v3 = 1,200 mm/s

v2 Activated space-specific velocity; v2 = 1,000 mm/s
v1 95% of velocity v2; v1 = 950 mm/s
Override reduction is automatically activated because the pro-
t1
grammed velocity exceeds velocity limit v1
Override reduction is automatically deactivated because the pro-
t2
grammed velocity is lower than the velocity limit v1
$SR_WORKSPACE_ The variable $SR_WORKSPACE_RED can be used to configure override re-

RED duction for monitoring spaces with the function “Stop before reaching bound-
aries” activated. If this override reduction is activated, the override is reduced
automatically. The stopping distance of the robot and the permissible distance
between the robot and the workspace limits depend on the velocity of the ro-
bot.
Example:
An override of 100% is set. If $SR_WORKSPACE_RED = TRUE and the robot
approaches a workspace limit, the override is continuously reduced to allow
the robot to get as close as possible to the workspace limit without being
stopped by the SafeRDC.
In example 1 (>>> Fig. 2-10), the robot stops before it reaches the limit of the
workspace.
Fig. 2-10: Example 1: Override reduction with $SR_WORKSPACE_RED
s2 Override reduction is activated automatically

s1 Calculated minimum distance from workspace limit

s0 Workspace limit
v1 Programmed velocity
v0 Velocity V0 = 0
t1 Override reduction is activated automatically
t2 Robot stops with a STOP 0
In example 2 (>>> Fig. 2-11), the robot moves towards the workspace limit,
reducing its velocity, and then moves away again. As soon as it has reached
a certain minimum distance from the workspace limit, the robot moves at its
programmed velocity once again.
Fig. 2-11: Example 2: Override reduction with $SR_WORKSPACE_RED
s2 Override reduction is activated automatically

s1 Calculated minimum distance from workspace limit
s0 Workspace limit
v1 Programmed velocity
v0 Velocity V0 = 0
t1 Override reduction is activated automatically
t2 Override reduction is deactivated automatically
2.8 Safe state (output OUT_STATUS)
Description The following conditions must be met for a safe state (OUT_STATUS=HIGH).
If at least one of the conditions is not met, the safe state is violated
(OUT_STATUS=LOW).
Operating Stop
Condition
mode reaction
Hardware and software components are T1 STOP 0
in flawless condition and in good work- T2, AUT,
STOP 0
ing order. AUT EXT
T1 STOP 0
Safety parameters are confirmed. T2, AUT,
STOP 0
AUT EXT
T1 STOP 0
There are no encoder errors. T2, AUT,
STOP 0
AUT EXT

Operating Stop
Condition
mode reaction
T1 No stop
Safe inputs and outputs are free from
T2, AUT,
errors. STOP 0
AUT EXT
T1 No stop
Robot is mastered. T2, AUT,
STOP 0
AUT EXT
T1 No stop
Mastering test has been performed suc-
T2, AUT,
cessfully. No stop
AUT EXT
Caution!
If there is a LOW level signal at output OUT_STATUS, the robot system is
not safely monitored and suitable system-specific safety precautions must be
taken.
2.9 Mastering test
Description The mastering test is used to check whether the current position of the robot
and the external axes corresponds to a reference position. If the deviation is
too great, the mastering test has failed. The robot stops with a STOP 1 and
can now only be moved in T1 mode. In this case, the robot controller gener-
ates the message "Mastering test failed". If the mastering test run was suc-
cessful, the robot can be safely monitored using the SafeRDC.
The mastering test must be carried out in the following cases:
After the robot controller has booted
Once the robot controller has booted, the robot can be moved normally for
2 hours without a reference test. Once this time has elapsed, the robot
stops with a STOP 2.
After mastering
The mastering test can be called in the following ways:
External request via a signal and automatic call of the program MasRe-
fReq.SRC
Internal request caused by lack of mastering or booting of the robot con-
troller and automatic call of the program MasRefReq.SRC
Manual selection of the program MasRefReq.SRC
If, during operation, the mastering test is requested via the external signal, the
mastering test is performed next time the program MasRefReq.SRC is auto-
matically called. The message “Mastering test required” is generated.
2.9.1 Reference position
The reference position must be taught in the program MasRefStart.SRC and

in the configuration window (>>> 6.12 "Programming the mastering test"
page 86). The reference position can be approached with the actuating plate
or with a ferromagnetic part of the tool.

Fig. 2-12: Example: position of the actuating plate on the reference

switch
1 Tool
2 Actuating plate
3 Reference switch
4 Mechanical mounting fixture for the reference switch
5 Actuated reference switch
The reference run must be selected in accordance with the following criteria:
The position of the reference switch must not hinder normal program exe-
cution.
The reference position must not be a position in which the axes are in a
singularity.
In the reference position, both proximity switch surfaces of the reference
switch must be actuated by the switching surface (actuating plate or tool).
In the reference position, the robot axes must be at least ±5° away from
the mastering position.
2.9.2 Mastering test signal diagram
The signal diagram for the mastering test applies in the following case:
One reference switch is connected.
No fault signal at reference switch.

Mastering test is requested internally because of lack of mastering or boot-

ing of the robot controller.
Fig. 2-13: Signal diagram of the mastering test
Item Description
1 Mastering test is requested internally.
2 Automatic call of the program MasRefReq.SRC
Start of the mastering test
3 Actual position is identical to the reference position and the ref-
erence switch is actuated.
4 Reference switch is no longer actuated.
End of the mastering test
The message “Mastering test has been performed successfully”
is generated.
2.10 Brake test
Brake test In the brake test, the robot controller checks the functionality and wear of the
brakes. During the brake test, all robot axes and up to 2 external axes that are
set in the brake test configuration are tested one after the other. Only axes
contained in the first DSE are tested.
Decouplable axes cannot be safely monitored.
Functional principle of the brake test:

1. The robot accelerates to a defined velocity.
2. Once the robot has reached the defined velocity, the brakes are applied
and the results of the brake test are displayed for each tested axis in the
message window.
3. If a brake is identified as being defective, the brake test can be repeated
or the robot can be moved to the parking position. If a brake has reached
the wear limit, the robot controller generates a message. The robot can be
moved without restrictions.

Warning!
If a brake has been identified as being defective, the drives remain under ser-
vo-control for 2 hours following the start of the brake test (monitoring time).
Once this time has elapsed, the drives are deactivated.
The brake test must be carried out in the following cases:

After the robot controller has booted
After a modified brake test configuration has been saved
Cyclically during operation, every 46 hours at the latest
The brake test can be called in the following ways:
As a subprogram after the parameterized brake test cycle time
Via an external signal
Manually
The brakes to be tested and the brake test cycle time can be set in the brake
test configuration. If these parameters are modified, a brake test is requested.
(>>> 6.15 "Defining the brake test" page 88)
The remaining brake test cycle time is indicated in the configuration and in the
timer $BREMSENTEST_TIMER. When this time has elapsed, a brake test is
requested and the robot controller generates the following message: “Brake
test required”. The monitoring time is started and the robot can still be moved
for another 2 hours. Once the monitoring time has elapsed, the robot stops
and the robot controller generates the following acknowledgement message:
“Test cycle for brake test request exceeded”. Once this message has been ac-
knowledged, the robot can be moved for 2 hours.
If no brakes are set for the brake test, no brake test is carried out.
If a brake test is carried out, a LOG file is created.
(>>> 12.3 "Results of the brake test" page 128)
2.10.1 Parking position
The parking position must be taught in the program BrakeTestPark.SRC. If a

brake is identified as being defective, the robot can be moved to the parking
position. The parking position must be selected in a position where the robot
can sag safely.
The parking position can correspond to the transport position, for example.

Fig. 2-14: Transport position of the robot
2.10.2 Signal diagram of the brake test
The signal diagram for the brake test applies in the following case:
Each monitored axis is OK.
Brake test is successful.
No brake has reached the wear limit.
Brake test is requested internally when the brake test cycle time has
elapsed or when the robot controller is booted.
Fig. 2-15: Signal diagram of the brake test
Item Description
1 The brake test is requested internally.
2 Automatic call of the program BrakeTestReq.SRC
Start of the brake test
3 End of the brake test
The message “Brake test has been performed successfully” is
generated.

2.11 T1 mode (safe robot retraction)
Description If the robot has violated a monitoring space and been stopped, it can only be
moved out of the violated workspace in T1 mode. The monitoring spaces re-
main active and messages are displayed in the message window. In T1 mode,
the robot can be moved to any position, irrespective of what monitoring spaces
are active.
The robot can be moved free in T1 mode in the following cases:
Safe input/output error
Error in the cross comparison (system error 3000/3001/3002)
Monitoring space is violated or has been exceeded
Standstill monitoring is violated or has been exceeded
Mastering test was not successful
In an activated monitoring space, the reference stop has been activated
and no mastering test has been carried out
The following monitoring functions are active in T1 mode:
Tool velocity for T1
Axis velocity for T1 is active if “Safe axis monitoring” is activated.
Axis acceleration for T1 is active if “Safe axis monitoring” is activated and
“Monitoring axis acceleration for T1” is activated.
In order to prevent the monitoring functions being violated in T1 mode, the
maximum velocity in T1 mode must be adapted in $CUSTOM.DAT using
system variables $SR_VEL_RED and $SR_OV_RED.
(>>> 9.6 "Variables for override reduction" page 105)
If “Safe reduced velocity” and/or “Space-specific velocity” is activated in T1

mode, the lowest velocity limit value is recognized as the limit by the SafeRDC.
Reaction of the robot if a limit is exceeded:
If the robot exceeds a limit in T1 mode, the robot stops with a STOP 2 and a
message is generated. Once the message has been acknowledged, robot mo-
tion can be resumed. Every time a limit is subsequently exceeded, the robot
stops.
Reaction of the robot if standstill monitoring is activated:
If standstill monitoring is active in T1 mode, the robot stops with a STOP 2 af-
ter the configured axis angle or distance tolerance has been reached and a
message is generated. Once the message has been acknowledged, the robot
can be moved freely.
2.12 Monitoring functions that can be activated
Inputs Depending on the mode that has been set and the signal level at the safe in-
put, the monitoring functions are activated:
Input Level T1 T2, AUT, AUT EXT

E0...E3 Monitoring spaces are Monitoring spaces are
LOW not subjected to safe subjected to safe moni-
Configurable:
monitoring. toring.
Monitoring spaces 2 to 8
Default: HIGH Monitoring spaces are not monitored.

Input Level T1 T2, AUT, AUT EXT

E_HALT Not safe standstill mon- Safe standstill monitor-
LOW
itoring ing
Standstill monitoring
HIGH No standstill monitoring.
E_DV Axis velocity is subjected to safe monitoring.
Safe reduction of velocity Tool velocity is subjected to safe monitoring.
LOW
Axis acceleration is subjected to safe monitoring (if ac-
tive).
HIGH Safe reduced velocity is not monitored
Outputs If monitoring functions are violated, the following outputs can be activated or
deactivated:
Output Level T1 T2, AUT, AUT EXT

OUT_A0...OUT_A2
Configurable: LOW Monitoring spaces have been violated.
Default:
Monitoring spaces 6 to 8 HIGH Monitoring spaces have not been violated.
OUT_STATUS LOW Safe robot monitoring is not activated.

Status of the monitoring HIGH Safe robot monitoring is activated.
functions
2.13 Components
Software These software components are included in the KUKA.SafeOperation pack-

age:
KUKA.SafeOperation 2.0
Hardware These hardware components are included in the KUKA.SafeOperation pack-

age:
Reference group
(>>> 2.13.2 "Reference group" page 33)
Data cable X21 - X31
Data cable X21.1 - X41
2.13.1 SafeRDC
Description The SafeRDC consists of the following components:

SafeRDC board
I/O Print board
SafeRDC box

Fig. 2-16: SafeRDC hardware components
1 SafeRDC box
2 SafeRDC board with I/O Print board
The SafeRDC board redundantly evaluates the resolver signals and monitors
the position of the robot axes. The resolver signals are compared with the
safety parameters that have been set.
The I/O Print board is plugged onto the SafeRDC board and provides the 24-
volt input and output signals.
The SafeRDC box contains the SafeRDC board with the I/O Print board and
is mounted on the base frame of the robot.
Fig. 2-17: SafeRDC box on base frame
1 SafeRDC box
2 Robot
Functions Monitoring of the robot according to the safety parameters that have been
set and the signals at the safe inputs
Monitoring of the safe inputs and outputs for violation of dual-channel op-
eration
Safe evaluation of the actual position
Safe disconnection of the drives

Communication with the robot controller

Pulsing of the safe inputs and outputs
2.13.2 Reference group
Description A reference group consists of the following components:

Reference switch
Actuating plate
Reference cable and reference connector
Accessories
Fig. 2-18: Reference group hardware components
1 Inductive reference switch for 1 reference group

2 Actuating plate
3 Mechanical reference switches for 3 reference groups
(optional)
Reference group Standard Optional

Number of refer-
1 3
ence groups
Number of actuat-
1 3
ing plates
Inductive Mechanical
XS Ref XS Ref.1
Reference switch
XS Ref.2
XS Ref.3
X42.1 - XS Ref.1
Reference cable X42 - XS Ref X42.2 - XS Ref.2
X42.3 - XS Ref.3

Reference group Standard Optional

Number of refer-
1 3
ence groups
X42.1
Reference con-
X42 X42.2
nector
X42.3
Electrical installations
Accessories --- X904 - X902
SafeRDC box lid (optional)
2.14 Connecting cables
Overview The diagram (>>> Fig. 2-19) shows an example of the connecting cables of
the robot system. One mechanical reference group is used.
Fig. 2-19: Overview of connecting cables
Item Description
1 Robot controller
2 Robot
3 Reference switch XS Ref
Alternatively, 3 reference switches XS Ref.1, XS Ref.2 and XS
Ref.3 can be used.
4 Reference cable X42 - XS Ref
Alternatively, 3 reference cables X42.1 - XS Ref.1, X42.2 - XS
Ref.2 and X42.3 - XS Ref.3 can be used.
5 Connecting cable X40 - external safety logic
6 Data cable X21 - X31
7 Data cable X21.1 - X41

2.14.1 Connections on the SafeRDC box
Overview
Fig. 2-20: Connections on the SafeRDC box
X02 Junction box on SafeRDC box

X31 Connection for data cable X21 - X31
X32 Connection for electronic measuring tool (EMT)
X40 Connection for safe inputs and outputs
X41 Connection for data cable X21.1 - X41
X42 Connection for reference cable X42 - XS Ref
2.14.2 Connections on the SafeRDC box (optional)
Description If 3 reference groups are used, additional connections are available on the
SafeRDC box.
Overview
Fig. 2-21: Connections on the SafeRDC box (optional)
X02 Junction box on SafeRDC box

X31 Connection for data cable X21 - X31
X32 Connection for electronic measuring tool (EMT)
X40 Connection for safe inputs and outputs
X41 Connection for data cable X21.1 - X41
X42.1 Connection for reference cable X42.1 - XS Ref.1

2.14.3 Connector pin assignment of data cable X21 - X31
Description
Pin Signal designation Pin Signal designation

1 +24V_CR 10 A_FSR1 inverted
2 GND_P 11 A_FSR1
3 +24V 12 A_DR1 inverted
4 A_CLKR1 inverted 13 A_DR1
5 A_CLKR1 14 A_CLKX1 inverted
6 A_FSX1 15 A_CLKX1
7 A_FSX1 inverted 16 Coding pin or hole
8 A_DX1 17 GND_CR
9 A_DX1 inverted
2.14.4 Connector pin assignment of data cable X21.1 - X41
Description

1 TA24V(A)-ESC 10 E_T1_A_24V
2 GND ESC 11 E_T1_B_24V
3 TA24V(B)-ESC 12 COROB_EN_A_24V
4 ENA_A_24V 13 COROB_EN_B_24V
5 ENA_B_24V 14 GND_E
6 QE_A_24V 15 GND_P
7 QE_B_24V 16 Coding pin or hole
8 TA24V(B) inverted 17 Not used.
9 TA24V(A) inverted

2.14.5 Connector pin assignment of reference cable X42 - XS Ref
Description

1 /TA24V_A 4 /TA24V_B
2 E_REF_A_24V 5 E_REF_B_24V
3 GND 6 Not used.
2.14.6 Wiring diagram for 3 reference groups (optional)
Description If 3 reference groups are used, all 3 reference switches must be connected to
the SafeRDC box.
Fig. 2-22: Wiring diagram for 3 reference groups (optional)
1 SafeRDC box
2 Reference switch 3

2.15 Interface X40
Overview
Fig. 2-23: Interface X40
1 Module a (pins)
2 Module b (female contacts)
3 Module c (pins)
4 Module d (female contacts)
Module a Module a contains the safe inputs of the SafeRDC for activating the monitoring
spaces and tools.
Channels A and B of the safe inputs must have a LOW level for activating the
monitoring spaces.
Module b Module b contains the connections for the internal and external supply voltag-
es of the safe inputs and outputs.
Module c Module c contains the connections for the reduced velocity and acceleration
and the standstill monitoring.
Channels A and B of the safe inputs must have a LOW level for activating the
monitoring.
Module d Module d contains the safe outputs of the SafeRDC that can be wired exter-
nally and are only used for communication. The voltage supplied via pins b5
and b6 is present at the safe outputs.
The safe outputs have a max. load rating of 100 mA per output.

