Appendix No.
APPENDIX 3 – KUKA LBR
Global
Manufacturing
Standards
Per Standard No.
w-EL10
Programmable Safety Systems
APPENDIX 3 – KUKA LBR
Date:
August 9, 2017
Rev No.
1.0
APPENDIX 3 – KUKA LBR
August 9, 2017
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Global
Manufacturing
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Per Standard No.
w-EL10
Programmable Safety Systems
APPENDIX 3 – KUKA LBR
Date:
August 9, 2017
Rev No.
1.0
1. Purpose
The purpose of this document is to provide examples of checklists used by the KUKA Safety
Configuration.
2. Scope
The provisions of this document shall apply to all suppliers that are providing automation equipment
or engineering services to Ford Motor Company.
3. General
It is the obligation of the OEM to perform all safety acceptance checks for activated KUKA safety
systems. The acceptance test must check all values which have been entered for enable safety
systems, checking for limit exceptions to confirm they are working correctly.
A qualified person must perform each test, and the person carrying out the acceptance test must
have obtained proper training and knowledge of the KUKA safety systems. Upon completion of each
checklist the qualified person must sign and date the checklist. All pertinent checklists and
certificates must be kept for each machine.
4. Safety Configuration Report Flowchart
The safety configuration report is generated by the KUKA Sunrise controller and provides a checklist
that the qualified person can use to validate the safety systems. The following flowchart can be used
to locate a description and worksheet for safety systems that require more detail from the report.
In the example safety configuration report contained in Section 6 the values highlighted in red are
example text and are provided for reference. The system that is being evaluated will have values
appropriate for that system and may not be the same as the examples provided. The checkboxes are
provided for the qualified person to record that the safety system has been evaluated and is
accepted.
Every application is unique; therefore, the safety configuration report contains a super set of the
programmable safety systems that are available. It is the responsibility of the qualified person doing
the acceptance testing to validate the parts of the safety report that are necessary for the application
being evaluated.
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Programmable Safety Systems
APPENDIX 3 – KUKA LBR
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Appendix No.
APPENDIX 3 – KUKA LBR
Global
Manufacturing
Standards
Per Standard No.
w-EL10
Programmable Safety Systems
APPENDIX 3 – KUKA LBR
Date:
August 9, 2017
Rev No.
1.0
5. Printing the Safety Configuration Report
The Safety Configuration Report is a record of the current safety configuration of the KUKA Sunrise
Project.
It is used in conjunction with other checklists and the list of AMF objects to test and document the
results of said tests.
The checkboxes located in cells of different tables are used by the safety maintenance technician to
indicate that the item has been verified per the instructions provided by the AMF object checklists, or
other checklists as appropriate.
Procedure
To print the safety configuration report, perform the following steps.
1. Open the Sunrise Workbench
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Per Standard No.
w-EL10
Programmable Safety Systems
APPENDIX 3 – KUKA LBR
Date:
August 9, 2017
Rev No.
1.0
2. Right-click on the Sunrise project, select Sunrise, and then Create safety configuration
report
The report representing the current safety configuration is created and opened in the editor area
within Sunrise Workbench.
NOTE: The following is an example of a printed safety configuration report, it is provided to
demonstrate the contents of the report. The safety configuration report is a representation of the
safety settings in the application project and must be activated in the Sunrise controller.
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Per Standard No.
w-EL10
Programmable Safety Systems
APPENDIX 3 – KUKA LBR
Date:
August 9, 2017
Rev No.
1.0
6. Example KUKA Safety Configuration Report
Sunrise project: System Generated
Safety version: System Generated
Safety ID: System Generated
Last modification: System Generated
Notes
KUKA PSM
Row
Category
1
Emergency
stop local
2
Enabling
Device
Hand
guiding device
inactive
Instance 1
Operating
mode Test
Instance 1
3
Velocity
Monitoring
Hand
guiding device
active
Instance 1
Cartesian
velocity monitoring
Instance 100
Printed: 7/24/2017
AMF 1
AMF 2
AMF 3
Emergency
stop smartPAD
Instance 1
Reaction
OK
Stop 1 (onpath)
Control panel
enable smartPAD
inactive
Instance 1
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Stop 1 (onpath)
Stop 1 (onpath)
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Programmable Safety Systems
Date:
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Rev No.
