KUKA SafeOperation 3.6: Assembly & Operating Instructions

KST System Technology KUKA.SafeOperation 3.6 For KUKA System Software 8.7 Assembly and Operating Instructions Issued: 10.10.2022 KST SafeOperation 3.6 V3 KUKA Deutschland GmbH KUKA.SafeOperation 3.6 © Copyright 2022 KUKA Deutschland 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 KUKA Deutschland GmbH. 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 described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee 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-PS5-DOC Translation of the original documentation Publication: Pub KST SafeOperation 3.6 (PDF) en PB14570 Book structure: KST SafeOperation 3.6 V3.1 BS13138 Version: 2/304 | www.kuka.com KST SafeOperation 3.6 V3 KST SafeOperation 3.6 V3 | Issued: 10.10.2022 KUKA.SafeOperation 3.6 Contents 1 Introduction.............................................................................................. 9 1.1 1.2 1.3 1.4 1.5 1.6 Target group.......................................................................................................... Industrial robot documentation.............................................................................. Representation of warnings and notes................................................................. Trademarks............................................................................................................ Terms used............................................................................................................ Licenses................................................................................................................. 9 9 9 10 10 12 2 Product description................................................................................. 13 2.1 2.2 2.3 2.4 2.4.1 2.4.2 2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.5.7 2.5.8 2.5.9 2.5.10 2.6 2.7 2.8 Product description................................................................................................ Functional description............................................................................................ Safety interfaces.................................................................................................... Hardware components.......................................................................................... Reference switch module (optional)..................................................................... Connecting cables................................................................................................. Monitoring spaces................................................................................................. Stop reactions without “Braking before restricted areas”..................................... Stop reactions with “Braking before restricted areas”.......................................... Cell area................................................................................................................ Cartesian workspaces........................................................................................... Cartesian protected spaces.................................................................................. Axis-specific workspaces....................................................................................... Axis-specific protected spaces.............................................................................. Braking before restricted areas............................................................................. Space-specific velocity.......................................................................................... Reference stop...................................................................................................... Safety-oriented tools.............................................................................................. Velocity monitoring functions................................................................................. Safe operational stop for axis groups.................................................................. 13 13 15 16 16 17 18 19 20 20 22 23 25 26 28 30 30 31 32 33 3 Safety......................................................................................................... 35 3.1 3.1.1 3.1.2 3.1.3 3.2 3.3 3.3.1 3.4 3.5 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.6 General.................................................................................................................. Disclaimer.............................................................................................................. EC declaration of conformity and declaration of incorporation............................ Terms in the “Safety” chapter............................................................................... Personnel............................................................................................................... Workspace, safety zone and danger zone........................................................... Determining stopping distances............................................................................ Triggers for stop reactions: KSS........................................................................... Triggers for stop reactions: VSS........................................................................... Safety functions..................................................................................................... Overview of the safety functions.......................................................................... Safety controller..................................................................................................... “Operator safety” signal: KSS............................................................................... “Operator safety” signal: VSS............................................................................... EMERGENCY STOP device................................................................................. Logging off from the higher-level safety controller............................................... 35 35 35 36 39 40 40 41 41 42 42 43 43 44 44 45 KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 3/304 KUKA.SafeOperation 3.6 3.6.7 3.6.8 3.6.9 3.6.10 3.7 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5 3.7.6 3.7.7 3.7.8 3.8 3.9 3.10 3.11 3.12 3.12.1 3.12.2 3.12.3 3.12.4 3.12.4.1 3.12.4.2 3.12.5 3.12.6 3.12.7 3.12.8 3.12.9 3.12.10 External EMERGENCY STOP device.................................................................. Enabling device..................................................................................................... External enabling device....................................................................................... Velocity monitoring in T1....................................................................................... Additional protective equipment............................................................................ Jog mode............................................................................................................... Software limit switches.......................................................................................... Mechanical end stops........................................................................................... Mechanical axis limitation (optional)..................................................................... Options for moving the manipulator without drive energy................................... Labeling on the industrial robot............................................................................ External safeguards............................................................................................... “Drives ready” lamp............................................................................................... Operating mode selection: KSS............................................................................ Overview of operating modes and safety functions: KSS................................... Operating mode selection: VSS............................................................................ Overview of operating modes and safety functions: VSS................................... Safety measures.................................................................................................... General safety measures...................................................................................... IT security.............................................................................................................. Transportation........................................................................................................ Start-up and recommissioning: KSS/VSS............................................................. Checking machine data and safety configuration................................................ Start-up mode........................................................................................................ Manual mode......................................................................................................... Simulation.............................................................................................................. Automatic mode..................................................................................................... Maintenance and repair........................................................................................ Decommissioning, storage and disposal.............................................................. Safety measures for single point of control......................................................... 46 46 47 47 48 48 48 48 49 49 50 50 51 51 52 52 54 54 54 56 56 57 59 62 63 64 64 64 66 66 4 Technical data.......................................................................................... 69 4.1 4.2 4.3 4.4 4.5 Service life............................................................................................................. Reference switch................................................................................................... Reference cable XG42 - XS Ref.......................................................................... Circuit diagram of reference switch XS Ref......................................................... Hole pattern for actuating plate............................................................................ 69 69 71 72 73 5 Installation................................................................................................ 75 5.1 5.2 5.2.1 5.2.2 5.3 5.3.1 5.3.2 System requirements............................................................................................. Installing via WorkVisual....................................................................................... Installing or updating KUKA.SafeOperation 3.6................................................... Uninstalling KUKA.SafeOperation 3.6................................................................... Installing via smartHMI.......................................................................................... Installing or updating KUKA.SafeOperation 3.6................................................... Uninstalling KUKA.SafeOperation 3.6................................................................... 75 75 75 76 77 77 78 6 Operation.................................................................................................. 81 6.1 6.2 User groups........................................................................................................... Displaying user rights............................................................................................ 81 82 4/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 KUKA.SafeOperation 3.6 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 Opening the safety configuration.......................................................................... Overview of buttons.............................................................................................. Displaying information about the safety configuration......................................... Displaying the revision log.................................................................................... Displaying machine data....................................................................................... Importing the safety configuration (XML import).................................................. Exporting the safety configuration (XML export).................................................. Safe robot retraction in case of space violation.................................................. 82 82 83 84 84 84 87 87 7 Start-up and configuration..................................................................... 89 7.1 7.2 7.3 7.4 7.4.1 7.4.2 7.4.3 7.5 7.5.1 7.5.2 7.5.2.1 7.5.3 7.5.4 7.5.5 7.5.6 7.5.7 7.5.7.1 7.5.7.2 7.5.8 7.5.9 7.5.10 7.5.11 7.6 7.7 7.7.1 7.7.1.1 7.7.1.2 7.7.1.3 7.7.1.4 7.7.1.5 7.7.1.6 7.7.1.7 7.7.1.8 7.7.2 7.7.2.1 7.7.2.2 7.7.2.3 7.7.2.4 7.7.2.5 System safety instructions.................................................................................... Jogging the robot without a higher-level safety controller................................... Overview: start-up and configuration.................................................................... Information about the safety configuration........................................................... Safe definition of Cartesian protected spaces..................................................... Safe definition of Cartesian protected spaces for BBRA..................................... Unexpected protected space violation at space corners..................................... Configuring safety monitoring functions................................................................ Activating safe monitoring..................................................................................... Configuring global parameters.............................................................................. Switching safe Cartesian monitoring on/off.......................................................... Configuring a safety-oriented tool......................................................................... Configuring a cell area.......................................................................................... Configuring a Cartesian monitoring space........................................................... Configuring an axis-specific monitoring space..................................................... Configuring axis-specific velocity monitoring functions and braking time............ Parameter: Braking time....................................................................................... Parameter: Maximum velocity T1......................................................................... Configuring safe operational stop for axis groups............................................... Activating “Braking before restricted areas”......................................................... Configuring the reference position and reference group..................................... Saving the safety configuration............................................................................. Editing the local safety configuration in WorkVisual............................................ Mastering test........................................................................................................ Mastering test via reference switch...................................................................... Programs for the mastering test........................................................................... Selecting a reference position.............................................................................. Installing the reference switch and actuating plate.............................................. Connecting the reference switch.......................................................................... Configuring the reference groups to be checked in file....................................... Teaching positions for the mastering test............................................................. Checking the reference position (actuation with tool).......................................... Performing a mastering test manually.................................................................. System variables for mastering test..................................................................... $MASTERINGTEST_ACTIVE............................................................................... $MASTERINGTEST_GROUP............................................................................... $MASTERINGTEST_REQ_INT............................................................................. $MASTERINGTEST_REQ_EXT............................................................................ $MASTERINGTEST_SWITCH_OK....................................................................... 89 90 91 92 93 95 96 97 97 97 99 101 105 107 111 115 119 121 122 124 128 131 131 132 133 135 135 137 138 139 140 142 143 144 144 144 145 145 146 KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 5/304 KUKA.SafeOperation 3.6 7.7.3 7.7.3.1 7.7.3.2 7.8 7.8.1 7.8.2 7.8.3 7.8.4 7.8.4.1 7.8.4.2 7.8.4.3 7.8.4.4 7.8.4.5 7.8.4.6 7.8.5 7.8.5.1 7.8.5.2 7.8.5.3 7.8.6 7.8.7 7.8.7.1 7.8.7.2 7.9 7.9.1 7.9.2 7.9.3 7.9.4 7.9.5 7.9.6 7.10 7.11 7.11.1 7.11.2 7.11.3 7.11.4 7.11.5 7.11.6 7.11.7 7.11.8 7.11.9 7.12 7.13 7.14 Mastering test with external mastering confirmation............................................ Signal diagram: external mastering confirmation................................................. Safety acceptance: checking the external mastering confirmation...................... Brake test.............................................................................................................. Overview of the brake test.................................................................................... Sequence when testing a brake........................................................................... Programs for the brake test.................................................................................. Overview of the brake test setup......................................................................... Activating the brake test, defining the cycle time and axes................................ “Brake test configuration” window......................................................................... Configuring input and output signals for the brake test...................................... Signal diagram of the brake test – examples...................................................... Teaching positions for the brake test................................................................... Testing the sequence in the case of defective brakes........................................ Performing a brake test........................................................................................ Performing a brake test for requested axes (cyclically via program).................. Performing a brake test for active axes (manually)............................................. Performing a brake test for further axes (e.g. couplable axes)........................... Automatic brake check.......................................................................................... System functions for the brake test...................................................................... GET_AXESMASK: requesting information about the axes for the brake test.... GET_BRAKETEST_TIME: requesting time values for brake test....................... Override reduction................................................................................................. $SR_VEL_RED...................................................................................................... $SR_OV_RED....................................................................................................... $SR_WORKSPACE_RED..................................................................................... Override reduction before space limits without BBRA......................................... Override reduction before space limits with BBRA.............................................. Changing workspace: override reduction for velocity limits (example without BBRA).................................................................................................................... Safety acceptance overview................................................................................. Checking the safety functions for correct operation............................................ Checking a safety-oriented tool............................................................................ Checking a cell area............................................................................................. Checking Cartesian monitoring spaces................................................................ Checking axis-specific monitoring spaces............................................................ Checking the space-specific velocity.................................................................... Checking Cartesian velocity limits........................................................................ Checking axis-specific velocity limits.................................................................... Checking the safe operational stop for axis groups............................................ Checking the values for the maximum braking ramp.......................................... Checking the values for the safe axis monitoring functions................................ Activating the safety configuration........................................................................ Deactivating safe monitoring................................................................................. 176 177 178 178 179 180 181 182 183 184 186 187 190 191 192 8 Interfaces to the higher-level controller............................................... 193 8.1 8.1.1 8.1.2 Safety functions via Ethernet safety interface (optional)..................................... KUKA.SafeOperation via Ethernet safety interface.............................................. Diagnostic signals via Ethernet interface............................................................. 193 197 201 6/304 | www.kuka.com 147 148 149 149 149 151 151 152 153 154 155 158 159 160 161 161 163 165 166 167 167 168 169 170 171 172 172 174 KST SafeOperation 3.6 V3 | Issued: 10.10.2022 KUKA.SafeOperation 3.6 8.2 8.3 KUKA.SafeOperation via interface XG13............................................................. Mastering test via interface XG42........................................................................ 205 208 9 Diagnosis.................................................................................................. 209 9.1 9.2 9.3 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.3.7 9.3.8 9.3.9 9.3.10 9.3.11 9.4 Displaying the diagnostic data with the diagnostic monitor................................. Displaying the diagnostic data for the safety interface........................................ System variables for diagnosis of the safety monitoring functions..................... $SR_ACTIVETOOL............................................................................................... $SR_AXISSPEED_OK.......................................................................................... $SR_CARTSPEED_OK......................................................................................... $SR_DRIVES_ENABLE........................................................................................ $SR_MOVE_ENABLE........................................................................................... $SR_RANGE_ACTIVE.......................................................................................... $SR_RANGE_OK.................................................................................................. $SR_SAFEMON_ACTIVE..................................................................................... $SR_SAFEOPSTOP_ACTIVE............................................................................... $SR_SAFEOPSTOP_OK...................................................................................... $SR_SAFEREDSPEED_ACTIVE.......................................................................... Outputs for space monitoring................................................................................ 209 209 209 209 210 210 211 211 211 212 213 213 214 214 214 10 Messages.................................................................................................. 217 10.1 10.2 10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6 10.2.7 10.2.8 10.2.9 10.2.10 10.2.11 10.2.12 10.2.13 10.2.14 10.2.15 10.2.16 10.2.17 10.2.18 10.2.19 10.2.20 10.2.21 10.2.22 10.2.23 10.2.24 10.2.25 10.2.26 Information about the messages.......................................................................... System messages from module: CrossMeld (KSS)............................................. KSS15016.............................................................................................................. KSS15017.............................................................................................................. KSS15018.............................................................................................................. KSS15019.............................................................................................................. KSS15033.............................................................................................................. KSS15034.............................................................................................................. KSS15035.............................................................................................................. KSS15036.............................................................................................................. KSS15037.............................................................................................................. KSS15039.............................................................................................................. KSS15040.............................................................................................................. KSS15041.............................................................................................................. KSS15042.............................................................................................................. KSS15043.............................................................................................................. KSS15044.............................................................................................................. KSS15045.............................................................................................................