2.15.1 Connector pin allocation X40
Module a
Pin Signal designation Description
a1 E0_A_24V LOW = configured monitoring space is
activated.
HIGH = configured monitoring space is
deactivated.
Default: monitoring space 2
a2 E0_B_24V LOW = configured monitoring space is
activated.
deactivated.
activated.
deactivated.
activated.
deactivated.
activated.
deactivated.
activated.
deactivated.
activated.
deactivated.
activated.
deactivated.
a9 E4_B_24V LOW = tool 2 is activated (if tool 3 is
deactivated).
HIGH = tool 2 is deactivated.


a10 E4_A_24V LOW = tool 2 is activated (if tool 3 is
deactivated).
a11 E5_B_24V LOW = tool 3 is activated (if tool 2 is
deactivated).
a12 E5_A_24V LOW = tool 3 is activated (if tool 2 is
deactivated).
Module b Pin Signal designation Description

b1 /TA24V_A Pulsed voltage channel A for input test
Connect pin b1 via floating contacts to
channel A of the safe inputs.
b2 /TA24V_B Pulsed voltage channel B for input test
Connect pin b2 via floating contacts to
channel B of the safe inputs.
b3 GND-E Reference potential for safe inputs
Connect pin b4 to pin b3.
b4 GND-P Reference potential for safe inputs with
internal power supply
Connect pin b4 to pin b3.
b5 +24V_AUSG_A +24 V connection, channel A, for supply-
ing the safe outputs A0...A2
In the case of operation with an external
safety logic, connect pin b5 to external
+24 V.
In the case of operation without an
external safety logic, connect pin b5 to
pin b8.
If the safe outputs are routed to the safe
inputs, connect pin b5 to pin b1.
The safe outputs are pulsed.
b6 +24V_AUSG_B +24 V connection, channel B, for supply-
ing the safe outputs A0...A2
In the case of operation with an external
safety logic, connect pin b6 to external
+24 V.
In the case of operation without an
external safety logic, connect pin b6 to
pin b8.
If the safe outputs are routed to the safe
inputs, connect pin b6 to pin b3.
The safe outputs are pulsed.


b7 GND-A1 Reference potential for the safe outputs,
channels A and B
If the safe outputs A0...A2 are supplied
with the internal +24 V, connect pin b7 to
pin b9.
If the safe outputs A0...A2 are supplied
externally with internal +24 V, connect
pin b7 to the reference potential of the
external supply.
b8 +24V-P Internal +24 V supply of the SafeRDC for
the safe outputs A0...A2
The internal +24 V supply is required for
operation without an external safety
logic.
If the outputs are supplied with the inter-
nal 24 V of the SafeRDC, connect pin b8
to pin b5 and pin b6.
b9 GND-P Reference potential for the safe outputs,
channels A and B
This GND-P is required if the safe out-
puts A0...A2 are supplied with the inter-
nal +24 V of the SafeRDC.
In this case, connect pin b9 to pin b7.
b10 GND-P Reference potential for the safe outputs,
channels A and B
This GND-P is required if the safe out-
puts A0...A2 are supplied with the inter-
nal +24 V of the SafeRDC. It serves as
an additional connection for the refer-
ence potential if pin b9 is not sufficient.
In this case, connect pin b10 to pins b9
and b7.
b11 +24V_AUSG_B_2 Not used.
b12 +24V_AUSG_A_2 Not used.
Module c
c1 E6_A_24V Not used.
c2 E6_B_24V Not used.
c3 E_HALT_A_24V LOW = safe standstill monitoring is acti-
vated.
HIGH = safe standstill monitoring is
deactivated.
c4 E_HALT_B_24V LOW = safe standstill monitoring is acti-
vated.
HIGH = safe standstill monitoring is
deactivated.
c5 E_DV_A_24V LOW = reduced velocity is activated.
HIGH = reduced velocity is deactivated.


c6 E_DV_B_24V LOW = reduced velocity is activated.
HIGH = reduced velocity is deactivated.
c7 N. C. N. C.
c8 N. C. N. C.
c9 N. C. N. C.
c10 N. C. N. C.
c11 N. C. N. C.
c12 N. C. N. C.
Module d
d1 OUT_A0_A LOW = configured monitoring space has
been violated.
HIGH = configured monitoring space has
not been violated.
d2 OUT_A0_B LOW = configured monitoring space has
been violated.
not been violated.
been violated.
not been violated.
been violated.
not been violated.
been violated.
not been violated.
been violated.
not been violated.
d7 OUT_STATUS_B LOW = status is not subjected to safe
monitoring.
HIGH = status is subjected to safe moni-
toring.


d8 OUT_STATUS_A HIGH = status is subjected to safe moni-
toring.
LOW = status is not subjected to safe
monitoring.
d9 OUT_5_B Not used.
d10 OUT_5_A Not used.
d11 N. C. N. C.
d12 N. C. N. C.
2.15.2 Safe inputs
Description Monitoring functions on the SafeRDC can be activated and deactivated by

means of safe inputs. The inputs can be connected via a safety PLC or floating
contacts.
The safe inputs of the SafeRDC are of a redundant design and LOW active.
All safety functions are retained in the event of a break in the cable, a short-
circuit or a power failure and an error is detected at a safe input.
If an error occurs at a safe input, the SafeRDC triggers a STOP 0 and goes to
the state “Safety mode not possible”. The message “Failure safety input no.
XXX” appears.
Caution!
In order to allow safe retraction of the robot, the safe inputs are not subjected
to safe monitoring in T1 mode. If an error occurs at a safe input in T1 mode,
the robot is not stopped safely and there is a risk of personal injury and ma-
terial damage.
Overview
Input Description
E0_A_24V and E0_B_24V at X40
0 Configured monitoring space
4
Tool 2
5
Tool 3
E_REF_A_24V and E_REF_B_24V at X42
6
Mastering test

Input Description
7 Not used.
E_HALT_A_24V and E_HALT_B_24V at X40
8
Standstill monitoring
E_DV_A_24V and E_DV_B_24V at X40
9
Safe reduced velocity and acceleration
10 Not used.
11 Not used.
E_T1_A_24V and E_T1_B_24V at X41
12
T1 mode
Any number of the monitoring spaces 2 to 8 can be assigned to inputs 0 to 3.
Characteristics Electrical characteristics of the safe inputs:

Voltage: 24 V DC
Rated current: 3 mA (with special external circuit max. 10 mA)
Channels per safe input: 2
Check of dual-channel operation:
The 6 channels may differ within a tolerance of 2 s.
If one channel twice fails to follow the other, this is considered a dual-
channel violation.
Example: Channel A switches to HIGH then back to LOW, but channel
B remains LOW.
The signal level must change at both input channels; only then does the
SafeRDC accept the new state.
Pulse duration T(LOW) of the pulsed voltage /TA24V: 2 ms if check suc-
cessful, max. 4 ms if check fails
Pulse duration T(HIGH) of the pulsed voltage /TA24V: 330 ms
Pulse duty factor T(HIGH):T(LOW) of the pulsed voltage /TA24V: 165:1 if
check successful, max. 82.5:1 if check fails
Delay time when switching signal level:
HIGH/LOW: 5 ms
LOW/HIGH: 10 ms
2.15.3 Safe outputs
Description The safe outputs are used to signal the safety states on the SafeRDC to the
Electronic Safety Circuit (ESC) and a safety PLC:
The safe outputs of the SafeRDC are of a redundant design and LOW active.
All safety functions are retained in the event of a break in the cable, a short-
circuit or a power failure and an error is detected at a safe output.
Caution!
In order to allow safe retraction of the robot, the safe outputs are not subject-
ed to safe monitoring in T1 mode. If an error occurs at a safe output in T1
mode, the robot is not stopped safely and there is a risk of personal injury and
material damage.

If an error occurs at a safe output, the SafeRDC triggers a STOP 0 and goes
to the state “Safety mode not possible”. The message “Failure safety output
no. XXX” appears and there is a LOW level at the safe output. Once the error
has been eliminated, the message “Ackn. Enable safety output no. XXX” ap-
pears. Once the message has been acknowledged, the original signal level is
set once again at the safe output.
Overview
Output Description
OUT_A0_A and OUT_A0_B at X40
0 Configured monitoring space output 1
QE_A_24V and QE_B_24V at X41
3
Qualifying inputs (STOP 0)
ENA_A_24V and ENA_B_24V at X41
4
External E-STOP (STOP 1)
OUT_STATUS_A and OUT_STATUS_B at X40
5
Safe state
6
Not used.
Each of the outputs 0 to 2 can be assigned to one of the monitoring spaces

2 to 8.
Characteristics Electrical characteristics of the safe outputs:

Voltage: 24 V DC
Maximum load rating: 100 mA
Channels per safe output: 2
Pulse duration T(LOW) of the pulsed voltage /TA24V: 375 μs
Pulse duration T(HIGH) of the pulsed voltage /TA24V: 330 ms
Pulse duty factor T(HIGH):T(LOW) of the pulsed voltage /TA24V: 825:7


Nullserien-Dokument 3. Technical data
3 Technical data
3.1 Technical data of the SafeRDC
Designation Values
Permissible ambient transportation -25 °C to +70 °C
temperature Storage: -25 °C to +60 °C
Operation: +10 °C to +55 °C
Supply voltage DC 18 V to 33 V
Relative atmospheric Class 3K3 to EN 50178 (non-condensing)
humidity
Shock sensitivity Duration: 5 ms
Strength: 20 g
Vibration resistance Amplitude: 1 mm at ≤ 13.2 Hz
Acceleration: 0.7 g at 13.2 Hz to 100 Hz
Electromagnetic com- Immunity from interference with mains filter to
patibility (EMC) EN 61800-3
Degree of fouling Degree of fouling 2 to VDE 0110 part 2
Altitude 1000 m with no reduction in power
Protection classifica- IP 65
tion
Permissible cable With internal power supply to the safe inputs and
length for data cable outputs:
X21 - X31
7m
15 m
With external power supply to the safe inputs
and outputs:
25 m
35 m
3.2 Reference switch
Designation Values
Ambient temperature -25 °C to +70 °C
Switching function Break contact
DC operating voltage or HIGH level in the case 24 V
of pulsed operating voltage of the reference
switch
Permissible range for the DC operating voltage 20 to 33 V
or HIGH level for pulsed voltage
Required pulse duty factor T(HIGH):T(LOW) for Min. 4:1
pulsed voltage
Supported pulse duration T(LOW) for pulsed 0.1 to 20 ms
voltage
Operating current (power consumption) without 5 mA
load
Permissible load current max. 250 mA
Permissible switching frequency max. 500 Hz

Designation Values
Permissible switching distance at the proximity 0 to 4 mm
switch surfaces
Short circuit and overload protection, pulsed Yes
Outputs PNP
LOW-active
Dual-channel
LED function indicator Yes
Hysteresis when installed 0.2 to 1 mm
EMC conformity IEC 60947-5-2
3.3 Reference switch hole pattern
Description
1 2 holes for fastening elements, Ø 6.6 mm

2 2 holes for roll pins, Ø 4 mm

Nullserien-Dokument 3. Technical data
3.4 Hole pattern for actuating plate
Description
1 2 M6 threaded holes for fastening elements

2 2 holes for fastening elements, Ø 9 mm


Nullserien-Dokument 4. Safety
4 Safety
Personnel All persons working with the robot system must have read and understood
the robot system documentation, including the safety chapter.
Further information is contained in the operating and programming instruc-
tions, in the robot operating instructions and in the robot controller operating
instructions.
A KUKA.SafeOperation training course is recommended for all persons

working on the robot system.
Start-up work, maintenance and repairs may only be carried out by trained
personnel.
The safety parameters may only be set and modified by authorized per-
sonnel. No other persons may modify the safety parameters.
Robot system This robot system must be operated in accordance with the applicable na-
tional laws, regulations and standards.
The user must ensure that the system can be operated in complete safety.
The maximum permissible service life of safety-relevant hardware compo-
nents is 40 000 operating hours as counted by the operating hours meter.
The operating hours meter is running as long as the drives are under ser-
vo-control. Once this time has been reached, the safety-relevant hardware
components must be exchanged.
Decouplable axes cannot be safely monitored.
All axes configured in the machine data and contained in the first DSE can
be monitored. One DSE contains a maximum of 8 axes. External axes in
the top-mounted cabinet cannot be monitored.
The Cartesian positions and velocities at the robot tool are calculated with
robot axes A 1 to A 6. External axes are not taken into consideration.
Mastering test When a mastering test is carried out, all external axes must be switched
to synchronous.
All robot axes and all monitored external axes are included in the master-
ing test.
If the reference switch is actuated by a ferromagnetic part of the tool, the
accuracy requirements on the reference position must be met and must
not be exceeded.
(>>> 6.13 "Checking the reference position (actuation with tool)" page 87)
If the tool is exchanged, the reference position and the accuracy of the ref-
erence position must be checked.
(>>> 6.13 "Checking the reference position (actuation with tool)" page 87)
Brake test During the brake test, all activated robot axes and up to 2 external axes
are tested. All axes configured in the machine data and in the brake test
configuration and contained in the first DSE are moved.
If a brake has been identified as being defective, the parking position must
be approached with a maximum velocity of 10%.
The parameters for robot axes A 1 to A 6 are preconfigured for the brake
test and may only be modified in consultation with the KUKA Robot Group.
All external axes used must be configured for the brake test.
Cables Do not connect and disconnect cables or hoses during operation.

Only the data cables and reference cable X42 - XS Ref supplied by the
KUKA Robot Group may be used.
The data cables and reference cable X42 - XS Ref are suitable for instal-
lation in a cable carrier. The minimum bending radii must be observed
when routing cables.
Type of routing Bending radius

Fixed installation Min. 5xØ of cable
Installation in cable carrier Min. 10xØ of cable
The connectors of the data cables and reference cable X42 - XS Ref are
coded and cannot be interchanged.
Start-up Risk analysis must be carried out before start-up and after any safety-rel-
evant modification. As a minimum, the following values must be deter-
mined:
Axes that must be tested in the brake test
Brake test cycle time
Axis-specific and Cartesian limit values for the reduced velocity
Limit value for the reduced acceleration
Axis-specific and Cartesian monitoring spaces
Start-up must be carried out and checked as described in Chapter
(>>> 6 "Start-up" page 57).
Before the robot is moved, it must be ensured that the correct machine
data for the robot system have been transferred to the SafeRDC and con-
firmed.
The values in the machine data may only be modified by authorized per-
sonnel. Modifying values in the machine may deactivate monitoring func-
tions.
The password for logging onto the KUKA System Software as “Safety
Maintenance” must be changed before start-up and must only be commu-
nicated to authorized personnel.
Operation KUKA.SafeOperation may not be operated until after safety acceptance

has been carried out in accordance with the checklists in the Appendix.
The checklists must be completed fully and confirmed in writing.
If there is a LOW level at output signal OUT_STATUS, the robot system is
not subjected to safe monitoring.
If the robot violates one of the limits of monitoring spaces 6 to 8 (default
configuration), the robot continues its motion without slowing down.
If the robot is stopped by a monitoring function, it requires a certain stop-
ping distance before coming to a standstill. The stopping distance de-
pends on the robot type, the velocity of the robot, the position of the robot
axes, the payload and other parameters. The stopping distances of the ro-
bot axes are generally max. 30° and must be determined for the specific
application by means of trials. In these trials, the monitoring ranges must
be violated with the maximum load and maximum process velocity in order
to be able to determine and set the correct monitoring limits.
When the brake test is carried out, the program override is automatically
set to 100%.
If a brake is identified as being defective, the robot may sag. Slowly move
the robot to the parking position without executing any safety functions
(e.g. E-STOP, opening the safety gate, change of operating mode, etc.).
(>>> 2.10 "Brake test" page 27)

Nullserien-Dokument 4. Safety
In order to be able to carry out a cold restart in the case of a robot controller
with SafeRDC, the main switch on the robot controller must always be
switched to OFF. If the start type Cold start is selected via the menu se-
quence File > Shut down KRC, the robot controller with SafeRDC is not
reinitialized and no cold restart is carried out.
After loss of mastering (e.g. resulting from an encoder error) of the follow-
ing axes, the robot can only be moved free in T1 mode. In all other oper-
ating modes, the robot stops with a STOP 0.
Robot axes
Monitored axes
Axes subjected to standstill monitoring


Nullserien-Dokument 5. Installation
5 Installation
5.1 System requirements
Hardware KUKA robot with SafeRDC
More detailed information about the availability of robots with SafeRDC can
be obtained from the KUKA Robot Group.
KR C2 edition05 robot controller with SafeRobot option
Software KUKA System Software (KSS) 5.5

Combination with the KUKA.Servogun FC technology package is not pos-
sible.
The following KRL resources must be free:
KRL resource Number

Interrupt 19
Flag 1010
The values for the interrupt and the flag are default values and can be
modified in the brake test configuration.
5.2 Installing or updating KUKA.SafeOperation
It is advisable to archive all relevant data before updating or uninstalling a

software package.
Precondition KUKA.SafeOperation 2.0 installation CD is in the CD-ROM drive.
Procedure 1. Select the menu sequence Setup > Install Additional Software.
2. Press the New SW softkey. If a software package on the CD-ROM in the
drive is not yet displayed, press the Refresh softkey.
3. Select the software to be installed and press the softkey Install. Answer
the request for confirmation with Yes. The files are copied onto the hard
drive.
4. If another additional software package is to be installed, repeat step 3.
5. Depending on the specific additional software, it may be necessary to re-
boot the controller. In this case, a corresponding message will be dis-
played. Confirm with OK and restart the robot controller. The installation is
resumed and completed.
LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.
5.3 Uninstalling KUKA.SafeOperation
It is advisable to archive all relevant data before updating or uninstalling a

software package.
Precondition KUKA.SafeOperation 2.0 is installed.

Procedure 1. Select the menu sequence Setup > Install Additional Software. All in-
stalled additional programs are displayed.
2. Select the software to be uninstalled and press the softkey Uninstall. An-
swer the request for confirmation with Yes. Uninstallation is prepared.
3. Reboot the robot controller. Uninstallation is resumed and completed.
LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.