1.0
APPENDIX 3 – KUKA LBR
Customer PSM
Row
Category
1
Emergency stop
external
2
Operator
protection
3
Emergency stop
local
AMF 1
AMF 2
Input signal
Instance 1
Input signal
Instance 2
AMF
3
Reaction
OK
Stop 1 (on-path)
Operating mode with
high speed
Instance 1
Emergency stop
smartPAD
Instance 1
Stop 1 (on-path)
Output PROFIsafe
Byte 0/0
AMF Cartesian velocity monitoring
The AMF can be tested by moving a monitored point of the monitored kinematic system at a Cartesian
velocity of approx. 10% over the configured velocity limit.
Instance 100
No.
1
Activity
OK
The configured reaction is triggered if the maximum permissible Cartesian velocity of a
monitored point is exceeded.
Parameter
Value
Monitored kinematic system First kinematic system
Monitored structure
Robot and tool
Maximum velocity
250 mm/s
AMF Collision detection
The AMF can be tested by displaying the current measured external axis torques of the monitored
kinematic system on the smartPAD and then loading the individual axes. In order to verify the mounting
position the torque sensors have to be referenced.
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Date:
August 9, 2017
Programmable Safety Systems
Rev No.
1.0
APPENDIX 3 – KUKA LBR
Instance 1
No.
1
Activity
OK
The configured reaction is triggered if the external torque of one axis of the monitored
kinematic system exceeds the maximum permissible external torque.
Parameter
Value
Monitored kinematic system First kinematic system
Maximum external torque
30 Nm
Notes
AMF Control panel enable smartPAD inactive
Instance 1
No.
Activity
OK
1
The configured reaction is triggered by releasing an enabling switch on the smartPAD.
AMF Emergency stop smartPAD
Instance 1
No.
Activity
1
The configured reaction is triggered by pressing the E-STOP on the smartPAD.
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Global
Manufacturing
Standards
Per Standard No.
w-EL10
Programmable Safety Systems
Date:
August 9, 2017
Rev No.
1.0
APPENDIX 3 – KUKA LBR
AMF Hand guiding device active
All configured enabling and panic switches for the hand guiding device must be tested.
Instance 1
No.
Activity
OK
1
The configured reaction is triggered by pressing enabling switch 1.
2
The configured reaction is triggered by pressing enabling switch 2.
3
The configured reaction is triggered by pressing enabling switch 3.
AMF Hand guiding device inactive
All configured enabling and panic switches for the hand guiding device must be tested.
Instance 1
No.
Activity
OK
1
The configured reaction is triggered by releasing of enabling switch 1.
2
The configured reaction is triggered by pressing fully down on enabling switch 1 on the hand
guiding device.
3
The configured reaction is triggered by releasing of enabling switch 2.
4
The configured reaction is triggered by pressing fully down on enabling switch 2 on the hand
guiding device.
5
The configured reaction is triggered by releasing of enabling switch 3.
6
The configured reaction is triggered by pressing fully down on enabling switch 3 on the hand
guiding device.
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Manufacturing
Standards
Per Standard No.
w-EL10
Programmable Safety Systems
Rev No.
1.0
APPENDIX 3 – KUKA LBR
Parameter
Enabling switch 1 used
Date:
August 9, 2017
Value
false
Enabling switch 1 input signal Input CIB_SR.1
Enabling switch 2 used
false
Enabling switch 2 input signal Input CIB_SR.1
Enabling switch 3 used
false
Enabling switch 3 input signal Input CIB_SR.1
Panic switch 1 used
false
Panic switch 1 input signal
Input CIB_SR.1
Panic switch 2 used
false
Panic switch 2 input signal
Input CIB_SR.1
Panic switch 3 used
false
Panic switch 3 input signal
Input CIB_SR.1
AMF Input signal
Instance 1
No.
Activity
1
The configured reaction is triggered if the input is LOW (state “0”).
Parameter
OK
Value
Input for safety signal Input PROFIsafe Byte 0/0
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w-EL10
Programmable Safety Systems
Date:
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Rev No.
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APPENDIX 3 – KUKA LBR
Instance 2
No.
Activity
1
The configured reaction is triggered if the input is LOW (state “0”).
Parameter
OK
Value
Input for safety signal Input PROFIsafe Byte 0/1
AMF Operating mode Automatic
Instance 1
No.
Activity
OK
1
The configured reaction is triggered in AUT.
AMF Operating mode Test
Instance 1
No.
Activity
1
The configured reaction is triggered in T1.
2
The configured reaction is triggered in T2.
3
The configured reaction is triggered in CRR.
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OK
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Programmable Safety Systems
Date:
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Rev No.
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APPENDIX 3 – KUKA LBR
AMF Operating mode with high speed
Instance 1
No.
Activity
OK
1
The configured reaction is triggered in T2.