. KSS15046.............................................................................................................. KSS15047.............................................................................................................. KSS15048.............................................................................................................. KSS15049.............................................................................................................. KSS15050.............................................................................................................. KSS15051.............................................................................................................. KSS15052.............................................................................................................. KSS15053.............................................................................................................. KSS15054.............................................................................................................. KSS15065.............................................................................................................. 217 217 217 217 218 221 225 225 226 227 227 228 230 231 233 234 236 237 241 241 242 242 243 244 245 247 248 249 KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 7/304 KUKA.SafeOperation 3.6 10.2.27 10.2.28 10.2.29 10.2.30 10.2.31 10.2.32 10.2.33 10.2.34 10.2.35 10.2.36 10.2.37 10.2.38 10.2.39 10.2.40 10.2.41 KSS15066.............................................................................................................. KSS15079.............................................................................................................. KSS15081.............................................................................................................. KSS15083.............................................................................................................. KSS15107.............................................................................................................. KSS15108.............................................................................................................. KSS15109.............................................................................................................. KSS15110.............................................................................................................. KSS15111.............................................................................................................. KSS15112.............................................................................................................. KSS15113.............................................................................................................. KSS15114.............................................................................................................. KSS15127.............................................................................................................. KSS15134.............................................................................................................. KSS15135.............................................................................................................. 249 254 255 256 256 258 259 261 261 262 263 265 265 267 267 11 Appendix................................................................................................... 269 11.1 11.1.1 11.1.2 11.1.3 11.1.4 11.1.5 11.1.6 11.1.7 11.1.8 11.1.9 11.1.10 11.1.11 11.2 Checklists for safety acceptance.......................................................................... Precondition for safety acceptance based on the checklists............................... Checklist: Robot and system................................................................................ Checklist: Safety functions.................................................................................... Checklist: Safety-oriented tools............................................................................. Checklist: Cell area............................................................................................... Checklist: Cartesian monitoring spaces................................................................ Checklist: Axis-specific monitoring spaces........................................................... Checklist: Cartesian velocity monitoring functions............................................... Checklist: axis-specific velocity monitoring functions........................................... Checklist: Safe operational stop for axis groups................................................. Checklist: Braking before restricted areas............................................................ Applied standards and regulations....................................................................... 269 269 269 270 275 280 282 284 288 290 293 295 297 12 KUKA Service........................................................................................... 299 12.1 12.2 Requesting support............................................................................................... KUKA Customer Support...................................................................................... 299 299 Index 301 8/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 1 Introduction 1.1 Target group Introduction KUKA.SafeOperation 3.6 This documentation is aimed at users with the following knowledge and skills: • Advanced knowledge of the robot controller system • Advanced KRL programming skills For optimal use of KUKA products, we recommend the training courses offered by KUKA College. Information about the training program can be found at www.kuka.com or can be obtained directly from our subsidiaries. 1.2 Industrial robot documentation The industrial robot documentation consists of the following parts: • • • • • • Documentation for the robot arm Documentation for the robot controller Documentation for the smartPAD-2 or smartPAD pro (if used) Operating and programming instructions for the System Software Instructions for options and accessories Spare parts overview in KUKA Xpert Each set of instructions is a separate document. 1.3 Representation of warnings and notes Safety These warnings are provided for safety purposes and must be observed. DANGER These warnings mean that it is certain or highly probable that death or severe injuries will occur, if no precautions are taken. WARNING These warnings mean that death or severe injuries may occur, if no precautions are taken. CAUTION These warnings mean that minor injuries may occur, if no precautions are taken. NOTICE These warnings mean that damage to property may occur, if no precautions are taken. These warnings contain references to safety-relevant information or general safety measures. These warnings do not refer to individual hazards or individual precautionary measures. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 9/304 KUKA.SafeOperation 3.6 Introduction This warning draws attention to procedures which serve to prevent or remedy emergencies or malfunctions: SAFETY INSTRUCTION The following procedure must be followed exactly! Procedures marked with this warning must be followed exactly. Notices These notices serve to make your work easier or contain references to further information. Tip to make your work easier or reference to further information. 1.4 Trademarks CIP Safety® is a trademark of ODVA. EtherCAT® is a registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany. PROFINET is a trademark of the PROFIBUS users’ organization. 1.5 Terms used Term Description Workspace Monitoring space that the defined axes or the safety-oriented tool are not allowed to leave. The axes or the safety-oriented tool must always move within the limits of the workspace. BBRA Braking before restricted areas BBRA is an optionally selectable safety function that changes the way the robot behaves at the limits of monitoring spaces: • With this function, the fictitious STOP 1 - DRS end position based on the actual position is monitored in addition to the actual position. • If the end point of this precalculated stop threatens to violate a monitoring space, a drive ramp stop with stop category 1 is triggered. CIP Safety Common Industrial Protocol Safety CIP Safety is an Ethernet/IP-based safety interface for connecting a safety PLC to the robot controller (PLC = master, robot controller = slave). CK Customer-built Kinematics DRS Drive Ramp Stop Synchronous stop at drive level (also: maximum braking) EtherCAT Ethernet for Control Automation Technology Ethernet-based field bus that is suitable for real-time requirements (Ethernet interface). 10/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 EtherNet/IP Ethernet Industrial Protocol EtherNet/IP is an Ethernet-based field bus (Ethernet interface). Fictitious STOP 1 DRS end position End position of a drive ramp stop calculated from the current robot state. FSoE FailSafe over EtherCAT Protocol for transferring safety-relevant data via EtherCAT. An FSoE master and an FSoE slave are used for this. IFBSafeExt Interface Board Safe Extended Interface Board with the safety-oriented I/Os for implementation of the discrete safety interface XG13 Mastering test A mastering test checks at a suitable reference position whether the saved reference position of the motor of an axis corresponds to the actual mechanical position of the axis. KL KUKA linear unit KR C KUKA Robot Control Robot controller Alarm space An alarm space signals a workspace violation by setting an output. The alarm spaces are permanently assigned to the configurable outputs of the safety interface used. Monitoring time Time interval beginning with the request for a mastering test or brake test The monitoring time is 2 hours. The mastering test or brake test is to be carried out within this time. The robot then stops and can no longer be moved without a mastering test or brake test. Polygon, convex Polygon consisting of at least 3 different corners, e.g. triangle, rectangle, etc. PROFINET Ethernet-based field bus (Ethernet interface) PROFIsafe PROFINET-based safety interface for connecting a safety PLC to the robot controller (PLC = master, robot controller = slave) Reference group A reference group contains the axes of a kinematic system that are required for moving to a reference position and are to be subjected to safety-oriented monitoring. Reference position Cartesian position to which the robot moves during the mastering test Reference switch Sensor that is used for the mastering test and detects when an axis has reached the saved reference position Reference stop Safety stop that is triggered if the mastering test is missing. The reference stop can be activated for monitoring spaces. Protected space Monitoring space into which the defined axes or the safety-oriented tool are not allowed to intrude. The axes or the safety-oriented tool must always move outside the limits of the protected space. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 11/304 Introduction KUKA.SafeOperation 3.6 Introduction KUKA.SafeOperation 3.6 Safety-oriented tool A safety-oriented tool can be modeled using up to 12 configurable spheres. These spheres are monitored against the limits of the Cartesian monitoring spaces. Each safety-oriented tool has a safety-oriented TCP against which the configured velocity limits are monitored. Monitoring space A monitoring space can be defined as a Cartesian cuboid or by means of individual axis ranges. Each monitoring space can be set as a workspace or protected space. Cell area Cartesian workspace that forms a convex polygon with 3 … 10 vertices (corners) and is limited in ±Z direction. The cell area is the maximum permitted working range of the robot. 1.6 Licenses The KUKA license conditions and the license conditions of the opensource software used can be found in the following folders: • Under .\LICENSE on the data storage medium with the installation files of the KUKA software • On the KUKA smartHMI, in the main menu under Help > Info, tab Licenses • Under D:\KUKA_OPT\Option package name\LICENSE on the robot controller • In the license folder under the name of the option package in the Options catalog in WorkVisual Further information about open-source licenses can be requested from the following address: opensource@kuka.com 12/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 2 Product description 2.1 Product description Product description KUKA.SafeOperation 3.6 Description KUKA.SafeOperation 3.6 is a safety option that can be used to implement safety-oriented monitoring functions. Areas of application include HRC applications or the replacement of conventional workspace monitoring functions. Functions • Safety-oriented monitoring of up to 16 user-defined, axis-specific or Cartesian monitoring spaces • Safety-oriented monitoring of a user-defined cell area • Braking before restricted areas (BBRA) • Safety-oriented monitoring of the axis-specific, Cartesian and spacespecific velocities • Modeling of up to 16 safety-oriented tools with safety-oriented TCP • Safe stop via safety controller • Safe operational stop of up to 6 axis groups (maximum of 8 axes in each axis group) • Connection to a higher-level controller, e.g. to a safety PLC • Safety-oriented inputs for activation of the monitoring functions • Safety-oriented outputs for status messages of the monitoring functions • Creation and editing of the safety configuration on the robot controller and in WorkVisual. • Configurable motion to verify position mastering: ‒ Mastering test via KUKA reference switch ‒ Mastering test via external system with external mastering confirmation 2.2 Functional description Description The industrial robot moves within the limits that have been configured and activated. The actual positions are continuously calculated and monitored against the safety parameters that have been set. If the “Braking before restricted areas” function is active, the fictitious STOP 1 - DRS end position based on the actual position is monitored in addition to the actual position. The safety controller monitors the industrial robot by means of the safety parameters that have been set. If a monitoring limit is violated, the robot and external axes stop. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 13/304 Product description KUKA.SafeOperation 3.6 Fig. 2-1: Example of a cell with SafeOperation 1 Reference switch 5 System control panel 2 Robot 6 Robot controller 3 Loading station 7 Bending machine 4 Safety mat Areas of application • Human-robot cooperation • Direct loading of workpieces without an intermediate support • Replacement of conventional axis range monitoring systems Supported kinematic systems The following KUKA kinematic systems support KUKA.SafeOperation 3.6: Kinematic type Description 6-axis robot Robots with 6 serial rotational axes, e.g. KR AGILUS, KR QUANTEC or TITAN 5-axis palletizing robots Palletizing robots with 5 serial rotational axes 4-axis palletizing robots Palletizing robots with 4 serial rotational axes Axis 5 is moved by a coupling rod. Palletizing robots with 4 rotational axes and main axis coupling Axes 3 and 5 are moved by a coupling rod. 4-axis robots Robots with 4 serial rotational axes (without complete wrist) JET robots on JET TRACK Robots with 5 serial rotational axes mounted on a JET TRACK A JET TRACK is a linear axis module. The carriage constitutes axis 1 of the robot. 14/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Kinematic type Description Robots on ROBROOT kinematic system Robots mounted on a ROBROOT kinematic system ROBROOT kinematic systems can consist of any combination of up to 3 serial axes (linear or rotational). 3-axis linear gantry without wrist axes Robots with up to 3 serial linear main axes 3-axis linear gantry with wrist axes Robots with up to 3 serial linear main axes and up to 3 serial rotational wrist axes Restrictions • Some robot models are not available with KUKA.SafeOperation 3.6 due to their dynamic properties. • Whether a KUKA kinematic system supports BBRA is stored in the machine data. • KUKA.SafeOperation 3.6 cannot and must not be used in conjunction with a CK. • In the case of couplable external axes, safe position sensing is not possible, as the safety controller does not evaluate any mastering information for these axes and the machine data change during the runtime of the controller. On account of this restriction, only the following safety functions are available for couplable external axes: ‒ Monitoring of the maximum axis velocity in T1 ‒ Braking ramp monitoring ‒ Standstill monitoring Safety configuration in WorkVisual The safety configuration can be created and edited either on the robot controller or in WorkVisual. (>>> 7.6 "Editing the local safety configuration in WorkVisual" Page 131) Brake test The brake test serves as a diagnostic measure for the robot axis and external axis brakes. The brakes are activated for the stop reactions safety stop 0 and safety stop 1. If a safety option is installed and the safe monitoring is active, the brake test is automatically active. 2.3 Safety interfaces The following safety interfaces are available for connection to a higher-level controller. The safety-oriented I/Os of these interfaces can be used, for example, to signal a violation of safety monitoring functions. • Ethernet safety interfaces: ‒ EtherCAT/FSoE ‒ EtherNet/IP/CIP Safety ‒ PROFINET/PROFIsafe • Discrete safety interface for safety options: ‒ XG13 via IFBSafeExt KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 15/304 Product description KUKA.SafeOperation 3.6 KUKA.SafeOperation 3.6 Product description The safety-oriented I/Os of the discrete safety interface only offer a reduced range of signals. KUKA.SafeOperation 3.6 can be used without the aforementioned safety interfaces. • Precondition: ‒ Discrete mastering test input available • Reduced range of functions, as no safety-oriented I/Os available: ‒ Only static safety monitoring functions possible ‒ No safe operational stop available for axis groups ‒ No alarm spaces available 2.4 Hardware components 2.4.1 Reference switch module (optional) Description A reference switch module is optionally available for the mastering test via KUKA reference switch. The reference switch module consists of the following components: • Inductive reference switch • Straight or angled actuating plate • Reference cable XG42 - XS Ref Fig. 2-2: Reference switch with straight actuating plate 1 Inductive reference switch 2 Straight actuating plate Cable lengths In combination with a straight or angled actuating plate, reference switch modules are available with various cable lengths. Length Actuating plate 7 m Straight or angled 15 m 25 m 40 m 16/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 2.4.2 Connecting cables Description The diagram (>>> Fig. 2-3) shows an example of the connecting cables of the industrial robot with connected KUKA reference switch. The reference switch is connected to the robot controller via the reference cable. The maximum cable length is 40 m. NOTICE Only the reference cable supplied by KUKA may be used. Only 1 reference switch can be connected directly to the robot controller. If multiple reference groups are required, the reference switches can be connected to the safety PLC and activated via the bus interface that is in use. The safety PLC must evaluate the reference switches and set the Mastering test input accordingly. Ensure 2-channel referencing with external activation of the reference switch If the reference switch is activated via the bus interface, 1-channel referencing must be prevented. • The safety PLC may only set the Mastering test signal to LOW if both input channels have a low level. Fig. 2-3: Connecting cables 1 Robot controller 2 Robot 3 Reference switch 4 Reference cable XG42 - XS Ref 5 Data cable XF21 Bending radius The following bending radii must be observed when installing the reference cable: KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 17/304 Product description KUKA.SafeOperation 3.6 Product description KUKA.SafeOperation 3.6 • Fixed installation: At least 5 x cable diameter • Cable carrier installation: At least 10 x cable diameter 2.5 Monitoring spaces Description A maximum of 16 