Nullserien-Dokument 6. Start-up
6 Start-up
6.1 Start-up overview
Overview Step Description

Install reference switch and actuating plate.
1 (>>> 6.2 "Installing the reference switch and actuating plate"
page 58)
Exchange lid of SafeRDC box (if 3 reference groups are used).
2
(>>> 6.3 "Exchanging the lid of the SafeRDC box" page 59)
Connect the connecting cables.
3
(>>> 6.4 "Connecting the connecting cables" page 60)
Connect safety PLC (if a safety PLC is used).
4
(>>> 6.5 "Connecting the Safety PLC" page 61)
5 Master the robot.
Assign input and output signals.
6
(>>> 6.6 "Assigning input and output signals" page 61)
Define monitoring spaces.
7
(>>> 6.7 "Defining monitoring spaces" page 62)
Define tools.
8
(>>> 6.8 "Defining tools" page 69)
Define reference position.
9
(>>> 6.9 "Defining the reference position" page 72)
Set safety parameters via the tree structure in the configuration
10 window.
(>>> 6.10 "Safety parameters" page 74)
Assign external axes to the reference group (if external axes
are being used).
11
(>>> 6.11 "Assigning external axes to the reference group"
page 85)
Program mastering test.
12
(>>> 6.12 "Programming the mastering test" page 86)
Check reference position (if the reference switch is actuated by
the tool).
13
(>>> 6.13 "Checking the reference position (actuation with
tool)" page 87)
Perform mastering test.
14
(>>> 6.14 "Performing a mastering test manually" page 87)
Define brake test.
15
Program brake test.
16
(>>> 6.16 "Programming the brake test" page 92)

Step Description
Perform brake test.
17
(>>> 6.17 "Performing a manual brake test" page 93)
Carry out safety acceptance.
18 (>>> 6.18 "Safety acceptance of KUKA.SafeOperation"
page 93)
Danger!
The robot is not subjected to safe monitoring during start-up and can cause
personal injury or material damage. Only move the robot in T1 mode during
start-up.
Exception: Perform brake test (>>> 6.17 "Performing a manual brake test"
page 93).
6.2 Installing the reference switch and actuating plate
Precondition The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
A tool must be mounted on the mounting flange.
For axes A 1 to A 6, the axis-specific coordinates of the reference position
must be at least 5° away from the mastering position.
The reference position must not result in a singularity of the robot.
The reference position must be situated within the motion range of the ro-
bot.
The installation position of the reference switch must not hinder the work
sequence of the robot.
Procedure 1. Prepare a mechanical mounting fixture for mounting the reference switch.
(>>> 3.3 "Reference switch hole pattern" page 48)
2. Attach the reference switch to the mounting fixture.
3. If the actuating plate is being used, fasten the actuating plate to the tool.
The mounting position of the actuating plate depends on the specific tool
that is mounted.
4. If more than one reference group is being used, repeat steps 1 to 3 for
each additional reference group.

Example
Fig. 6-1: Example of an actuating plate mounted on the tool
1 Robot
2 Actuating plate mounted on the tool
3 Tool
6.3 Exchanging the lid of the SafeRDC box
Precondition 3 reference groups are being used.

The robot controller must be switched off and secured to prevent unau-
The SafeRDC and I/O Print boards must be protected against static
charge.
Procedure 1. Unscrew the 4 screws on the lid of the SafeRDC box.

Fig. 6-2: Screws on the lid of the SafeRDC box
2. Carefully open the lid of the SafeRDC box forwards.

3. Unscrew the 4 screws on the lid hinge.
4. Carefully remove the lid of the SafeRDC box.
5. Fit the lid with 3 reference switches on the SafeRDC box and screw it firmly
in place with 4 screws on the lid hinge.
6. Connect and route electrical installations X904 - X902. Connect X904 to
the SafeRDC box and X902 to the lid.
7. Carefully close the lid of the SafeRDC box.
8. Screw the lid firmly in place using the 4 screws on the housing.
6.4 Connecting the connecting cables
The reference switch must be installed.
Danger!
The robot controller is preconfigured for specific robots. If cables are inter-
changed, the robot may receive incorrect data and can thus cause personal
injury or material damage. If a system consists of more than one robot, al-
ways connect the connecting cables to the robots and their corresponding ro-
bot controllers.
Procedure 1. Connect and route data cable X21 - X31. Connect X21 to the robot con-
troller and X31 to the SafeRDC box.
2. Connect and route data cable X21.1 - X41. Connect X21.1 to the robot
controller and X41 to the SafeRDC box.
3. Connect and route reference cable X42 - XS Ref. Connect X42 to the Saf-
eRDC box and XS Ref to the reference switch.
Alternatively, connect and route 3 reference cables X42.1 - XS Ref.1,
X42.2 - XS Ref.2 and X42.3 - XS Ref.3. Connect X42.X to the SafeRDC
box and XS Ref.X to the reference switch.

6.5 Connecting the Safety PLC
Description The safety PLC must be connected to interface X40 via a safe field bus mod-
ule and optocoupler.
Preconditions for the safe outputs of the safe field bus module:
Channel A of the safe outputs at the safe field bus module is HIGH-active.
Channel B of the safe outputs at the safe field bus module is LOW-active.
Fig. 6-3: Connecting the safety PLC
1 Optocoupler
2 Safe field bus module
3 Safe field bus system
4 Safety PLC
6.6 Assigning input and output signals
Description All signals are declared in the file $MACHINE.DAT in the directory
C:\KRC\ROBOTER\KRC\STEU\MADA.
Caution!
These signals are not redundant in design and can supply incorrect informa-
tion. Do not use these signals for safety-relevant applications.
By default, the input signals are routed to $IN[1026]. The output signals are
preset to FALSE and must be assigned to an output. The output signals can-
not be used until they have been assigned to an output.
If the output signals are not assigned to outputs, the mastering test and brake
test cannot be performed.
(>>> 9.2 "Signals for the mastering test" page 101)
(>>> 9.5 "Signals for the brake test" page 104)
All system variables are listed in Chapter (>>> 9 "System variables"

page 101).

Example $MACHINE.DAT file without comments:

&PARAM VERSION=6.0.1
DEFDAT $MACHINE PUBLIC
CHAR $V_STEUMADA[32]
$V_STEUMADA[]="V6.0.1/KUKA5.4"
SIGNAL $MASTERINGTEST_REQ_EX $IN[1]
SIGNAL $BRAKETEST_REQ_EX $IN[2]
SIGNAL $MASTERINGTEST_REQ_INT $OUT[1]
SIGNAL $MASTERINGTESTSWITCH_OK $OUT[2]
SIGNAL $BRAKETEST_REQ_INT $OUT[3]
ENDDAT
6.7 Defining monitoring spaces
Precondition The monitoring spaces may only be defined or modified by authorized per-
sonnel.
User group “Safety maintenance”
Operating mode T1
Procedure 1. Select the menu sequence Setup > Service > Safe Robot > Configura-
tion. The data are loaded.
2. Select safety parameter Monitoring Spaces.
3. Press the Properties softkey.
4. Select the monitoring space by pressing the softkeys Space + and Space
-.
5. Enter the name of the monitoring space. The name is saved in
KUKA_CON.MDB.
The maximum length of the text is 24 characters.
6. Enter parameters.
Fig. 6-4: Defining monitoring spaces

Parameter Description
Type Protected space = monitoring space is a pro-
tected space
Working space = monitoring space is a work-
space
Default: Working space
Definition Cartesian = monitoring space is Cartesian.
Axis specific = monitoring space is axis-spe-
cific.
Default: Cartesian
Digital input Permanent active = monitoring space is moni-
tored.
Permanent inactive = monitoring space is not
monitored.
Input triggered = monitoring space can be acti-
vated via inputs 0 to 3 at X40
Default monitoring space 2: can be activated via
input 0
input 1
input 2
input 3
Default monitoring spaces 6 to 8: permanently
active
Digital output No output = no output is assigned to the moni-
toring space.
0 = output 0 at X40 is assigned to the monitoring
space.
space.
space.
Default monitoring spaces 2 to 5: no output
Default monitoring space 6: 0
V max Cartesian velocity limit value
Range of values: 5 ... 10,000 mm/s
Default: 10,000 mm/s
V max valid in Working Space = Cartesian velocity is moni-
tored inside the monitoring space.
Protected Space = Cartesian velocity is moni-
tored outside the monitoring space.
Default: Working Space

Stop at boundaries TRUE = robot stops if the monitoring space limits
are exceeded.
FALSE = robot does not stop if the monitoring
space limits are exceeded.
Default monitoring spaces 2 to 5: TRUE
Default monitoring spaces 6 to 8: FALSE
Stop before reaching TRUE = robot stops before touching the monitor-
boundaries ing space limits.
FALSE = robot does not stop before the monitor-
ing space limits.
Default: FALSE
Stop if mastering test TRUE = reference stop is activated for the moni-
not yet done toring space.
FALSE = reference stop is deactivated for the
monitoring space.
Default: TRUE
6.7.1 Defining a cell area
sonnel.
Operating mode T1
The cell area has been selected.
Procedure 1. Press the Properties softkey.

2. Under Represented in $ROBROOT and Tool no, select the number of
the current TOOL coordinate system in the KUKA System Software.
Variable: TOOL_DATA[1…16]
Range of values: 1...16
3. Move the robot to one corner of the cell area.
4. Press the Touch Up softkey and confirm the message.
5. Press the Activate or Deactivate softkey to activate or deactivate the in-
dividual corners.
There must be at least 3 corners activated.
6. Press the Node + softkey.

7. Repeat steps 3 to 6 to define further corners.
The corners form a convex polygon.
8. Close the configuration window and save the changes. The data are
saved.
Only values indicated in red will be applied and saved.

Fig. 6-5: Defining a cell area
ing space limits.
Default: FALSE
X X coordinate of corner 1 to 6 relative to the ROB-
ROOT coordinate system in mm
(X coordinate)
Range of values: -30,000 … +30,000 mm
Default corner 1 or 4: +10,000 mm
Default corner 2 or 3: -10,000 mm
Default corner 5 or 6: 0 mm
Y Y coordinate of corner 1 to 6 relative to the ROB-
(Y coordinate)
Active TRUE = corner of cell area is activated.
(node activated) FALSE = corner of cell area is not activated.
Default corner 1 to 4: TRUE
Default corner 5 to 6: FALSE
6.7.2 Defining axis-specific monitoring spaces
sonnel.


An axis-specific monitoring space has been selected.
Axis-specific jogging
Operating mode T1

2. Move the selected axis to the upper axis limit.
3. Press the Touch-Up up. softkey and confirm the message.
4. Move the selected axis to the lower axis limit.
5. Press the Touch-Up low. softkey and confirm the message.
6. Press the Axis + softkey.
7. Repeat steps 2 to 6 to define the axis ranges for further axes.
saved.
Fig. 6-6: Defining axis-specific monitoring spaces

Lower limit The lower limit of an axis-specific workspace
must be at least 0.5° or 1.5 mm less than the
(lower axis limit)
upper limit.
The lower limit of an axis-specific safeguarded
zone must be at least 5° or 15 mm less than the
upper limit.
Range of values for rotational axes:
-360° ... +360°
Range of values for linear axes:
-30,000 to +30,000 mm
Default value for rotational axes: -180°
Default value for linear axes: -10,000 mm
Upper bound The upper limit of an axis-specific workspace
must be at least 0.5° or 1.5 mm greater than the
(upper axis limit)
lower limit.
The upper limit of an axis-specific safeguarded
zone must be at least 5° or 15 mm greater than
the lower limit.
-360° ... +360°
-30,000 to +30,000 mm
Default value for rotational axes: 180°
Default value for linear axes: 10,000 mm
6.7.3 Defining Cartesian monitoring spaces
sonnel.
Operating mode T1
A Cartesian monitoring space has been selected.

2. Under Represented in $ROBROOT and Tool no, select the number of
the current TOOL coordinate system in the KUKA System Software.
Variable: TOOL_DATA[1…16]
Range of values: 1...16
3. Move robot to auxiliary point A.
4. Press the Touch-Up A softkey and confirm the message.
5. Move robot to auxiliary point B.
6. Press the Touch-Up B softkey and confirm the message.
7. Auxiliary points A and B are used to form a cuboid. The data for the cuboid
are calculated and displayed.
saved.

Fig. 6-7: Defining Cartesian monitoring spaces
The taught auxiliary points A and B are defined relative to the current TOOL
coordinate system and converted into the safety parameters contained in the
following table.
Origin X, Y, Z Origin X, Y and Z of the Cartesian monitoring
space relative to the ROBROOT coordinate sys-
tem in mm
Default: 0 mm
Origin A, B, C Origin A, B and C of the Cartesian monitoring
tem cannot be configured.
Default: 0°

Point X1 Dimension of the Cartesian monitoring space to
the origin in mm
X coordinate,
Y coordinate, The limits of the Cartesian monitoring space
Z coordinate depend on the global velocity. A defined mini-
mum size of the cuboid is derived from the global
velocity; the size of the cuboid must not fall
below this value. If this minimum value is vio-
lated, a message appears.
Range of values: -30,000 … 30,000 mm
Default: -500 mm
the origin in mm
X coordinate,
Default: 500 mm
Example A Cartesian monitoring space can be defined in one of 2 ways.
Fig. 6-8: Example: Defining a Cartesian monitoring space
1 Teach 2 auxiliary points to define the monitoring space

Calculate the Cartesian position of the origin and distances in the X,
2
Y, and Z directions to define the monitoring space
6.8 Defining tools
Precondition The tools may only be defined or modified by authorized personnel.

Operating mode T1
Procedure Defining properties of the tools

1. Select the menu sequence Setup > Service > Safe Robot > Configura-
2. Select safety parameter Tools.
3. Press the Properties softkey.

4. Select the tool by pressing the softkeys Tool - and Tool +.

5. Enter the name of the tool. The name is saved in KUKA_CON.MDB.
Tool 0 has the name Default. This name cannot be changed.
The maximum length of the text is 24 characters.
Fig. 6-9: Defining properties of the tools
Safe input The parameter is only displayed in the tree struc-
ture.
The input cannot be configured.
-1 = tool 0 (default) is not assigned to an input.
4 = tool 1 can be activated via input 4 at X40.
TCP X, Y, Z X, Y and Z coordinates of the TCP relative to the
velocity monitoring
(TCP X coordinate,
TCP Y coordinate, Default: 0 mm
TCP Z coordinate)

Sphere 1 X, Y, Z X, Y and Z coordinates of the sphere center
points at the tool relative to the FLANGE coordi-
Sphere 2 X, Y, Z
nate system
(Sphere center point X
Range of values: -30,000 to 30,000 mm
coordinate,
sphere center point Y Default: 0 mm
coordinate,
sphere center point Z
coordinate)
Radius Radius of the spheres at the tool in mm
The radius is dependent on the global velocity. A
defined minimum value for the radius is derived
from the global velocity; the radius must not be
less than this value. If this minimum value is vio-
Range of values: 0 to 30,000 mm
Default: 500 mm
Procedure Defining load data of the tools

1. Press the Load data softkey.
2. Select the tool by pressing the softkeys Tool - and Tool +.
saved.
Fig. 6-10: Defining load data of the tools

Payload mass (M) Mass of the tool in kg
The range of values depends on the type of
robot used. A violation of these values will be
displayed in the message window.
Default: 0.01 kg
Payload centre of Center of gravity of the tool in mm and °
mass (CM)
X, Y, Z robot used. A violation of these values will be
A, B, C
Default X, Y, Z: 0 mm
Default A, B, C: 0°
Inertia of payload (J) Principal moments of inertia of the tool in kgm2
X, Y, Z The range of values depends on the type of
Default: 0 kgm2
6.9 Defining the reference position
Precondition The reference position may only be defined or modified by authorized per-
sonnel.
Operating mode T1
Procedure 1. Move robot to the reference position.

3. Press the softkey Ref. Pos..
4. Press the Touch-Up softkey to accept the current position of the robot as
the reference position.
saved.

Fig. 6-11: Defining the reference position
Axis number Indicates the status of the axes.
Minimum distance between the current posi-
tion of the axis and the mastering position is
maintained.
Minimum distance between the current posi-
tion of the axis and the mastering position is not
maintained.
Axis is not configured or is not monitored.
If this icon appears, the minimum axis dis-

tance between the reference position and the
mastering position has not been maintained.
Reference group Each configured axis must be assigned to a ref-
erence group.
ence groups.
Reference position To monitor the mastering, the axis angles of all
robot axes are defined for a specific reference
position. At defined time intervals, the robot
moves to this position and a comparison is made
between the setpoint position and the actual
position on the SafeRDC.
Range of values for rotational axes =
-360° to +360°
Range of values for translational axes =
-30,000 mm to +30,000 mm
Current position Contains the axis-specific actual position of the
axes.