2
The configured reaction is triggered in AUT.
AMF Operating mode with reduced speed
Instance 1
No.
Activity
OK
1
The configured reaction is triggered in T1.
2
The configured reaction is triggered in CRR.
Tool selection table
Row Assigned kinematic system Selected tool Activation signal
1
First kinematic system
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No tool
OK
Always active
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Per Standard No.
w-EL10
Programmable Safety Systems
APPENDIX 3 – KUKA LBR
Date:
August 9, 2017
Rev No.
1.0
Mounting position
Kinematic system 1
Parameter Value
Orientation
A 0.0°
B 0.0°
C 0.0°
This parameter is verified by means of the relevant AMFs and does not need to be verified explicitly. It is
not relevant for mobile platforms.
General settings
This parameter determines which safe input is used in order to activate the external position referencing.
No.
1
Activity
OK
When the external position referencing input is set to HIGH for less than 2 s, the warning
"Axis not referenced" will no longer be shown, if the external position referencing is
configured to be allowed.
Parameter
Value
External position referencing allowed false
Input for external position referencing Input PROFIsafe Byte 0/0
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Manufacturing
Standards
Per Standard No.
w-EL10
Date:
August 9, 2017
Programmable Safety Systems
Rev No.
1.0
APPENDIX 3 – KUKA LBR
smartPAD unplugging
This parameter determines whether it is allowed to safely unplug the smartPAD during operation.
No.
1
Activity
OK
The configured value can be verified in AUT, when the robot is moving. Press the
unplugging button, unplug the smartPAD and verify the behavior.
Parameter
Value
smartPAD unplugging allowed true
Input for the deactivation of safety functions
This parameter determines which safe input is used in order to activate the muting.
No.
1
Activity
OK
Trigger a safety stop by a violation of one of the mutable AMFs. The expected behavior
occurs when you set the muting input and try to move the robot.
Parameter
Value
Muting allowed
false
Input for the deactivation of safety functions Input PROFIsafe Byte 0/0
Warnings
The following inconsistencies were found. Please explain why these do not have a detrimental effect on
your safety concept.
No.
Description
1
Position or torque-based AMFs are used;
therefore, a brake test should be planned and
an application created for this purpose. If this
is not planned, please explain your decision.
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Global
Manufacturing
Standards
Per Standard No.
w-EL10
Programmable Safety Systems
Date:
August 9, 2017
Rev No.
1.0
APPENDIX 3 – KUKA LBR
7. Worksheet - Tool Selection
This worksheet is used to check the mapped safety-oriented tools. For each row in the tool selection
table, it is necessary to check the tool has been correctly assigned.
Row Number:
Assigned kinematic system:
Selected tool:
Activation signal
(always active/name of input):
No.
Activity
1
The row has been checked successfully: the correct tool
has been assigned to the kinematic system?
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Yes
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Global
Manufacturing
Standards
Per Standard No.
w-EL10
Programmable Safety Systems
Date:
August 9, 2017
Rev No.
1.0
APPENDIX 3 – KUKA LBR
8. Worksheet - Pickup frame for fixed tools
If the fixed tool of a kinematic system can pick up activatable tools, and one of the following AMF,
which pertains to a fixed tool is used in the safety configuration, then position and orientation of the
pickup frame of the fixed tool must be checked.
•
•
•
•
•
•
•
•
Cartesian velocity monitoring
Only if the monitoring spheres on the tool are configured as a structure to be monitored.
Tool-related velocity component
Cartesian workspace monitoring/Cartesian protected space monitoring
Only if the monitoring spheres on the tool are configured as a structure to be monitored.
Tool orientation
Collision detection
TCP force monitoring
Base-related TCP force component
Torque referencing
Name of the fixed tool:
No.
Activity
1
Position and orientation of the pickup frame have been
checked successfully?
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Yes
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Global
Manufacturing
Standards
Per Standard No.
w-EL10
Programmable Safety Systems
Date:
August 9, 2017
Rev No.
1.0
APPENDIX 3 – KUKA LBR
9. Worksheet - Pickup frame for fixed tools with workpiece
If the fixed tool of a kinematic system can pick up workpieces, and one of the following AMF, which
pertains to a fixed tool is used in the safety configuration, then position and orientation of the pickup
frame of the fixed tool must be checked.
•
•
•
•
Collision detection
TCP force monitoring
Base-related TCP force component
Torque referencing
Name of the fixed tool:
No.
Activity
1
Position and orientation of the pickup frame have been
checked successfully?