Master position The axis angles at the mastering position are
permanently defined.
Min. distance For every axis, the reference position must be at
least a defined minimum distance away from the
mastering position.
Minimum value for rotational axes = 5°
Minimum value for translational axes = 15 mm
6.10 Safety parameters
Description The safety parameters contain all the values and settings for the robot with
safe monitoring. The safety parameters are displayed as a tree structure in the
configuration window.
Safety parameters Description

General information Display only
(>>> 6.10.2 "Parameters – General
information" page 76)
Monitored axes Configurable
(>>> 6.10.3 "Parameters – Moni-
tored axes" page 76)
Reduced axis velocity Configurable
(>>> 6.10.4 "Parameters –
Reduced axis velocity" page 76)
Cartesian velocity Configurable
(>>> 6.10.5 "Parameters – Carte-
sian velocity" page 77)
Reduced axis acceleration Configurable
(>>> 6.10.6 "Parameters –
Reduced axis acceleration"
page 77)
Monitoring spaces Configurable
toring Spaces" page 78)
Tools Configurable
(>>> 6.10.8 "Parameters – Tools"
page 82)
Monitoring of mastering Configurable
toring of mastering" page 83)
Standstill monitoring Configurable
(>>> 6.10.10 "Parameters – Stand-
still monitoring" page 84)
Interfaces Configurable
(>>> 6.10.11 "Parameters – Inter-
faces" page 84)

Safety parameters Description

Machine data ($robcor.dat) Display only
(>>> 6.10.12 "Parameters –
Machine data ($ROBCOR.DAT)"
page 84)
Machine data ($machine.dat) Display only
(>>> 6.10.13 "Parameters –
Machine data ($MACHINE.DAT)"
page 85)
6.10.1 Setting safety parameters
Precondition The safety parameters may only be defined or modified by authorized per-
sonnel.
Operating mode T1
2. In the tree structure in the configuration window, open the desired safety
parameter and enter or select the values.
3. Press the Enter key.
4. For all further relevant parameters and sub-entries, repeat steps 2 and 3.
5. Close the configuration window and save the changes.
Fig. 6-12: Safety parameters

6.10.2 Parameters – General information
Description Contains the version of the configuration file and the time stamp indicating
when the safety parameters were last saved.
Time stamp Date and time parameters last saved
Version Version of the configuration file with the safety
parameters
6.10.3 Parameters – Monitored axes
Description Axes 1 to 8 can be activated individually. An activated axis is monitored in all

monitoring spaces. An axis that is not being monitored is crossed out in the
display.
STOP 0.
Safe axis monitoring TRUE = axis is monitored.
FALSE = axis is not monitored.
Default for robot axes: TRUE
Default for external axes: FALSE
6.10.4 Parameters – Reduced axis velocity
Description Freely selectable limits can be defined for the axis velocity of axes 1 to 8.
Axis velocity Axis velocity limit value that can be activated by
means of the safe input “Safe reduced velocity”.
Range of values for rotational axes: 0.5 to 1000°/
s
Range of values for linear axes: 1.5 to 3000 mm/
s
Default value for rotational axes: 100°/s
Default value for linear axes: 100 mm/s
Axis velocity for T1 Axis velocity limit value for T1 mode
Range of values for rotational axes: 0.5 to 1000°/
s
Range of values for linear axes: 1.5 to 3000 mm/
s
Default value for rotational axes: 100°/s
Default value for linear axes: 100 mm/s
The monitoring depends on the mode that has been set and the signal level
at the safe input.
(>>> 2.15.2 "Safe inputs" page 43)

6.10.5 Parameters – Cartesian velocity
Description Freely selectable limits can be defined for the Cartesian velocity of the tool.
The reference point is the TCP of the current tool configured in the configura-
tion window.
The size of the cuboids and spheres of the Cartesian monitoring spaces de-
pends on the global velocity. The smaller the cuboids and spheres are mod-
eled, the lower the limit of the global velocity must be configured.
Global velocity Cartesian velocity limit value
Range of values: 5 to 10,000 mm/s
Reduced velocity Limit value that can be activated for the velocity
at the tool by means of the safe input “Safe
reduced velocity”
Range of values: 5 to 10,000 mm/s
Reduced velocity in T1 Velocity limit value for T1 mode
Range of values: 5 to 250 mm/s
Default: 250 mm/s
6.10.6 Parameters – Reduced axis acceleration
Description Freely selectable limits can be defined for the axis acceleration of axes 1 to 8.
Axis acceleration can only be monitored if reduced velocity is active.
The value for the reduced axis acceleration can be modified in order, for ex-
ample, to carry out a risk analysis for special applications.
Axis acceleration Axis acceleration limit value that can be acti-
vated by means of the safe input “Safe reduced
velocity”.
Range of values for rotational axes: 25 to
15,000°/s²
Range of values for linear axes: 75 to 15,000
mm/s²
Default value for rotational axes:
200°/s²
Default value for linear axes: 200 mm/s²
Axis acceleration for Axis acceleration limit value for T1 mode
T1
Range of values for rotational axes: 25 to
15,000°/s²
Range of values for linear axes: 75 to 15,000
mm/s²
Default value for rotational axes:
200°/s²
Default value for linear axes: 200 mm/s²

Monitoring axis accel- TRUE = axis acceleration can be activated by
eration means of the safe input “Safe reduced velocity”.
FALSE = axis acceleration cannot be activated.
Monitoring axis accel- TRUE = axis acceleration is monitored in T1
eration for T1 mode.
FALSE = axis acceleration is not monitored in T1
mode.
at the safe input.
6.10.7 Parameters – Monitoring Spaces
Description Monitoring space 1: cell area

The cell area is a Cartesian workspace in the form of a convex polygon with 3
to 6 corners. A maximum of 6 corners can be defined, each with an X and Y
coordinate. The Z coordinate of the corners is not limited. There must be at
least 3 corners activated.
The coordinates of the cell area can be taught.
(>>> 6.7.1 "Defining a cell area" page 64)
ing space limits.
Default: FALSE
X X coordinate of corner 1 to 6 relative to the ROB-
(X coordinate)
Y Y coordinate of corner 1 to 6 relative to the ROB-
(Y coordinate)
Active TRUE = corner of cell area is activated.
(node activated) FALSE = corner of cell area is not activated.
Default corner 1 to 4: TRUE
Default corner 5 to 6: FALSE

The parameters and values of axes 1 to 8 can be defined for each axis-specific
monitoring space. The parameters and values of the cuboids can be defined
for each Cartesian monitoring space.
The coordinates of the monitoring spaces can be taught.
Type Protected space = monitoring space is a pro-
tected space
Working space = monitoring space is a work-
space
Default: Working space
Definition Cartesian = monitoring space is Cartesian.
Axis specific = monitoring space is axis-spe-
cific.
Default: Cartesian
Digital input Permanent active = monitoring space is moni-
tored.
Permanent inactive = monitoring space is not
monitored.
Input triggered = monitoring space can be acti-
vated via inputs 0 to 3 at X40
input 0
input 1
input 2
input 3
Default monitoring spaces 6 to 8: permanently
active
Digital output No output = no output is assigned to the moni-
toring space.
space.
space.
space.
Default monitoring spaces 2 to 5: no output
V max Cartesian velocity limit value
Range of values: 5 ... 10,000 mm/s

V max valid in Working Space = Cartesian velocity is moni-
tored inside the monitoring space.
Protected Space = Cartesian velocity is moni-
tored outside the monitoring space.
Default: Working Space
Stop at boundaries TRUE = robot stops if the monitoring space limits
are exceeded.
FALSE = robot does not stop if the monitoring
space limits are exceeded.
Default monitoring spaces 2 to 5: TRUE
Default monitoring spaces 6 to 8: FALSE
ing space limits.
Default: FALSE
Stop if mastering test TRUE = reference stop is activated for the moni-
not yet done toring space.
FALSE = reference stop is deactivated for the
monitoring space.
Default: TRUE
Cartesian monitoring space:
Origin X, Y, Z Origin X, Y and Z of the Cartesian monitoring
tem in mm
Default: 0 mm
Origin A, B, C Origin A, B and C of the Cartesian monitoring
tem cannot be configured.
Default: 0°

the origin in mm
X coordinate,
Default: -500 mm
the origin in mm
X coordinate,
Default: 500 mm
Axis-specific monitoring space:
Lower limit The lower limit of an axis-specific workspace
must be at least 0.5° or 1.5 mm less than the
(lower axis limit)
upper limit.
The lower limit of an axis-specific safeguarded
zone must be at least 5° or 15 mm less than the
upper limit.
-360° ... +360°
-30,000 to +30,000 mm
Default value for rotational axes: -180°
Default value for linear axes: -10,000 mm
Upper bound The upper limit of an axis-specific workspace
must be at least 0.5° or 1.5 mm greater than the
(upper axis limit)
lower limit.
The upper limit of an axis-specific safeguarded
zone must be at least 5° or 15 mm greater than
the lower limit.
-360° ... +360°
-30,000 to +30,000 mm
Default value for rotational axes: 180°
Default value for linear axes: 10,000 mm

at the safe input.
6.10.8 Parameters – Tools
Description 3 tools can be defined. Tool 1 is set by default. 2 spheres are defined about
each tool; these are monitored against the configured limits of the monitoring
spaces. A TCP is defined for each of the tools 1 to 3 and monitored against
the configured velocity limits.
The values for the tools can be taught.
(>>> 6.8 "Defining tools" page 69)
Properties of the tools
Safe input The parameter is only displayed in the tree struc-
ture.
The input cannot be configured.
-1 = tool 0 (default) is not assigned to an input.
TCP X, Y, Z X, Y and Z coordinates of the TCP relative to the
velocity monitoring
(TCP X coordinate,
TCP Y coordinate, Default: 0 mm
TCP Z coordinate)
Sphere 1 X, Y, Z X, Y and Z coordinates of the sphere center
points at the tool relative to the FLANGE coordi-
Sphere 2 X, Y, Z
nate system
(Sphere center point X
Range of values: -30,000 to 30,000 mm
coordinate,
sphere center point Y Default: 0 mm
coordinate,
sphere center point Z
coordinate)
Radius Radius of the spheres at the tool in mm
The radius is dependent on the global velocity. A
defined minimum value for the radius is derived
from the global velocity; the radius must not be
less than this value. If this minimum value is vio-
Range of values: 0 to 30,000 mm
Default: 500 mm
Payload properties of the tools

Payload mass (M) Mass of the tool in kg
Default: 0.01 kg
Payload centre of Center of gravity of the tool in mm and °
mass (CM)
X, Y, Z robot used. A violation of these values will be
A, B, C
Default X, Y, Z: 0 mm
Default A, B, C: 0°
Inertia of payload (J) Principal moments of inertia of the tool in kgm2
X, Y, Z The range of values depends on the type of
Default: 0 kgm2
6.10.9 Parameters – Monitoring of mastering
Description The Cartesian and axis-specific coordinates of the reference position are de-
fined for the mastering monitoring. The Cartesian coordinates refer to the cent-
er point of the mounting flange.
The axes required for moving to a reference position are listed in a reference
group. These reference positions contain the coordinates of all axes. During a
mastering test, only the axes of a reference group may be situated in their ref-
erence position, otherwise there is a risk of the mastering test being falsified.
The coordinates of the reference position can be taught.
Cartesian position X X, Y and Z coordinates of the reference position
relative to the ROBROOT coordinate system
Cartesian position Y
Cartesian position Z
Reference position Contains the axis-specific coordinates of the ref-
erence position
Reference group Each configured axis must be assigned to a ref-
erence group.
ence groups.
A maximum of 3 reference groups can be cre-
ated.

6.10.10 Parameters – Standstill monitoring
Description The robot is at a monitored standstill, but may nonetheless move within the pa-
rameterized axis angle or distance tolerances. If the limit is exceeded or the
velocity is increased minimally, the robot is stopped by the SafeRDC.
The axis angle or distance tolerance can be activated and configured individ-
ually for axes 1 to 8. The axes that are activated in the case of standstill mon-
itoring are independent of the axes that are activated in the safety parameter
Monitored axes.
STOP 0.
Axis angle tolerance Limit value for the axis angle or distance toler-
ance of the standstill monitoring that can be acti-
vated by means of the safe input “Standstill
monitoring”.
Range of values for rotational axes: 0.001 to 1°
Range of values for linear axes: 0.003 to 3 mm
Default value for rotational axes: 0.01°
Default value for linear axes: 0.01 mm
Monitored for standstill TRUE = axis is monitored for standstill
FALSE = axis is not monitored for standstill
Default for robot axes: TRUE
Default for external axes: FALSE
at the safe input.
6.10.11 Parameters – Interfaces
Description The input test pulse must be activated in the configuration window for testing
the dual-channel operation of the safe inputs.
Warning!
The input test pulse must not be deactivated. If the input test pulse is deacti-
vated, the inputs are not pulsed and the robot is not in a safe state. This can
result in personal injury or material damage.
Input test pulse TRUE = input test pulse is activated.
FALSE = input test pulse is deactivated.
6.10.12 Parameters – Machine data ($ROBCOR.DAT)
Description The machine data in $ROBCOR.DAT that are displayed are for internal pur-
poses and make it possible to check the geometry of the robot used.

Fig. 6-13: Machine data ($ROBCOR.DAT)
6.10.13 Parameters – Machine data ($MACHINE.DAT)
Description The sub-entries in the safety parameter “Machine data ($MACHINE.DAT)” are
described in the KR C2 machine data documentation.
Fig. 6-14: Machine data ($MACHINE.DAT)
6.11 Assigning external axes to the reference group
Description Each axis that is to be subjected to safe monitoring must be assigned to a ref-
erence group.

All robot axes are assigned to reference group 1. External axes can be as-
signed to other reference groups.
Precondition The external axes may only be assigned to the reference group by author-
ized personnel.
Operating mode T1
2. In the tree structure in the configuration window, open the safety parame-
ter Monitoring of mastering.
3. Under Axis 7, in the box Reference group, enter the number for the ref-
erence group that is to be assigned to axis 7.
A maximum of 3 reference groups can be created.
5. To assign a second external axis to a reference group, open Axis 8 and

enter, in the box Reference group, the number for the reference group
that is to be assigned to axis 8.
7. Close the configuration window and save the changes.
6.12 Programming the mastering test
Precondition The mastering test may only be programmed by authorized personnel.

Reference switch is installed and connected.
Operating mode T1
Procedure 1. Open the program MasRefStart.SRC in the directory C:\KRC\ROBOT-

ER\KRC\R1\TP\SAFEROBOT.
2. Program a motion to a point approx. 10 cm before the reference switch
and teach the required points.
3. Program a LIN motion to the reference switch so that it is actuated. This
position is the reference position.
The distance from the supplied reference switch must not exceed 2 mm. If
the distance is greater, the reference switch will not be actuated.
4. Teach reference position in the program MasRefStart.SRC.

5. Do not move the robot.
6. Close and save the program MasRefStart.SRC.
7. Define the reference position in the configuration window.
8. Open the program MasRefBack.SRC.
9. Program the motion to the end position of the mastering test and teach the
required points.

10. Close and save the program MasRefBack.SRC.

11. Integrate the program MasRefReq.SRC in the application and run it, at the
latest, 2 hours after the internal request.
6.13 Checking the reference position (actuation with tool)
Precondition The accuracy of the mastering test may only be checked by authorized
personnel.
Reference switch is installed and connected.
The reference position has been taught in the program MasRefStart.SRC
and in the configuration window.
Axis-specific jogging
Operating mode T1
Procedure 1. Select the program MasRefStart.SRC in the directory C:\KRC\ROBOT-

2. Move to reference position.
Warning!
The robot can collide at the reference position and cause material damage.
The axes that are to be checked must only be moved in the directions in
which no collision is possible.
3. All axes subjected to safe monitoring must be moved in the positive and
negative directions until the reference switch is no longer actuated.
The maximum values by which the axes may deviate from the reference
position are as follows:
Maximum permissible tolerance per

Type of axis
axis
Robot axes A 1 to A 3 ±1.5°
Robot axes A 4 to A 6 ±3.0°
Linear axis ±10 mm
4. If a safely monitored axis has a greater deviation, the reference position

must be corrected.
Warning!
The robot can move beyond the configured limits and cause personal injury
or material damage if the accuracy requirements on the reference position
are not met. Check the tolerance of the reference position for each safely
monitored axis where this is possible without collision. If the reference posi-
tion tolerances are exceeded, a different reference position must be select-
ed.
6.14 Performing a mastering test manually
Precondition The reference switch is installed and connected.

The reference position has been taught in the program MasRefStart.SRC
and in the configuration window.
The connecting cables are connected.

All output signals are assigned to outputs.

(>>> 9.2 "Signals for the mastering test" page 101)
Operating mode T1 or T2.
Danger!
The robot moves in T2 mode at the programmed velocity and can cause per-
sonal injury or material damage. Make sure that the robot cannot collide and
that no persons are in the motion range of the robot.
Procedure 1. Select the program MasRefReq.SRC in the directory C:\KRC\ROBOT-

2. Execute the program MasRefReq.SRC to the end of the program.
If the actuating plate is actuated, the reference position must be reached
within 3 seconds. If the actuating plate is moved away from the reference po-
sition again, the actuated range must be exited within 3 seconds.
6.15 Defining the brake test
Precondition The brake test may only be defined or modified by authorized personnel.
User group “Expert”, “Administrator” or “Safety maintenance”
Operating mode T1
Procedure 1. Select the menu sequence Setup > Service > Brake Test Configuration.
The data are loaded.
3. Select the Robot Axis tab, using the Tab - and Tab + softkeys, and enter
the parameters.
(>>> 6.15.1 "Defining robot axes for the brake test" page 90)
4. If external axes are used, select the External Axis 1 and External Axis 2
tabs, using the Tab - and Tab + softkeys, and enter the parameters.
(>>> 6.15.2 "Defining external axes for the brake test" page 91)
5. Press the Close softkey to save the configuration.
6. Perform brake test.

Fig. 6-15: Defining the brake test
Movement Stop Flag Flag for the brake test.
The configured flag must not be used for any
other application in the KUKA System Software.
Range of values: 1 to 1024
Default: 1010
Movement Stop Inter- Priority of the interrupt for the brake test.
rupt
The configured interrupt must not be used for
any other application in the KUKA System Soft-
ware.
Range of values: 1, 2, 4 … 39 and 81 … 128
Default: 19
Brake Test Cycle Time INT value for the brake test cycle time in hours.
Default: 46
Remaining Time INT value for the remaining brake test cycle time
in hours.