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Yes
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Global
Manufacturing
Standards
Per Standard No.
w-EL10
Programmable Safety Systems
Date:
August 9, 2017
Rev No.
1.0
APPENDIX 3 – KUKA LBR
10. Worksheet - Pickup frame for activatable tools
If an activatable tool of a kinematic system can pick up a workpiece, and one of the following AMF is
used in the safety configuration, the position and orientation of the pickup frame of the activatable
tool must be checked.
•
•
•
•
Collision detection
TCP force monitoring
Base-related TCP force component
Torque referencing
Name of the activatable tool:
No.
Activity
1
Position and orientation of the pickup frame have been
checked successfully?
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Yes
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Global
Manufacturing
Standards
Per Standard No.
w-EL10
Programmable Safety Systems
Date:
August 9, 2017
Rev No.
1.0
APPENDIX 3 – KUKA LBR
11. Worksheet - Geometry data of the tool
If one of the following AMF is used in the safety configuration, it is necessary to check whether the
geometric tool data have been entered correctly:
•
•
Cartesian velocity monitoring
Only if the monitoring spheres on the tool are configured as a structure to be monitored.
Cartesian workspace monitoring/Cartesian protected space monitoring
only if the monitoring spheres on the tool are configured as a structure to be monitored.
Name of the safety-oriented tool:
No.
1
2
3
4
5
6
Activity
Yes
Not
Relevant
Comment
Tool sphere (frame name) ________________ Have
the radius and positon of the tool sphere been correctly
entered and checked?
Tool sphere (frame name) ________________ Have
the radius and positon of the tool sphere been correctly
entered and checked?
Tool sphere (frame name) ________________ Have
the radius and positon of the tool sphere been correctly
entered and checked?
Tool sphere (frame name) ________________ Have
the radius and positon of the tool sphere been correctly
entered and checked?
Tool sphere (frame name) ________________ Have
the radius and positon of the tool sphere been correctly
entered and checked?
Tool sphere (frame name) ________________ Have
the radius and positon of the tool sphere been correctly
entered and checked?
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Per Standard No.
w-EL10
Programmable Safety Systems
Date:
August 9, 2017
Rev No.
1.0
APPENDIX 3 – KUKA LBR
12. Worksheet - Load data of the tool
If one of the following AMF is used in the safety configuration, it is necessary to check whether the
load data of the safety-oriented tool has been configured correctly:
•
•
•
•
Collision detection
TCP force monitoring
Base-related TCP force component
Torque referencing
Name of the tool:
Mass:
Center of Mass
MS X:
MS Y:
MS Z:
No.
Activity
1
Has the load data of the tool been correctly entered and
checked?
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Yes
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Per Standard No.
w-EL10
Programmable Safety Systems
Date:
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Rev No.
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APPENDIX 3 – KUKA LBR
13. Worksheet - Safety-oriented workpieces
If one of the following AMF is used in the safety configuration, it is necessary to check whether the
load data of the safety-oriented workpieces has been entered correctly:
•
•
•
Collision detection
TCP force monitoring
Base-related TCP force component
No.
Activity
Yes
Not
Relevant
Comment
Name of workpiece: ____________________ Have the
load data of the workpiece been correctly entered and
check?
1
•
•
Mass: _____________________________
Center of Mass
o MS X: __________________________
o MS Y: __________________________
o MS Z: __________________________
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Per Standard No.
w-EL10
Programmable Safety Systems
Date:
August 9, 2017
Rev No.
1.0
APPENDIX 3 – KUKA LBR
14. Worksheet - Permanent Safety Monitoring (PSM) Table
Each row in the PSM table KUKA PSM and the PSM table Customer PSM must be tested to verify
that the expected reaction is triggered. This worksheet is used with the Safety Configuration Report
to test all combinations of AMF that comprise a row.
Row number:
No.
Activity
Yes
Not
Relevant
Comment
AMF 1 was tested successfully while AMF 2 and AMF 3
are violated?
1
AMF 1: _______________________________
AMF 2 was tested successfully while AMF 1 and AMF 3
are violated?
2
AMF 2: _______________________________
AMF 3 was tested successfully while AMF 1 and AMF 2
are violated?
3
AMF3: _______________________________
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Per Standard No.
w-EL10
Programmable Safety Systems
Date:
August 9, 2017
Rev No.
1.0
APPENDIX 3 – KUKA LBR
15. Worksheet - Event Safety Monitoring (ESM) states
Each row in the ESM state must be tested to verify the expected reaction is triggered when the
configured AMF is violated.
ESM State:
No.