6.15.1 Defining robot axes for the brake test
Description
Fig. 6-16: Defining robot axes for the brake test
Brake Test Axis 1 to 6 Check box active: test brake of axis 1 to 6
Check box not active: do not test brake of axis
1 to 6
Maximum Traverse INT value for the motion range of axis 1 to 6 dur-
Angle A1 to 6 ing the brake test.
The rotational axes are preconfigured to ±10° for
the brake test and cannot be modified.
Range of values for translational axes =
2 to 100 mm
Default: 10 mm

6.15.2 Defining external axes for the brake test
Description
Fig. 6-17: Defining external axes for the brake test
Brake Test Check box active: test brake of external axis
Check box not active: do not test brake of
external axis
Maximum Traverse INT value for the motion range of the external
Angle axis during the brake test.
Range of values: 2 to 100 mm or °
Default: 15 mm or °
Minimal Torsion FLOAT value with 2 decimal places for the hold-
Moment ing torque of the brake.
This is the minimum value that must be reached
in the brake test. If this value is not reached, the
brake is identified as being defective.
Set the parameter with the value from the motor
data sheet for the holding torque of the brake.
Range of values: 1.00 to 500.00 Nm
Default: 1.00 Nm

Current Limiting Dur- Value for limiting the maximum current of the
ing Test brake.
The value is only taken into consideration if auto-
matic motor current calculation is deactivated.
If the brake test is not carried out successfully
with automatic current limitation, set the parame-
ters to the lowest values with which the brake
test can still be carried out successfully. To do
so, reduce the values gradually and carry out the
brake test.
Automatic Motor Cur- Current limitation to protect the brake. The brake
rent Calculation is thus loaded in a targeted manner in the brake
test.
On = current is automatically limited.
Off = current is limited to the configured brake
test current limitation value.
Default: On
6.16 Programming the brake test
Precondition The brake test may only be programmed by authorized personnel.

The connecting cables are connected.
All output signals are assigned to outputs.
(>>> 9.5 "Signals for the brake test" page 104)
Brake test has been defined.
Operating mode T1
Procedure 1. Open the program BrakeTestStart.SRC in the directory C:\KRC\ROBOT-

2. Program the motion to the start position of the brake test and teach the re-
quired points.
3. Close and save program.
4. Open the program BrakeTestEnd.SRC in the directory C:\KRC\ROBOT-
5. Program the motion to the end position of the brake test and teach the re-
quired points.
The start and end position of the brake test can be identical.

7. Open the program BrakeTestPark.SRC in the directory C:\KRC\ROBOT-
8. Program the motion to the parking position of the robot and teach the re-
quired points.

10. Integrate the program BrakeTestReq.SRC in the application and run it, at
the latest, 2 hours after an internal request.
6.17 Performing a manual brake test
Precondition It must be ensured that no persons or objects are present within the motion
range of the robot.
The parking position is taught in the program BrakeTestPark.SRC.
(>>> 6.16 "Programming the brake test" page 92)
The safe inputs for the standstill monitoring and the safe reduced velocity
must be wired.
(>>> 14.1 "Interface X40 circuit example 1" page 137)
Operating mode T2
Procedure 1. Select the program BrakeTestReq.SRC in the directory C:\KRC\ROBOT-

Danger!
Program override is automatically set to 100%. The robot moves at high
speed and can cause personal injury or material damage. Make sure that the
robot cannot collide and that no persons are in the motion range of the robot.
2. Execute the program BrakeTestReq.SRC to the end of the program.

3. If a brake is identified as being defective, a dialog message appears.
Press the Repeat softkey to repeat the brake test.
Press the Park pos. softkey to move the robot to the parking position.
Warning!
If a brake has been identified as being defective, the drives remain under ser-
vo-control for 2 hours following the start of the brake test (monitoring time).
Once this time has elapsed, the drives are deactivated.
6.18 Safety acceptance of KUKA.SafeOperation
Description Following start-up, the acceptance procedures for KUKA.SafeOperation must

be carried out in accordance with the checklists in the Appendix. For success-
ful safety acceptance, the points in the checklists must be completed fully and
confirmed in writing. KUKA.SafeOperation must not be put into operation until
the safety acceptance procedure has been completed successfully.
The safety acceptance checklists must also be completed fully and confirmed
in writing in the following cases:
After reinstallation
After maintenance work
After a change to the robot system
After exchanging safety-relevant components
The safety acceptance checklists can be found in the Appendix of this docu-
mentation:
Checklist for robot and system
(>>> 14.4.1 "Checklist for robot and system" page 140)
Checklist for safe functions
(>>> 14.4.2 "Checklist for safe functions" page 141)
Checklist for velocity limits
(>>> 14.4.3 "Checklist for velocity limits" page 143)

Checklist for reduced accelerations

(>>> 14.4.4 "Checklist for reduced accelerations" page 145)
Checklist for standstill monitoring
(>>> 14.4.5 "Checklist for standstill monitoring" page 146)
Checklist for configuration of the cell area
(>>> 14.4.6 "Checklist for configuration of the cell area" page 148)
Checklist for configuration of axis-specific monitoring spaces
(>>> 14.4.7 "Checklist for configuration of axis-specific monitoring spac-
es" page 149)
Checklist for configuration of Cartesian monitoring spaces
(>>> 14.4.8 "Checklist for configuration of Cartesian monitoring spaces"
page 152)
Checklist for configuration of the tools
(>>> 14.4.9 "Checklist for configuration of the tools" page 154)
The completed checklists, confirmed in writing, must be kept as documentary

evidence.

Nullserien-Dokument 7. Programming
7 Programming
7.1 Programs for the mastering test
Description The programs for the mastering test are located in the directory C:\KRC\RO-
BOTER\KRC\R1\TP\SAFEROBOT.
The following programs are required for the mastering test:
Program Description
MasRefReq.SRC The program checks whether a mastering test is
required and must be executed, at the latest, 2
hours after an internal request. If the program is
not executed within 2 hours, the robot stops and
the robot controller generates a message.
If a mastering test is required, the robot performs
it immediately.
MasRefStart.SRC The program contains the reference position of
the robot.
MasRefBack.SRC The program contains the end position of the
robot. The robot moves to this position after the
mastering test.
If the end position is not taught, the robot
remains at the actual position after the mastering
test and the robot controller generates an error
message.
7.2 Programs for the brake test
Description The programs for the brake test are located in the directory C:\KRC\ROBOT-
The following programs are required for the brake test:
Program Description
BrakeTestReq.SRC The program checks whether a brake test is
required and must be executed, at the latest, 2
hours after an internal request. If the program is
not executed within 2 hours, the robot stops and
the robot controller generates a message.
If a brake test is required, the robot performs it
immediately.
BrakeTestPark.SRC The program contains the parking position of the
robot, to which the robot moves if a brake is
identified as being defective.

Program Description
BrakeTestStart.SRC The program contains the start position of the
brake test. The robot starts the brake test from
this position.
If the start position is not taught, the robot per-
forms the brake test at the actual position.
BrakeTestBack.SRC The program contains the end position of the
brake test. The robot moves to this position after
the brake test.
If the end position is not taught, the robot
remains at the actual position after the brake
test.

Nullserien-Dokument 8. Operation
8 Operation
8.1 Displaying safety parameters
Precondition No program is selected.
2. Open the desired safety parameters in the tree structure in order to display
the sub-entries, parameters and values.
3. To display the cell area, select the safety parameter Monitoring Spaces
> Cell Area and press the Properties softkey.
4. To display the monitoring spaces, select the safety parameter Monitoring
Spaces and press the Properties softkey.
5. To display the tools, select the safety parameter Tools and press the
Properties softkey.
6. Press the Properties softkey to display the coordinates of the reference
position.
Fig. 8-1: Safety parameters
8.2 Verifying safety parameters
Description During verification of the safety parameters, the consistency of the following
data is checked:
Machine data
Safety parameters in the configuration file on the hard drive
Safety parameters on the SafeRDC
During verification of the data, the safe output OUT_STATUS is set to LOW.
If, before verification, the safe output OUT_STATUS was HIGH, it is reset to
HIGH once the data verification has been successfully completed. The config-
uration window cannot be opened during the verification.

Procedure 1. Select the menu sequence Setup > Service > Safe Robot > Examina-
tion. The data are verified.
2. If the verification was successful and the message “Ackn. Invalid configu-
ration on SafeRDC” appears, acknowledge the message.
3. If the verification was unsuccessful, various data can be accepted.
(>>> 10.2 "Messages during verification of the safety parameters"
page 113)
8.3 Reading the operating hours meter
The operating hours meter is running as long as the drives are switched on.
Procedure 1. Select the menu sequence Help > Info.

2. Open the Robot tab.
3. The parameter Robot runtime indicates the operating hours of the robot.
Alternatively, the operating hours meter can also be displayed via the varia-
ble $ROBRUNTIME.
8.4 Archiving safety parameters
Voraussetzung Storage medium is present.

User group "Safety maintenance"
Directory set in KRC Configurator.
Further information is contained in the operating and programming instruc-

tions.
Procedure 1. Select the menu sequence File > Archive > Configuration > SafeRobot.
2. Confirm the message by pressing the Yes softkey. The safety parameters
are saved in the file KUKASafeRobot.CONFIG in the directory that has
been set.
The file has a digital signature and must not be manipulated.
8.5 Importing safety parameters
Precondition No program may be selected.
2. Press the Import softkey.
All the configuration files saved as .xml files in the configured directory are
displayed.
The directory is configured in the file SafeRobotParam.DLL.SafeRobotPar-

am.Config.CFG in the directory C:\KRC\HMI\CONFIG\SAVE.
3. Select the configuration file by pressing the File - and File + softkeys.

Nullserien-Dokument 8. Operation
4. Press the Import softkey and confirm the message with Yes. The config-
uration file is loaded.
Once the configuration file has been successfully imported, the old and new
values are listed for all safety parameters. The safety parameters that have
changed are indicated in red. If no safety parameters have changed, a mes-
sage is generated.
5. Check the safety parameters and confirm the message with Yes. The con-
figuration file is imported.
Fig. 8-2: Importing safety parameters
8.6 Restoring safety parameters
Precondition Safety parameters have been archived.

The configuration file containing the safety parameters has not been ma-
nipulated.
The storage medium containing the archived safety parameters is present.
Procedure 1. Select the menu sequence File > Restore > Configuration > SafeRobot.
2. Confirm the message by pressing the Yes softkey. The configuration file
containing the safety parameters is copied to the hard drive.
4. If the safety parameters in the configuration file are not identical to the
safety parameters on the SafeRDC, the following selection appears:
Softkey Description
Hard disk The safety parameters from the restored con-
figuration file are transferred to the SafeRDC.
RDC The current safety parameters from the Safe-
RDC are transferred to the configuration file.


Nullserien-Dokument 9. System variables
9 System variables
9.1 Signal declarations
Description All signals are declared in the file $MACHINE.DAT in the directory
Caution!
These signals are not redundant in design and can supply incorrect informa-
tion. Do not use these signals for safety-relevant applications.
By default, the input signals are routed to $IN[1026]. The output signals are
preset to FALSE and must be assigned to an output. The output signals can-
not be used until they have been assigned to an output.
The maximum number of available inputs and outputs is dependent on the

system variable $SET_IO_SIZE in the file $OPTION.DAT in the directory
9.2 Signals for the mastering test
Signal Description Range of values I/O

$MASTERINGTEST_ TRUE = robot was stopped due to TRUE|FALSE O
MONTIME elapsed monitoring time.
FALSE = monitoring time has not yet
elapsed.
$MASTERINGTEST_OK TRUE = mastering test has been TRUE|FALSE O
performed successfully.
FALSE = mastering test has not
been performed successfully.
$MASTERINGTEST_ TRUE = mastering test is being TRUE|FALSE I
REQ_EX requested externally and is to be
started (e.g. by Safety PLC).
FALSE = mastering test is not being
requested.
$MASTERINGTEST_ TRUE = robot controller is internally TRUE|FALSE O
REQ_INT requesting a mastering test.
FALSE = robot controller is not
requesting a mastering test.
$MASTERINGTEST_WORK TRUE = mastering test is being per- TRUE|FALSE O
formed.
FALSE = mastering test is not being
performed.
$MASTERINGTEST TRUE = no reference switch mal- TRUE|FALSE O
SWITCH_OK function.
FALSE = reference switch malfunc-
tion.

9.3 Signals for diagnosis

$SR_RANGE1_OK TRUE = monitoring space 1 has not TRUE|FALSE O
been violated.
FALSE = monitoring space 1 has
been violated.
been violated.
been violated.
been violated.
been violated.
been violated.
been violated.
been violated.
been violated.
been violated.
been violated.
been violated.
been violated.
been violated.
been violated.
$SR_RANGEINPUT1_ACTI TRUE = all monitoring spaces TRUE|FALSE O
VE assigned to input E0 are activated
and monitored.
FALSE = all monitoring spaces
assigned to input E0 are deactivated
and are not monitored.
and monitored.


and monitored.
and monitored.
$SR_TOOL1_ACTIVE TRUE = tool 1 is activated and moni- TRUE|FALSE O
tored.
FALSE = tool 1 is not monitored.
tored.
tored.
9.4 Robot status signals

$SR_AXISACC_OK TRUE = reduced axis acceleration TRUE|FALSE O
has not been exceeded.
FALSE = reduced axis acceleration
has been exceeded.
$SR_AXISSPEED_OK TRUE = reduced axis velocity has TRUE|FALSE O
not been exceeded.
FALSE = reduced axis velocity has
been exceeded.
$SR_CARTSPEED_OK TRUE = Cartesian velocity has not TRUE|FALSE O
been exceeded.
FALSE = Cartesian velocity has
been exceeded.
$SR_SAFEMON_ACTIVE TRUE = safe robot monitoring is TRUE|FALSE O
activated.
FALSE = safe robot monitoring is not
activated.
$SR_SAFEOPSTOP_ACTI TRUE = standstill monitoring is mon- TRUE|FALSE O
VE itored.
FALSE = standstill monitoring is not
monitored.
$SR_SAFEOPSTOP_OK TRUE = standstill monitoring has not TRUE|FALSE O
been violated.
FALSE = standstill monitoring has
been violated.


$SR_REDSPEED_ TRUE = the velocities and accelera- TRUE|FALSE O
ACTIVE tions are monitored.
FALSE = the velocities and accelera-
tions are not monitored.
$SR_STOP0 TRUE = robot has been stopped TRUE|FALSE O
with a STOP 0.
FALSE = robot has not been
stopped with a STOP 0.
with a STOP 1.
with a STOP 2.
9.5 Signals for the brake test

$BRAKES_OK TRUE = all brakes are OK. TRUE|FALSE O
FALSE = at least one brake is defec-
tive.
$BRAKETEST_MONTIME TRUE = robot was stopped due to TRUE|FALSE O
elapsed monitoring time.
FALSE = monitoring time has not yet
elapsed.
$BRAKETEST_REQ_EX TRUE = brake test is being TRUE|FALSE I
requested externally and is to be
started (e.g. by Safety PLC).
FALSE = brake test is not being
requested externally.
$BRAKETEST_REQ_INT TRUE = robot controller is internally TRUE|FALSE O
requesting a brake test.
FALSE = robot controller is not
requesting a brake test.
$BRAKETEST_WARN TRUE = at least one brake has TRUE|FALSE O
reached the wear limit.
FALSE = all brakes are OK.
$BRAKETEST_WORK TRUE = brake test is being per- TRUE|FALSE O
formed.
FALSE = brake test is not being per-
formed.

Variable Description Range of values

$BRAKETEST_ INT value for the brake test cycle 1 to 46
CYCLETIME time in hours.
Default: 46
$BRAKETEST_ INT value for the remaining brake 1 to 46
TIMER test cycle time in hours.
9.6 Variables for override reduction
Description The variables for override reduction can be modified in the $CUSTOM.DAT file
in the directory C:\KRC\ROBOTER\KRC\STEU\MADA, in a KRL program or
via the menu sequence Monitor > Variable > Single. If a variable is modified,
an advance run stop is triggered.
Variable Description Range of values

$SR_OV_MSG_SHOW System variable is set to default TRUE|FALSE
value after every cold restart.
Default: FALSE
TRUE = a message is generated in
Automatic mode if the velocity is
reduced by means of the override
reduction function.
FALSE = no message is generated
in Automatic mode if the velocity is
reduced by means of the override
reduction function.
$SR_OV_RED Maximum velocity limit with override 10 to 95%
reduction activated for the velocity.
Default: 95%
The value is a percentage and refers
to the lowest activated velocity limit.
$SR_TIME_N The variable is declared in 0.0 to 1.0
$MACHINE.DAT and may only be
Default: 0.1
modified in consultation with the
KUKA Robot Group.
Safety factor of the override reduc-
tion function for monitoring spaces.
0.1 = 10% safety factor
$SR_VEL_RED TRUE = override reduction is acti- TRUE|FALSE
vated for the velocity.
Default: TRUE
FALSE = override reduction is not
activated for the velocity.
$SR_WORKSPACE_RED TRUE = override reduction is acti- TRUE|FALSE
vated for all activated monitoring
Default: TRUE
spaces.
FALSE = override reduction is not
activated for monitoring spaces.


Nullserien-Dokument 10. Messages
10 Messages
10.1 Messages during operation
Configuration or operator errors may result in error messages in an applica-

tion.
No. Message Cause Remedy

390 Mastering test required Robot is unmastered. Perform mastering test.
Robot controller has been
rebooted.
391 Mastering test failed The spatial position of the 1. Teach reference posi-
robot and/or the external tion in the program Mas-
axes has changed. RefStart.SRC.
The actuating plate is too 2. Select the menu se-
far from the reference quence Setup > Serv-
switch. The distance ice > Safe Robot >
between the actuating plate Configuration.
and the reference switch 3. Press the softkey Ref.
must not exceed 2 mm. Pos..
4. Press the Touch Up
softkey and confirm the
message. The actual
position is applied as the
reference position.
5. Perform mastering test.
Robot stops at the refer- 1. Open MasRefBack.src.
ence position and the refer- 2. Teach end point of the
ence switch has been robot.
actuated for too long.
External axes are safely Assign external axes to the
monitored, but are assigned reference group.
to the wrong reference
group or no reference group
at all.
392 Monitoring range no. XXX The limit of monitoring 1. Perform safe retraction
exceeded. space XXX has been of the robot in operating
exceeded. mode T1.
2. Check the configuration
of the monitoring space
and adapt if required.
Deactivate monitoring
space XXX.
393 Safety position violated. The robot has exceeded the 1. Perform safe retraction
limit of the axis angle or dis- of the robot in operating
tance tolerance or the mode T1.
velocity has been minimally 2. Check the configuration
increased. of the standstill monitor-
ing and adapt if re-
quired.
Deactivate standstill moni-
toring.
The robot started moving Check motion program and
erroneously. adapt if required.


394 Safety parameters incor- At least one safety parame- 1. Open the configuration
rect XXX ter in the configuration win- window.
dow is incorrect. 2. Verify the correctness of
the safety parameters.
397 Assertion failed: XXX A serious exceptional error Cold start of the robot con-
has occurred. troller. If the message is still
present after the cold start,
contact the KUKA Robot
Group.
401 SafeRDC system error Error in cross comparison 1. Check inputs/outputs
3000. and eliminate error.
SafeRDC system error 2. Verify the safety param-
3001. eters.
SafeRDC system error 3. Master the robot.
3002.
4. Reboot robot controller
and force a cold restart.
5. If the error persists, ex-
change the SafeRDC
board.
SafeRDC system error XXX All other system errors are 1. Reboot robot controller
due to a faulty SafeRDC and force a cold restart.
board. 2. If the error persists, ex-
change the SafeRDC
board.
3. Reconfigure robot sys-
tem or restore archived
safety parameters.
404 EMERGENCY STOP safety The SafeRDC has caused This message is always
controller an EMERGENCY STOP. generated together with at
least one other message.
Observe the other mes-
sages to eliminate the fault.
411 Safety mode not possible Safety parameters are not Check safety parameters.
confirmed.
SafeRDC is not correctly Check SafeRDC.
initialized or is not running
without errors.
Mastering test was not suc- Perform mastering test.
cessful or referencing is not
current.
Safe inputs and outputs are Check wiring and eliminate
not free from errors. fault and/or exchange Safe-
RDC board.
414 Error while starting the The SafeRDC was not cor- 1. Reboot robot controller
SafeRDC rectly booted. and force a cold restart.
change the SafeRDC
board.


437 Calibration reference switch The reference switch and/or 1. Inspect reference switch
defect the reference cable X42 - and/or reference cable
XS Ref is defective. visually for damage.
2. Check whether the ref-
erence switch is actuat-
ed during the mastering
test.
change the reference
switch and/or reference
cable X42 - XS Ref.
440 SafeRDC memory failure in Memory area XXX of the 1. Reboot robot controller
area XXX SafeRDC is defective. and force a cold restart.
change the SafeRDC
board.
3. Reconfigure robot sys-
tem or restore archived
safety parameters.
441 Invalid configuration on At least one safety parame- 1. Open the configuration
SafeRDC ter in the configuration win- window.
dow is incorrect. 2. Verify the correctness of
the safety parameters.
442 Encoder failure monitored The encoder cable from the Exchange the encoder
resolver channel XXX on affected motor to the Safe- cable from the affected
SafeRDC. RDC is defective. motor to the SafeRDC.
Resolver is defective. Exchanging the motor.
443 Failure safety input no. XXX I/O Print board is faulty. 1. Reboot robot controller
2. If the error persists, shut
down the robot control-
ler and exchange the I/O
Print board.
SafeRDC board is faulty. 1. Reboot robot controller
ler and exchange the
SafeRDC board.
Defective wiring 1. Reboot robot controller
Short-circuit and force a cold restart.
Open circuit 2. Check wiring of safe in-
Cross-connection put/output XXX and
eliminate error.


444 Failure safety output no. I/O Print board is faulty. 1. Reboot robot controller
XXX and force a cold restart.
Print board.
SafeRDC board.
eliminate error.
449 Monitoring range no. XXX Monitoring space XXX has 1. Perform safe retraction
violated. been violated. of the robot in operating
mode T1.
space XXX.
460 More than one tool acti- 2 tools are being activated 1. Check safe inputs E4
vated on the SafeRDC. simultaneously via safe and E5.
inputs E4 and E5 at X40. 2. Activate current tool and
deactivate tool that is
not being used.
467 Kernel system and Safe- There are different versions For (65,XXX):
RDC version do not fit in the KUKA System Soft-
(XXX, XXX) ware XXX and in the Safe-
RDC XXX.
2. If the error persists, rein-
stall the KUKA System
Software.
3. If the error persists, rein-
stall KUKA.SafeOpera-
tion.
For (2,3):
SafeRDC board.


468 SafeRDW with different There are different firmware 1. Reboot robot controller
software versions versions running on side A and force a cold restart.
and side B of the SafeRDC. 2. If the error persists, rein-
stall KUKA.SafeOpera-
tion.
SafeRDC board.
470 Safe robot override reduc- Override reduction is acti-
---
tion active vated.
2981 Maximum acceleration of The maximum axis acceler- 1. Check the configuration
XXX exceeded ation of axis XXX has been of the axis acceleration
exceeded. and adapt if required.
2. Acknowledge message.
2983 Maximum speed of XXX The maximum axis velocity 1. Check the configuration
exceeded of axis XXX has been of the axis velocity and
exceeded. adapt if required.
1. Deactivate axis velocity.
2986 Maximum safe reduced car- The Cartesian velocity at 1. Check the configuration
tesian speed exceeded the flange center point has of the Cartesian velocity
been exceeded. and adapt if required.
1. Deactivate Cartesian
velocity.
2991 Stop by violated Safety The robot has exceeded the 1. Perform safe retraction
position. standstill monitoring limit of the robot in operating
and stops. mode T1.
of the standstill monitor-
ing and adapt if re-
quired.
1. Deactivate standstill
monitoring.
The robot started moving Check motion program and
erroneously. adapt if required.
3052 Stop before monitoring The modeled spheres on 1. Perform safe retraction
range no. XXX was violated the tool have reached the of the robot in operating
limit of monitoring space mode T1.
XXX and the robot stops. 2. Check the configuration
space XXX.
Deactivate “Stop before
reaching boundaries”.


3056 Cyclic check of request for Mastering test not per- 1. Acknowledge message.
calibration not done. formed within 2 hours of the 2. Perform mastering test.
request.
3060 Stop by failure safety input I/O Print board is faulty. 1. Reboot robot controller
no. XXX and force a cold restart.
Print board.
SafeRDC board.
eliminate error.
3061 Stop by failure safety output I/O Print board is faulty. 1. Reboot robot controller
no. XXX and force a cold restart.
Print board.
SafeRDC board.
eliminate error.
3067 Stop by violated monitoring The modeled spheres on 1. Perform safe retraction
range no. XXX the tool have exceeded the of the robot in operating
limit of monitoring space mode T1.
XXX and the robot stops. 2. Check the configuration
1. Deactivate monitoring
space XXX.


3072 Stop by more than one Several tools are active 1. Check the configuration
active tool on the SafeRDC. simultaneously and the of the tools and adapt if
robot stops. required. Only one tool
may be activated.
2. Check wiring and elimi-
nate any faults.
3081 Maximum global cartesian The robot has exceeded the 1. Check the configuration
speed limit exceeded maximum global Cartesian of the Cartesian velocity
velocity. and adapt if required.
3082 Maximum cartesian speed The robot has exceeded the 1. Check the configuration
limit in T1-mode exceeded maximum Cartesian veloc- of the Cartesian velocity
ity in T1 mode. and adapt if required.
3083 Maximum cartesian speed The robot has exceeded the 1. Check the configuration
limit for monitoring range maximum Cartesian veloc- of the Cartesian velocity
no. XXX exceeded ity of the monitoring space. and adapt if required.
3088 Ackn. Enable safety output If there is an error at an out- Acknowledge message.
no. XXX put, the output must be re-
enabled once the error has
been eliminated.
3100 Ackn. stop because of a Error in cross comparison in 1. Acknowledge message.
cross compare error T1 mode. 2. Perform safe retraction
of the robot in operating
mode T1.
10.2 Messages during verification of the safety parameters

tion.


103 All data sources are differ- All data are inconsistent. 1. Select the menu se-
ent (XML, RDC and quence Setup > Serv-
machine data). ice > Safe Robot >
Configuration. The
data are loaded.
2. Press the RDC softkey
to accept the data from
the SafeRDC or the
Hard disk softkey to ac-
cept the data from the
.xml file.
3. Press the Machine data
softkey to accept the
data from the machine
data.
105 Difference between XML The safety parameters in 1. Select the menu se-
and RDC data. the .xml file on the hard quence Setup > Serv-
drive do not match those on ice > Safe Robot >
the SafeRDC. Configuration. The
data are loaded.
the SafeRDC or the
.xml file.
114 Difference between XML The machine data do not 1. Select the menu se-
and RDC data and between match the data in the .xml quence Setup > Serv-
XML and machine data. file and the data on the Saf- ice > Safe Robot >
eRDC. Configuration.
2. Press the Machine data
softkey to accept the
data from the machine
data.
119 Nonexistent or invalid con- The safety parameters in 1. Select the menu se-
figuration file. the .xml file on the hard quence Setup > Serv-
drive do not match those on ice > Safe Robot >
the SafeRDC. Configuration. The
data are loaded.
the SafeRDC or the
.xml file.
The .xml file containing the 1. Select the menu se-
safety parameters is not quence Setup > Serv-
present. ice > Safe Robot >
Configuration. The
data are loaded.
the SafeRDC.

10.3 Messages for the brake test

tion.

27001 Brake XXX reached the The brake of the axis XXX Perform brake test.
wear barrier. will soon be identified as
The brake of axis XXX must
defective.
soon be exchanged.
27002 Cyclic check for the brake- Brake test cycle time 1. Acknowledge message.
test requirement not per- elapsed. 2. Perform brake test.
formed.
No brake test performed
within 2 hours of the
request.
rebooted.
No brake test performed
within 2 hours of the
request.
27004 Brake test required Brake test cycle time Perform brake test.
elapsed.
rebooted.
27007 Brake test failed XXX The brake on axis XXX has 1. Perform brake test.
insufficient braking torque. 2. Exchange the motor of
axis XXX.
27010 Evaluation brake XXX failed Calculation of the brake test Perform brake test.
was incorrect.
27011 Braketest for brake XXX not Brake test for brake XXX Perform brake test.
completed. was not completed or was
completed with errors.
27014 Holding torque for axis XXX No holding torques have 1. Load the correct $ROB-
not available been stored for this robot in COR.DAT file.
$ROBCOR.DAT. 2. Contact KUKA Service.
27015 Axis XXX not configured in A brake is to be tested that Check and adapt
R1/$machine.dat has not been configured in $MACHINE.DAT and the
$MACHINE.DAT for any brake test configuration.
axis.
27016 Fault by reading the An error occurred when 1. Open the brake test
BrakeTestDrv.ini reading BrakeTestDrv.ini. configuration and check
the parameters.
2. Contact KUKA Service.
--- Maximum motion of axis During the brake test, the 1. Open configuration and
XXX exceeded robot exceeded the maxi- increase motion range
mum motion range of axis of the axis.
XXX. 2. Perform brake test.
3. Contact KUKA Service.


Nullserien-Dokument 11. Diagnosis
11 Diagnosis
11.1 Opening diagnosis
Precondition All output signals are assigned to outputs.

(>>> 9.3 "Signals for diagnosis" page 102)
Procedure 1. Select the menu sequence Monitor > Diagnosis > Safe Robot. The di-
agnostic window opens.
2. Press the Spaces softkey to display detailed information about the moni-
toring spaces.
3. Press the Inputs softkey to display detailed information about the safe in-
puts.
4. Press the Outputs softkey to display detailed information about the safe
outputs.
5. Diagnosis can be closed at any time using the Close softkey.
11.2 Overview of diagnosis
Overview
Fig. 11-1: Overview of diagnosis
Description The following information can be displayed in the diagnosis:

Status of the monitoring spaces
No monitoring space is violated.
At least one monitoring space is active and violated.
(>>> 11.3 "Detailed information about the monitoring spaces" page 118)
Status of the safe inputs
There are no errors at any input.
There is an error at at least one input.
(>>> 11.4 "Detailed information about the safe inputs" page 122)

Status of the safe outputs

There are no errors at any output.
There is an error at at least one output.
(>>> 11.5 "Detailed information about the safe outputs" page 123)
In order for the information to be displayed correctly in the diagnosis, the out-
put signals must be assigned to outputs.
(>>> 9.3 "Signals for diagnosis" page 102)
11.3 Detailed information about the monitoring spaces
Overview
Fig. 11-2: Diagnosis: Monitoring spaces
Description The status of all monitoring spaces is displayed in the overview.
No. Description
1 Status of the monitoring spaces:
Monitoring space is active and not violated.
Monitoring space is active and violated.
Monitoring space is not active.

No. Description
2 Description of the monitoring space:
Number and name of the selected monitoring space
Type of monitoring space:
Workspace
Protected space
Activation of the monitoring space:
Can be activated via inputs 0 to 3
Permanently active
Permanently deactivated
3 Detailed information about the monitoring space:
Cell area
(>>> 11.3.1 "Detailed information about the cell area"
page 119)
Axis-specific monitoring space
(>>> 11.3.2 "Detailed information about the axis-specific
monitoring space" page 120)
Cartesian monitoring space
(>>> 11.3.3 "Detailed information about the Cartesian mon-
itoring space" page 121)
It is possible to change monitoring space using the softkeys Space - and

Space +.
11.3.1 Detailed information about the cell area
Overview
Fig. 11-3: Diagnosis: Cell area
Description The following detailed information about the selected monitoring space is dis-
played:

Configured polygon
Configured spheres of the active tool
If no tool is activated, the TCP on the mounting flange of the robot is dis-
played.
11.3.2 Detailed information about the axis-specific monitoring space
Overview
Fig. 11-4: Diagnosis: Axis-specific monitoring space
played:
Status of the axis ranges:
The axis is monitored and is located inside the configured axis range.
The axis is monitored and is located outside the configured axis range.
Axis is not monitored or is not configured.
Lower limit of the axis range
Current position of the axis
Upper limit of the axis range

11.3.3 Detailed information about the Cartesian monitoring space
Overview
Fig. 11-5: Diagnosis: Cartesian monitoring space
played:
Configured cuboid as working space or protected space
Configured spheres of the active tool
If no tool is activated, the TCP on the mounting flange of the robot is dis-
played.
Different views of the Cartesian monitoring space can be displayed:
XY plane
YZ plane
XZ plane
The XY, YZ and XZ softkeys can be used to switch between the different
views.

11.4 Detailed information about the safe inputs
Overview
Fig. 11-6: Diagnosis: Safe inputs
Description The following information about the safe inputs is displayed:
No. Description
1 Status of the safe inputs:
There are no errors at any input.
There is an error at at least one input.
2 Description of the safe input:
Number and name of the selected safe input
3 Detailed information about the safe input
The following detailed information about the selected safe input is displayed:
Error Error at the safe input

No error at the safe input
Level RDC HIGH level from channel A/B at input of SafeRDC
LOW level from channel A/B at input of SafeRDC
Level SW HIGH level from channel A/B after cross comparison
LOW level from channel A/B after cross comparison
Pulse Error Error at channel A/B during pulsing
No error at channel A/B during pulsing
Redun- Dual-channel violation at channel A/B
dancy
No dual-channel violation at channel A/B
Toggle Channel A/B toggles
Channel A/B does not toggle

It is possible to switch between the safe inputs using the softkeys Input - and
Input +.
The Reset softkey deletes the error marker for dual-channel violations that
have been eliminated.
11.5 Detailed information about the safe outputs
Overview
Fig. 11-7: Diagnosis: Safe outputs
Description The following information about the safe outputs is displayed:
No. Description
1 Status of the safe outputs:
Output is not violated.
Output is violated.
2 Description of the safe output:
Number and name of the selected safe output
3 Detailed information about the safe output
The following detailed information about the selected safe output is displayed:
Error Error at the safe output

No error at the safe output
Level RDC HIGH level from channel A/B at output of SafeRDC
LOW level from channel A/B at output of SafeRDC
Level SW HIGH level from channel A/B before cross comparison
LOW level from channel A/B before cross comparison
Pulse Error Error at channel A/B during pulsing with 0
High
No error at channel A/B during pulsing with 0

Pulse Error Error at channel A/B during pulsing with 1

Low
No error at channel A/B during pulsing with 1
Redun- Dual-channel violation at channel A/B
dancy
No dual-channel violation at channel A/B
Loopback Error at loopback input at channel A/B
No error at loopback input at channel A/B
Approved No error and output is not disabled
Error and output is disabled
It is possible to switch between the safe outputs using the softkeys Output -
and Output +.