Activity
Yes
Not
Relevant
Comment
AMF 1 was tested successfully.
1
AMF 1: _______________________________
AMF 2 was tested successfully.
2
AMF 2: _______________________________
AMF 3 was tested successfully.
3
AMF 3: _______________________________
AMF 4 was tested successfully.
4
AMF 4: _______________________________
AMF 5 was tested successfully.
5
AMF 5: _______________________________
City and Date:
Signature:
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Per Standard No.
w-EL10
Programmable Safety Systems
Date:
August 9, 2017
Rev No.
1.0
APPENDIX 3 – KUKA LBR
16. Worksheet - Non-Used Event Safety Monitoring (ESM) states
All ESM states which are not used must be tested as to whether a safety stop is triggered when the
ESM state is selected.
No.
Activity
1
Selection of non-used ESM state 1 was tested
successfully?
2
Selection of non-used ESM state 2 was tested
successfully?
3
Selection of non-used ESM state 3 was tested
successfully?
4
Selection of non-used ESM state 4 was tested
successfully?
5
Selection of non-used ESM state 5 was tested
successfully?
6
Selection of non-used ESM state 6 was tested
successfully?
7
Selection of non-used ESM state 7 was tested
successfully?
8
Selection of non-used ESM state 8 was tested
successfully?
9
Selection of non-used ESM state 9 was tested
successfully?
10
Selection of non-used ESM state 10 was tested
successfully?
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Yes
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Per Standard No.
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Programmable Safety Systems
Date:
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Rev No.
1.0
APPENDIX 3 – KUKA LBR
17. Worksheet - smartPAD unplugging allowed
The safety parameter smartPAD unplugging allowed in the station configuration determines whether
it is possible to move the robot with the smartPAD unplugged. The configured response must be
tested while the robot is moving in Automatic mode.
•
•
Disconnection is not allowed:
If the smartPAD is disconnected, the robot is topped with a safety stop.
Disconnection is allowed:
If the smartPAD is disconnected, the robot continues moving.
SmartPAD unplugging allowed
(true/false):
No.
1
Activity
Yes
Not
Relevant
Comment
The expected response occurs if the smartPAD is
unplugged while the robot is moving in Automatic
mode?
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Standards
Per Standard No.
w-EL10
Programmable Safety Systems
Date:
August 9, 2017
Rev No.
1.0
APPENDIX 3 – KUKA LBR
18. Worksheet - Allow muting via input
If a safety-oriented input that allows the deactivation of safety functions is configured in the project
settings, a safety stop triggered by one of the following AMF can be briefly suspended:
•
•
•
•
•
•
•
•
•
•
•
Axis range monitoring
Cartesian workspace monitoring
Cartesian protected space monitoring
Tool orientation
Tool-related velocity component
Standstill monitoring of all axes
Position referencing
Torque referencing
Collision detection
TCP force monitoring
Base-related TCP force component
The configured input must be tested. For this, a safety stop must be triggered using at least one of
the above AMF.
•
•
Deactivation of safety functions via an input is not allowed:
If the configured input is set to HIGH and retains this value, the robot cannot be moved when the
corresponding AMF is violated.
Deactivation of safety functions via an input is allowed:
If the configured input is set to HIGH and retains this value, the robot can be moved for five
seconds even though the corresponding AMF is violated.
Allow muting via input
(true/false):
Configured input:
No.
Activity
1
The expected response occurs when the configured
input is set to HIGH and an attempt is made to move the
robot?
Printed: 7/24/2017
Yes
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Relevant
Comment
Originated:
Revised:
24-Jul-2017
24-Jul-2017
Appendix No.
APPENDIX 3 – KUKA LBR
Global
Manufacturing
Standards
Per Standard No.
w-EL10
Programmable Safety Systems
Date:
August 9, 2017
Rev No.
1.0
APPENDIX 3 – KUKA LBR
19. Worksheet - Allow external position referencing
If a safety-oriented input that allows external position referencing is configured in the project settings,
this input must be tested.
The axis positions are not referenced after a reboot of the robot controller. If the safety configuration
contains a position-based AMF, the warning “Axis not referenced” is displayed. The warning may no
longer be displayed if the input via which the external position referencing is carried out is set to
HIGH for less than two seconds.
Allow external position referencing
(true/false):
Configured input:
No.
Activity
1
The expected response occurs if the configured input is
set HIGH for less than two seconds?
Printed: 7/24/2017
Yes
Page 27 of 27
UNCONTROLLED DOCUMENT
Not
Relevant
Comment
Originated:
Revised:
24-Jul-2017
24-Jul-2017