Nullserien-Dokument 12. Troubleshooting
12 Troubleshooting
12.1 LEDs on the SafeRDC board
If the LEDs indicate faulty operation, reboot the robot controller and force a
cold start. If the error persists, exchange the SafeRDC board.
Description
Fig. 12-1: LEDs on the SafeRDC board
Item Designation Color Description

1 H1700 Red LED for self-test of the SafeRDC, channel B
During boot-up of the SafeRDC board
On = Faulty operation
Off = Normal operation
Flashing = Faulty operation
After boot-up of the SafeRDC board
Off = Faulty operation
Flashing = Normal operation
2 H1701 Green LED for self-test of the SafeRDC, channel B
On = Normal operation
3 H1702 Green Not used.
4 H1502 Green Busy LED, channel B


5 H1501 Green Status LED, channel B
6 H1500 Green Operation LED, channel B
Flashing = Normal operation (software running)
7 H1402 Green Busy LED, channel A
8 H1401 Green Status LED, channel A
9 H1400 Green Operation LED, channel A


10 H1800 Red LED for self-test of the SafeRDC, channel A
11 H1801 Green LED for self-test of the SafeRDC, channel A
12 H2100 Green On = HIGH level at output QE_A_24V
Off = LOW level at output QE_A_24V
13 H2101 Green On = HIGH level at output ENA_A_24V
On = LOW level at output ENA_A_24V
14 H2102 Green On = HIGH level at output QE_B_24V
Off = LOW level at output QE_B_24V
15 H2103 Green On = HIGH level at output ENA_B_24V
Off = LOW level at output ENA_B_24V

12.2 LEDs on the I/O Print board
Description
Fig. 12-2: LEDs on the I/O Print board

3 H703 Green On = HIGH level at OUT_STATUS_B
Off = LOW level at OUT_STATUS_B
4 H702 Green On = HIGH level at OUT_A2_B
Off = LOW level at OUT_A2_B
7 H701 Green On = HIGH level at OUT_STATUS_A
Off = LOW level at OUT_STATUS_A
8 H600 Green On = HIGH level at OUT_A0_A
Off = LOW level at OUT_A0_A
11 H1 Green On = Pulsed voltage /TA24V_A present
Off = Pulsed voltage /TA24V_A not present
12 H2 Green On = Pulsed voltage /TA24V_B present
Off = Pulsed voltage /TA24V_B not present
12.3 Results of the brake test
Description When a brake test is carried out, the following information is saved in the file
BrakeTest.LOG, in the directory C:\KRC\ROBOTER\LOG:
Date and time at start and end of the brake test

Configured minimum holding torque of the brakes of all axes to be tested

Total number of axes to be tested
Axis velocity determined for all axes tested
The value is a percentage and refers to the rated speed.
Configured motion range of all axes tested
Start and end position determined for all axes tested
Safety factor determined for the holding torque of the brakes of all axes
tested
1.1 = 110 % holding torque = 10 % safety factor
Minimum holding torque determined for the brakes of all axes tested
Results for all axes tested and result of the brake test


Nullserien-Dokument 13. Repair
13 Repair
13.1 Connections on the SafeRDC board
Description
Fig. 13-1: Connections on SafeRDC board
Item Designation Description

1 X2000 Connection for I/O Print expansion board
2 X1900 Not used.
3 X1700 Not used.
4 X1500 Not used.
5 X901 Connection of safe inputs and outputs to the
ESC circuit
6 X1600 Not used.
7 X1800 Not used.
8 X900 SSI interface A to first DSE
9 X1000 Not used.
10 X9 Connection for RoboTeam lamp
11 X1...X8 Connections for resolvers (X1 for resolver of axis
1)
12 X1200 Connection for external sensor 1
Not supported
Not supported
Not supported
Not supported
16 X1204 Slot for sensor module 1
Not supported
Not supported
Not supported


Not supported
20 X1301 Fast measurement connection
21 X10 Connection for electronic measuring tool (EMT)
22 X1400 Not used.
23 --- Ground conductor connection
The contact to the SafeRDC box is established
using a screw.
13.2 Connections on the I/O Print board
Description
Fig. 13-2: Connections on the I/O Print board

1 X902 Connection of safe inputs and outputs
2 X1 Not used.
3 X905 Connection for enabling input for KUKA Guiding
Device (KGD)
4 X904 Connection for reference switch input
5 X901 Connection for SafeRDC board
13.3 Removing the SafeRDC board
charge.
Procedure 1. Unscrew the 4 screws on the lid of the SafeRDC box.

2. Carefully open the lid of the SafeRDC box forwards.

3. Carefully disconnect all cables leading to the SafeRDC and I/O Print
boards. Pull the cables out of the SafeRDC box, if possible, or bend them
out of the way to the sides.
4. Loosen and remove the 6 fastening screws of the SafeRDC board.
Fig. 13-4: Fastening screws on the SafeRDC board
5. Carefully pull the SafeRDC board out of the SafeRDC box without tilting it.

13.4 Removing the I/O Print board
Precondition The SafeRDC and I/O Print boards must be protected against static
charge.
Procedure 1. Remove SafeRDC board.

(>>> 13.3 "Removing the SafeRDC board" page 132)
2. Loosen and remove the 5 hexagon nuts on the I/O Print board.
Fig. 13-5: Hexagon nuts on the I/O Print board
3. Carefully remove the I/O Print board from the SafeRDC board.
13.5 Installing the I/O Print board
Precondition The SafeRDC and I/O Print boards must be protected against static
charge.
Procedure 1. Carefully plug the I/O Print board onto the SafeRDC board.
Fig. 13-6: Hexagon nuts on the I/O Print board
2. Screw the I/O Print board onto the SafeRDC board with 5 hexagon nuts.
Tightening torque 0.9 Nm
3. Install SafeRDC board.

(>>> 13.6 "Installing the SafeRDC board" page 135)
13.6 Installing the SafeRDC board
charge.
The I/O Print board must be fastened to the SafeRDC board.
Procedure 1. Securely screw the SafeRDC board into the SafeRDC box.
Caution!
If the fastening screws are screwed in too tightly, this can damage the thread,
resulting in material damage. Screw in the M4 fastening screws all the way
to the stop without exerting major force.
Fig. 13-7: Fastening screws on the SafeRDC board
1 2 Allen screws M6x10 8.8 with lock washers

Tightening torque: 6.0 Nm
2 Plastic screw M4x6
3 2 Allen screws M4x8 8.8 with lock washers
4 Allen screw M6x30 8.8 with lock washer
2. Connect all cables that were unplugged during removal.

3. Carefully close the lid of the SafeRDC box.
4. Screw the lid of the SafeRDC box firmly in place using the 4 screws on the
housing.

5. Switch on the robot controller and let it run up.

6. Verify the safety parameters.
(>>> 8.2 "Verifying safety parameters" page 97)
7. Carry out new safety acceptance.
(>>> 6.18 "Safety acceptance of KUKA.SafeOperation" page 93)

Nullserien-Dokument 14. Appendix
14 Appendix
14.1 Interface X40 circuit example 1
The circuit example of connector X40 applies in the following case:

Operation without external safety logic
Default values are set in the configuration window.
Monitoring spaces 2 to 8 are monitored.
Default tool 1 is monitored.
Standstill monitoring is deactivated.
Reduced velocities and accelerations that can be activated are not moni-
tored.
Fig. 14-1: Interface X40, circuit example 1


Operation without external safety logic
Monitoring spaces 2 and 3 are activated with floating contacts.
Monitoring spaces 4 to 8 are monitored.
Tools 1, 2 and 3 can be activated with floating contacts.
Standstill monitoring is activated with floating contacts.
Reduced velocities and accelerations that can be activated are not moni-
tored.


Operation without external safety logic with pulsed output voltage as sup-
ply voltage for safe outputs
Monitoring spaces 2, 3 and 5 to 8 are monitored.
Safe input (monitoring space 4) can be activated via safe output (monitor-
ing space 7).
Tool 2 is activated.
Standstill monitoring is not activated.
Reduced velocities and accelerations that can be activated are activated
via safe output (monitoring space 6).

14.4 Checklists
14.4.1 Checklist for robot and system
Precondition Mechanical and electrical installation of the robot system have been com-
pleted.
KUKA.SafeOperation is configured.
Checklist Serial number of the robot: ____________________

Time stamp of the configuration window: ____________________
Not
No. Activity Yes
relevant
1 Robot and tool are in flawless mechanical
---
condition and correctly installed?
2 The permissible rated payload of the robot has
---
not been exceeded?
3 All connections and connectors are in flawless
---
condition?
4 All connecting cables are in flawless condition
---
and connected correctly?
5 The system meets all the relevant laws, regu-
lations and norms valid for the installation ---
site?
6 All system safety equipment is in flawless con-
---
dition and in good working order?
7 All safety equipment used corresponds to the
---
safety level required in the system?
8 Ground conductor connection on robot con-
troller and on robot has been checked in
---
accordance with DIN EN 60204-1 and is in
good working order?
Place, date
Signature
By signing, the signatory confirms the correct and complete performance of

the safety acceptance test.

14.4.2 Checklist for safe functions
pleted.

Not
No. Activity Yes
relevant
1 The machine data $ROBCOR.DAT and
$MACHINE.DAT have been checked and ---
match the robot used?
Designation of the robot on the rating plate is
identical to the value in the system variable ---
$TRAFONAME[].
All data in $ROBCOR.DAT and
$MACHINE.DAT are identical to the data on
the CD supplied.
User-specific changes must be taken into con- ---
sideration.
Modifications may only be carried out after
consultation with the KUKA Robot Group.
2 All configuration data have been transferred to
the SafeRDC and confirmed?
---
(>>> 8.2 "Verifying safety parameters"
page 97)
3 Robot is mastered? ---
4 The reference position has been taught in the
program MasRefStart.SRC and in the configu- ---
ration window?
5 Was the mastering test successful? ---
6 The message “Safety mode not possible” is no
---
longer displayed in the message window?
7 Was the brake test successful? ---
8 The correct configuration of the cell area was
checked by moving to all the limits?
The checklist (>>> 14.4.6 "Checklist for con- ---
figuration of the cell area" page 148) must be
completed and confirmed in writing for the cell
area.
9 The input test pulse in the safety parameter
---
'Interfaces' has been set to TRUE?
10 Output OUT_STATUS safely monitored?

Not
No. Activity Yes
relevant
11 The correct configuration of the monitoring
spaces used was checked by moving to all the
limits?
The checklist or (>>> 14.4.8 "Checklist for ---
configuration of Cartesian monitoring spaces"
page 152) must be completed and confirmed
in writing for each monitoring space used.
Axis-specific
Monitoring space 2
Cartesian
Axis-specific
Monitoring space 3
Cartesian
Axis-specific
Monitoring space 4
Cartesian
Axis-specific
Monitoring space 5
Cartesian
Axis-specific
Monitoring space 6
Cartesian
Axis-specific
Monitoring space 7
Cartesian
Axis-specific
Monitoring space 8
Cartesian
12 The correct configuration of the tools used has
been checked?
The checklist (>>> 14.4.9 "Checklist for con-
figuration of the tools" page 154) must be
completed and confirmed in writing for each
tool used.
13 The correct configuration of the reduced
velocities has been checked?
The checklist must be completed and con-
firmed in writing for the reduced velocities.
14 The correct configuration of the reduced
accelerations has been checked?
firmed in writing for the reduced accelerations.
15 The correct configuration of the standstill mon-
itoring has been checked?
firmed in writing for the standstill monitoring.
Place, date
Signature


14.4.3 Checklist for velocity limits
pleted.
A test program has been created that successively violates the configured
limit values to verify the correct operation of the KUKA.SafeOperation
monitoring function.

Not
No. Activity Yes
relevant
1 The configuration of the Cartesian velocity for
---
T1 has been checked and is correct?
Value determined: __________ mm/s
---
Configured value: __________ mm/s
2 The configuration of the safe reduced Carte-
sian velocity has been checked and is cor-
rect?
3 The configuration of the global Cartesian
velocity has been checked and is correct?
4 The configuration of the reduced axis velocity
has been checked and is correct?
Value for axis 1: __________ °/s or mm/s
Value for axis 2: __________ °/s
5 The configuration of the reduced axis velocity
for T1 has been checked and is correct?
Place, date
Signature



14.4.4 Checklist for reduced accelerations
pleted.

Not
No. Activity Yes
relevant
1 The configuration of the reduced axis acceler-
ation has been checked and is correct?
Value for axis 1: __________ °/s² or mm/s²
Value for axis 2: __________ °/s²
Value for axis 3: __________ °/s²
Value for axis 4: __________ °/s²
Value for axis 5: __________ °/s²
Value for axis 6: __________ °/s²
2 The configuration of the reduced axis acceler-
ation for T1 has been checked and is correct?
Value for axis 2: __________ °/s²
Value for axis 3: __________ °/s²
Value for axis 4: __________ °/s²
Value for axis 5: __________ °/s²
Value for axis 6: __________ °/s²
Place, date
Signature


14.4.5 Checklist for standstill monitoring
pleted.
Standstill monitoring is active.
T2 mode
Danger!

The configured limit values for all axes must successively be violated very
slowly in the positive and negative direction in order to demonstrate the correct
functioning of the standstill monitoring. If the limit values are tested at high ve-
locity, the standstill monitoring is not activated because of the configured axis
angle or distance tolerance, but because of the velocity limits.
Not
No. Activity Yes
relevant
1 Axis 1 has been correctly configured and
checked?
Determined positive axis angle tolerance:
__________ ° or mm
Determined negative axis angle tolerance:
__________ ° or mm
Configured axis angle tolerance: __________
° or mm
checked?
__________ °
__________ °
°
checked?
__________ °
__________ °
°

Not
No. Activity Yes
relevant
checked?
__________ °
__________ °
°
checked?
__________ °
__________ °
°
checked?
__________ °
__________ °
°
checked?
__________ ° or mm
__________ ° or mm
° or mm
checked?
__________ ° or mm
__________ ° or mm
° or mm
Place, date
Signature


14.4.6 Checklist for configuration of the cell area
pleted.
All monitoring spaces are deactivated.
T2 mode
Danger!

Tool used: ____________________
The configured limit values must successively be violated to demonstrate the
correct functioning of the cell area.
Not
No. Activity Yes
relevant
1 Corner 1 has been correctly configured and
checked?
X coordinate: __________ mm
Y coordinate: __________ mm
checked?
checked?
checked?
checked?
checked?
Place, date
Signature


14.4.7 Checklist for configuration of axis-specific monitoring spaces
pleted.
The monitoring space to be checked is activated. All other monitoring
spaces are deactivated.
Axis-specific monitoring space is defined.
T2 mode
Danger!

Monitoring space checked: __________
Protected space: __________
Stop at limits (TRUE|FALSE): __________
Reference stop (TRUE|FALSE): __________
Space-specific velocity (TRUE|FALSE): __________
Digital input: __________
Digital output: __________
correct functioning of the monitoring spaces.
Not
No. Activity Yes
relevant
checked?
Determined lower axis limit: __________ ° or
mm
Configured lower axis limit: __________ ° or
mm
Determined upper axis limit: __________ ° or
mm
Configured upper axis limit: __________ ° or
mm
checked?
Determined lower axis limit: __________ °
Configured lower axis limit: __________ °
Determined upper axis limit: __________ °
Configured upper axis limit: __________ °
checked?

Not
No. Activity Yes
relevant
checked?
checked?
checked?
checked?
mm
mm
mm
mm
checked?
mm
mm
mm
mm
The following preconditions must be met to demonstrate the correct function-

ing of the reference stop.
Reference stop is activated.
Checked monitoring space is not violated.
Robot stops with a reference stop.

Not
No. Activity Yes
relevant
9 The correct functioning of the reference stop
has been checked?

ing of the space-specific Cartesian velocity.
Space-specific Cartesian velocity is active in the permissible range.
The configured limit value of the space-specific Cartesian velocity is less
than the limit value of the global Cartesian velocity.
Robot stops at the limits.
Monitored monitoring space is activated.
Robot exceeds the configured space-specific Cartesian velocity.
Not
No. Activity Yes
relevant
10 The space-specific Cartesian velocity has
been correctly configured and checked?
Determined limit: __________ mm/s
Configured limit: __________ mm/s
Place, date
Signature


14.4.8 Checklist for configuration of Cartesian monitoring spaces
pleted.
The monitoring space to be checked is activated. All other monitoring
spaces are deactivated.
Cartesian monitoring space is defined.
T2 mode
Danger!

Monitoring space checked: __________
Protected space: __________
Stop at limits (TRUE|FALSE): __________
Reference stop (TRUE|FALSE): __________
Space-specific velocity (TRUE|FALSE): __________
Tool used: ____________________
Digital input: __________
Digital output: __________
correct functioning of the monitoring spaces.
Not
No. Activity Yes
relevant
1 Coordinates of the monitoring space have
Lower X plane, Y plane, Z plane
Upper X plane, Y plane, Z plane
Origin X: __________ mm
Origin Y: __________ mm
Origin Z: __________ mm
---
Origin A, B, C = 0°
Lower X plane: __________ mm
Lower Y plane: __________ mm
Lower Z plane: __________ mm
Upper X plane: __________ mm
Upper Y plane: __________ mm
Upper Z plane: __________ mm

ing of the reference stop.
Reference stop is activated.
Checked monitoring space is not violated.

Robot stops with a reference stop.
Not
No. Activity Yes
relevant
9 The correct functioning of the reference stop
has been checked?

ing of the space-specific Cartesian velocity.
Space-specific Cartesian velocity is active in the permissible range.
The configured limit value of the space-specific Cartesian velocity is less
than the limit value of the global Cartesian velocity.
Robot stops at the limits.
Monitored monitoring space is activated.
Robot exceeds the configured space-specific Cartesian velocity.
Not
No. Activity Yes
relevant
10 The space-specific Cartesian velocity has
Determined limit: __________ mm/s
Configured limit: __________ mm/s
Place, date
Signature


14.4.9 Checklist for configuration of the tools
pleted.

Tool checked: __________
Load data: __________
Not
No. Activity Yes
relevant
1 1st sphere on tool
Coordinates have been correctly configured
and checked?
X: __________ mm
Y: __________ mm
Z: __________ mm
Radius: __________ mm
2 2nd sphere on tool
and checked?
X: __________ mm
Y: __________ mm
Z: __________ mm
Radius: __________ mm
3 TCP of the tool
and checked?
X: __________ mm
Y: __________ mm
Z: __________ mm
Place, date
Signature


14.5 Applied norms and directives
The functional safety of KUKA.SafeOperation complies with the specifications

of Category 3 in accordance with EN 954-1.


Nullserien-Dokument 15. KUKA Service
15 KUKA Service
15.1 Requesting support
Introduction The KUKA Robot Group documentation offers information on operation and
provides assistance with troubleshooting. For further assistance, please con-
tact your local KUKA subsidiary.
Faults leading to production downtime are to be reported to the local KUKA

subsidiary within one hour of their occurrence.
Information The following information is required for processing a support request:

Model and serial number of the robot
Model and serial number of the controller
Model and serial number of the linear unit (if applicable)
Version of the KUKA System Software
Optional software or modifications
Archive of the software
Application used
Any external axes used
Description of the problem, duration and frequency of the fault
15.2 KUKA Customer Support
Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.
Argentina Ruben Costantini S.A. (Agency)
Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com
Australia Marand Precision Engineering Pty. Ltd. (Agency)

153 Keys Road
Moorabbin
Victoria 31 89
Australia
Tel. +61 3 8552-0600
Fax +61 3 8552-0605
robotics@marand.com.au

Austria KUKA Roboter GmbH

Vertriebsbüro Österreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
office@kuka-roboter.at
www.kuka-roboter.at
Belgium KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
info@kuka.be
www.kuka.be
Brazil KUKA Roboter do Brasil Ltda.

Avenida Franz Liszt, 80
Parque Novo Mundo
Jd. Guançã
CEP 02151 900 São Paulo
SP Brazil
Tel. +55 11 69844900
Fax +55 11 62017883
info@kuka-roboter.com.br
Chile Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
robotec@robotec.cl
www.robotec.cl
China KUKA Flexible Manufacturing Equipment (Shanghai) Co., Ltd.

Shanghai Qingpu Industrial Zone
No. 502 Tianying Rd.
201712 Shanghai
P.R. China
Tel. +86 21 5922-8652
Fax +86 21 5922-8538
Franz.Poeckl@kuka-sha.com.cn
www.kuka.cn

France KUKA Automatisme + Robotique SAS

Techvallée
6 Avenue du Parc
91140 Villebon s/Yvette
France
Tel. +33 1 6931-6600
Fax +33 1 6931-6601
commercial@kuka.fr
www.kuka.fr
Germany KUKA Roboter GmbH

Blücherstr. 144
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
info@kuka-roboter.de
www.kuka-roboter.de
Hungary KUKA Robotics Hungaria Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu
India KUKA Robotics, Private Limited

621 Galleria Towers
DLF Phase IV
122 002 Gurgaon
Haryana
India
Tel. +91 124 4148574
info@kuka.in
www.kuka.in
Italy KUKA Roboter Italia S.p.A.

Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
kuka@kuka.it
www.kuka.it

Korea KUKA Robot Automation Korea Co. Ltd.

4 Ba 806 Sihwa Ind. Complex
Sung-Gok Dong, Ansan City
Kyunggi Do
425-110
Korea
Tel. +82 31 496-9937 or -9938
Fax +82 31 496-9939
info@kukakorea.com
Malaysia KUKA Robot Automation Sdn Bhd

South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 3 8061-0613 or -0614
Fax +60 3 8061-7386
info@kuka.com.my
Mexico KUKA de Mexico S. de R.L. de C.V.

Rio San Joaquin #339, Local 5
Colonia Pensil Sur
C.P. 11490 Mexico D.F.
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx
Norway KUKA Sveiseanlegg + Roboter

Bryggeveien 9
2821 Gjövik
Norway
Tel. +47 61 133422
Fax +47 61 186200
geir.ulsrud@kuka.no
Portugal KUKA Sistemas de Automatización S.A.

Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
kuka@mail.telepac.pt

Russia KUKA-VAZ Engineering

Jushnoje Chaussee, 36 VAZ, PTO
445633 Togliatti
Russia
Tel. +7 8482 391249 or 370564
Fax +7 8482 736730
Y.Klychkov@VAZ.RU
South Africa Jendamark Automation LTD (Agency)

76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za
Spain KUKA Sistemas de Automatización S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 814-2353
Fax +34 93 814-2950
Comercial@kuka-e.com
www.kuka-e.com
Sweden KUKA Svetsanläggningar + Robotar AB

A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
info@kuka.se
Switzerland KUKA Roboter Schweiz AG

Riedstr. 7
8953 Dietikon
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
info@kuka-roboter.ch
www.kuka-roboter.ch

Taiwan KUKA Robot Automation Taiwan Co. Ltd.

136, Section 2, Huanjung E. Road
Jungli City, Taoyuan
Taiwan 320
Tel. +886 3 4371902
Fax +886 3 2830023
info@kuka.com.tw
www.kuka.com.tw
Thailand KUKA Robot Automation (M)SdnBhd

Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
atika@ji-net.com
www.kuka-roboter.de
UK KUKA Automation + Robotics

Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
sales@kuka.co.uk
USA KUKA Robotics Corp.

22500 Key Drive
Clinton Township
48036 Michigan
USA
Tel. +1 866 8735852
Fax +1 586 5692087
info@kukarobotics.com
www.kukarobotics.com

Nullserien-Dokument Index
Index
Symbols C
$BREMSENTEST_TIMER 28 Cable carrier 52
$SR_OV_MSG_SHOW 22, 105 Cable length, data cable X21 - X31 47
$SR_OV_RED 22, 105 Cables, safety 51
$SR_TIME_N 105 Cartesian 12
$SR_VEL_RED 22, 105 Cartesian monitoring spaces, defining 67
$SR_WORKSPACE_RED 23, 105 Cartesian position X 83
/TA24A, pulse duty factor 45 Cartesian position Y 83
/TA24V, pulse duration T(HIGH) 44, 45 Cartesian position Z 83
/TA24V, pulse duration T(LOW) 44, 45 Cartesian protected spaces 15
/TA24V, pulse duty factor 44 Cartesian velocity 51, 77
Cartesian workspaces 14
A Cell area 10, 12, 13, 14, 78
Acceleration monitoring 20 Cell area, defining 64
Accuracy requirements, reference position 51 Checking the reference position 87
Actuating plate, hole pattern 49 Checklists 140
Altitude 47 Checklists, acceptance 140, 141, 143, 145, 146,
Ambient temperature 47 148, 149, 152, 154
Ambient temperature, reference switch 47 Circuit example, X40 137, 138, 139
Appendix 137 Components 31
Archiving safety parameters 98 Connecting cables, connecting 60
Areas of application 11 Connecting cables, overview 34
Assigning input signals 61 Connecting the connecting cables 60
Assigning output signals 61 Connection, electronic measuring tool 35
Atmospheric humidity 47 Connections, I/O Print board 132
Availability, robots 19, 55 Connections, SafeRDC board 131
Axes, decouplable 27, 51 Connections, SafeRDC box 35
Axes, synchronous 51 Connector pin allocation X40 39
Axis acceleration 77 Connector pin assignment, data cable X21 - X31
Axis acceleration for T1 77 36
Axis angle tolerance 84 Connector pin assignment, data cable X21.1 - X41
Axis limits 8, 16, 17 36
Axis lower bound 67, 81 Connector pin assignment, reference cable X42 -
Axis number 73 XS Ref 37
Axis ranges 8, 16, 17 Criteria, reference position 26
Axis upper bound 67, 81 Current position, reference position 73
Axis velocity 76
Axis velocity for T1 76 D
Axis-specific 12 Decouplable axes 27, 51
Axis-specific monitoring spaces, defining 65 Defective brake 52
Axis-specific protected spaces 17 Definition 63, 79
Axis-specific workspaces 16 Degree of fouling 47
Description, signal declarations 61, 101
B Detailed information, axis-specific monitoring
Brake test 8 space 120
Brake test cycle time 8, 28 Detailed information, Cartesian monitoring space
Brake test, defining 88 121
Brake test, defining external axes 91 Detailed information, cell area 119
Brake test, defining robot axes 90 Detailed information, monitoring spaces 118
Brake test, description 27 Detailed information, safe inputs 122
Brake test, programming 92 Detailed information, safe outputs 123
Brake test, results 128 Diagnosis 117
Brake test, safety 51 Diagnosis, overview 117
Brake test, signals 104 Diagnosis, signals 102
Brake, defective 52 Digital input 63, 79
Braking distance 8 Digital output 63, 79
Directives 155

Documentation, robot system 7 K

Knowledge, required 7
E KUKA Customer Support 157
E_DV 31 KUKA.SafeOperation, overview 11
E_HALT 31
E0 30 L
E1 30 LEDs, I/O Print board 128
E2 30 LEDs, SafeRDC board 125
E3 30 Lower bound 67, 81
E4 20
E5 20 M
Electromagnetic compatibility 47 Machine data, $MACHINE.DAT 85
Electronic measuring tool, connection 35 Machine data, $ROBCOR.DAT 84
EMC conformity, reference switch 48 Maintenance, personnel 51
EN 954-1, Category 3 155 Master position, reference position 74
Exchanging the tool 51 Mastering test 8
External axes, brake test 51 Mastering test, overview 25
External axes, reference group 85 Mastering test, performing manually 87
Mastering test, programming 86
F Mastering test, safety 51
Fixed installation 52 Mastering test, signals 101
Flag 55 Messages 107
Functional principle 12 Messages, brake test 115
Functions, KUKA.SafeOperation 11 Messages, operation 107
Functions, SafeRDC 32 Messages, verification of the safety parameters
113
G Min. distance, reference position 74
General information 76 Module a, X40 38, 39
Global velocity 77 Module b, X40 38, 40
Module c, X40 38, 41
H Module d, X40 38, 42
Hardware 55 Monitored axes 76
Hardware components 31 Monitoring axis acceleration 78
Hardware components, scope of supply 31 Monitoring axis acceleration for T1 78
Hole pattern, actuating plate 49 Monitoring functions that can be activated 30
Hole pattern, reference switch 48 Monitoring of mastering 83
Hysteresis, reference switch 48 Monitoring space 10
Monitoring Spaces 78
I Monitoring spaces 12
I/O Print board, connections 132 Monitoring spaces, axis-specific 65
I/O Print board, installing 134 Monitoring spaces, Cartesian 67
I/O Print board, LEDs 128 Monitoring spaces, defining 62
I/O Print board, removing 134 Monitoring spaces, status 118
Import, safety parameters 98 Monitoring time 8, 28
Input signals 61
Input test pulse 8, 84 N
Inputs, status 122 Norms 155
Installation 55
Installation, fixed 52 O
Installation, KUKA.SafeOperation 55 Opening SafeRobot diagnosis 117
Installing the actuating plate 58 Operating current, reference switch 47
Installing the I/O Print board 134 Operating hours meter, reading 98
Installing the reference switch 58 Operating voltage, reference switch 47
Installing the SafeRDC board 135 Operation 97
Interface X40 38 Operation, safety 52
Interfaces 84 Optocoupler 61
Interrupt 55 OUT_A0 31
Introduction 7 OUT_A1 31
OUT_A2 31
OUT_STATUS 24, 31

Nullserien-Dokument Index
Output signals 61 Safe inputs 43

Outputs, reference switch 48 Safe outputs 44
Outputs, status 123 Safe outputs, load rating 38
Override reduction 22 Safe robot retraction 30
Override reduction, variables 105 SafeRDC 31
Overview of connecting cables 34 SafeRDC board, connections 131
Overview, mastering test 25 SafeRDC board, installing 135
SafeRDC board, LEDs 125
P SafeRDC board, removing 132
Parking position 8, 28 SafeRDC box 37
Parking position, velocity 51 SafeRDC box, connections 35
Performing a manual brake test 93 SafeRDC lid, exchanging 59
Permissible load current, reference switch 47 SafeRDC, technical data 47
Permissible switching distance, reference switch Safety 51
48 Safety acceptance, KUKA.SafeOperation 52, 93
Permissible switching frequency, reference switch Safety instructions 7
47 Safety parameters 51
Personnel, safety 51 Safety parameters, archiving 98
Polygon, convex 8, 12, 13 Safety parameters, displaying 97
Product description 11 Safety parameters, importing 98
Programming 95 Safety parameters, overview 74
Programming the brake test 92 Safety parameters, restoring 99
Programming the mastering test 86 Safety parameters, setting 75
Programs, brake test 95 Safety parameters, verifying 97
Programs, mastering test 95 Safety PLC 61
Protected spaces 9, 17 Safety PLC, connecting 61
Protection classification 47 Safety zone 12
Pulse duration T(HIGH), /TA24V 44, 45 Service life, SafeRDC 51
Pulse duration T(LOW), /TA24V 44, 45 Service, KUKA Roboter 157
Pulse duration, reference switch 47 Shock sensitivity 47
Pulse duty factor, /TA24V 44, 45 Signal declarations 101
Pulse duty factor, reference switch 47 Signal diagram, brake test 29
Signal diagram, mastering test 26
R Signals for the brake test 104
Reaction distance 8 Signals, diagnosis 102
Reduced axis acceleration 77 Signals, mastering test 101
Reduced axis velocity 76 Signals, robot status 103
Reduced velocity 77 Software components 31
Reduced velocity in T1 77 Software components, scope of supply 31
Reference group 9, 33, 73, 83 Space-specific velocity 18
Reference group, external axes 85 Standstill monitoring 9, 21, 84
Reference position 9, 25, 73, 83 Start-up 57
Reference position, defining 72 Start-up, overview 57
Reference stop 9, 19, 64, 80 Start-up, personnel 51
Reference switch 9 Start-up, safety 52
Reference switch, installation 58 STOP 0 9
Reference switch, technical data 47 STOP 1 9
Removing the I/O Print board 134 STOP 2 10
Removing the SafeRDC board 132 Stop at boundaries 64, 80
Repairs, personnel 51 Stop before reaching boundaries 19, 64, 65, 78,
Restoring safety parameters 99 80
Robot axes, brake test 51 Stop reactions 13, 21, 22
Robot status signals 103 Stopping distance 8
Robot system, safety 51 Supply voltage 47
Support request 157
S Switching function, reference switch 47
Safe axis monitoring 76 Synchronous axes 51
Safe field bus module 61 System requirements 55
Safe field bus system 61 System variables 101
Safe input 70, 82

T
T1 mode 30
Target group 7
Technical data 47
Technical data, reference switch 47
Technical data, SafeRDC 47
Terms 8
Terms used 8
Time stamp 76
Tool, exchanging 51
Tools 20, 82
Tools, defining 69
Training program 7
Troubleshooting 125
Type 63, 79
U
Uninstallation, KUKA.SafeOperation 55
Update, KUKA.SafeOperation 55
Upper bound 67, 81
V
V max 63, 79
V max valid in 63, 80
Velocity monitoring 20
Velocity, Cartesian 51
Verifying safety parameters 97
Version 76
Vibration resistance 47
W
Warnings 7
Wear limit 27
Wiring diagram, reference group 37
Workspace 12
Workspaces 8, 16
X
X40 circuit example 137, 138, 139
X40, connector pin allocation 39
X40, interface 38

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KUKA Robot Group

KUKA System Technology (KST)

Issued: 31.07.2007 Version: 0.6

2 Product description ......................................................................................... 11

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3 Technical data .................................................................................................. 47

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6.17 Performing a manual brake test ...................................................................................... 93

9 System variables .............................................................................................. 101

10 Messages .......................................................................................................... 107

11 Diagnosis .......................................................................................................... 117

12 Troubleshooting ............................................................................................... 125

13 Repair ................................................................................................................ 131

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14 Appendix ........................................................................................................... 137

15 KUKA Service ................................................................................................... 157

Index .................................................................................................................. 163

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1.1 Target group

1.2 Robot system documentation

The robot system documentation consists of the following parts:

1.3 Representation of warnings and notes

Tips to make your work easier or references to further information.

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1.4 Terms used

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2.1 KUKA.SafeOperation overview

KUKA.SafeOperation is an option with software and hardware components.

Functions  Connection to an external safety logic

Areas of application  Human-robot cooperation

Fig. 2-1: Example of a cell with KUKA.SafeOperation

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1 Installed reference switch 5 System control panel

2.2 Functional principle

2.3 Monitoring spaces

Description Up to 8 freely definable monitoring spaces are available.

Monitoring spaces 2 Monitoring spaces 2 to 8 can be defined as Cartesian cuboids or by means of

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(>>> 2.3.7 "Stop before reaching boundaries" page 19)

2.3.1 Cell area

The cell area is configured in the ROBROOT coordinate system as a convex

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1 Example of a convex polygon with 6 corners

Fig. 2-2: Example of a cell area

2.3.2 Cartesian workspaces

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The Cartesian workspace is configured in the ROBROOT coordinate system

Fig. 2-3: Example of a Cartesian workspace

2.3.3 Cartesian protected spaces

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The Cartesian protected space is configured in the ROBROOT coordinate

Fig. 2-4: Example of a Cartesian safeguarded zone

2.3.4 Axis-specific workspaces

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Fig. 2-5: Example of an axis-specific workspace

Functions Connection to an external safety logic

Areas of application Human-robot cooperation

Operating mode T2, AUT or AUT EXT

Mastering test is requested internally because of lack of mastering or boot-

OUT_STATUS LOW Safe robot monitoring is not activated.

Communication with the robot controller