monitoring spaces can be configured. A cell area must also be configured. A monitoring space can be defined as a Cartesian cuboid or by means of individual axis ranges. Each monitoring space can be set as a workspace or protected space. (>>> 2.5.4 "Cartesian workspaces" Page 22) (>>> 2.5.5 "Cartesian protected spaces" Page 23) (>>> 2.5.6 "Axis-specific workspaces" Page 25) (>>> 2.5.7 "Axis-specific protected spaces" Page 26) For every monitoring space, a space-specific Cartesian velocity can be defined inside or outside the monitoring space. (>>> 2.5.9 "Space-specific velocity" Page 30) For each monitoring space, a reference stop can be set that stops the robot if no mastering test has been carried out. (>>> 2.5.10 "Reference stop" Page 30) Monitoring can be activated and deactivated for each individual monitoring space, or activated by means of safety-oriented inputs. Safety-oriented outputs are permanently assigned to the monitoring spaces. The safety-oriented outputs are set if a monitoring space is violated. It is possible to configure the system in such a way that a safety stop is triggered when the monitoring space is violated (“Stop at boundaries” function). The type of safety stop and the time when the stop is triggered depend on whether the “Braking before restricted areas” function has been activated: • Without “Braking before restricted areas”: safety stop 0 is triggered at the space limit. • With “Braking before restricted areas”: safety stop 1 is triggered before the space limit. (>>> 2.5.8 "Braking before restricted areas" Page 28) Cell area The cell area is a Cartesian workspace in the form of a convex polygon with 3 to 10 vertices (corners) and is limited in the ±Z direction. (>>> 2.5.3 "Cell area" Page 20) The cell area is permanently monitored and always active. The corners can be configured, activated and deactivated individually. If the cell area is violated, a safety stop is triggered. The type of safety stop and the time when the stop is triggered depend on whether the “Braking before restricted areas” function has been activated: • Without “Braking before restricted areas”: Safety stop 0 is triggered at the space limit. • With “Braking before restricted areas”: Safety stop 1 is triggered before the space limit. 18/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 (>>> 2.5.8 "Braking before restricted areas" Page 28) Stopping distance If the robot is stopped by a monitoring function, it requires a certain stopping distance before coming to a standstill. The stopping distance depends primarily on the following factors: • • • • • Robot type Velocity of the robot Position of the robot axes Payload Category and type of stop (STOP 0 or STOP 1) Including stopping distances in the risk assessment The stopping distance when a safety function is triggered varies according to the specific robot type. Failure to take this into consideration when parameterizing the safety functions may result in death, severe injuries or damage to property. • The system integrator must include the stopping distances in the risk assessment and parameterize the safety functions accordingly. Further information about the stopping distances and stopping times can be found in the assembly instructions of the relevant robot. Stop reactions The stop reactions depend on whether the “Braking before restricted areas” function has been activated. (>>> 2.5.1 "Stop reactions without “Braking before restricted areas”" Page 19) (>>> 2.5.2 "Stop reactions with “Braking before restricted areas”" Page 20) 2.5.1 Stop reactions without “Braking before restricted areas” Reaction Description Example Safety stop 0 The stop is triggered in T2, AUT or AUT EXT mode if the robot exceeds a monitoring space limit. Robot exceeds the limit of an activated workspace in Automatic mode. Safety stop 1 The stop is triggered in T1 mode if the robot exceeds a monitoring space limit. Robot exceeds the limit of an activated workspace in T1 mode. The stop is triggered if a monitoring function is just being activated and the robot has already exceeded the monitoring space limit. A protected space in which the robot is currently situated is activated by a safety mat. The stop is triggered in T2, AUT or AUT EXT mode if a reference stop is enabled for an activated monitoring space and a mastering test is requested internally. After a restart of the robot controller, the safety controller requests a mastering test. This stops the robot. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 19/304 Product description KUKA.SafeOperation 3.6 Product description KUKA.SafeOperation 3.6 2.5.2 Stop reactions with “Braking before restricted areas” Reaction Description Example Safety stop 0 A stop is triggered if a safety stop 1 is not performed as expected, i.e. the monitoring of safety stop 1 is violated. The robot cannot execute the controlled safety stop 1 (drive ramp stop) due to overload, power failure or hardware defect. Safety stop 1 DRS The stop is triggered in T2, AUT or AUT EXT mode if there is an imminent space violation by the robot (fictitious STOP 1 - DRS end position exceeds monitoring space limit) or if the robot exceeds a monitoring space limit. Robot approaches a space limit in T2 mode. The robot is stopped as soon as the fictitious STOP 1 - DRS end position exceeds the monitoring space limit. Safety stop 1 The stop is triggered in T1 mode if the robot threatens to violate the space (fictitious STOP 1 - DRS target position exceeds monitoring space limit) or if the robot exceeds a monitoring space limit. The robot exceeds the limit of an activated workspace in T1 mode or the fictitious STOP 1 - DRS target position exceeds the limit of an activated workspace. The stop is triggered if a monitoring function is just being activated and the robot has already exceeded the monitoring space limit or the fictitious STOP 1 - DRS target position is in the activated monitoring space. A protected space in which the robot or the fictitious STOP 1 - DRS end position is currently located is activated by a safety mat. The stop is triggered in T2, AUT or AUT EXT mode if a reference stop for an activated monitoring space is active and a mastering test is requested internally. After a restart of the robot controller, the safety controller requests a mastering test. This brings the robot to a standstill. 2.5.3 Cell area Description The cell area is a Cartesian monitoring space that is limited in the ±Z direction. The cell area is permanently monitored and always active. The safety-oriented tool on the mounting flange of the robot is modeled using up to 12 configurable spheres; 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 violates the limits of the cell area, the robot stops with a safety stop 0 as long as the “Braking before restricted areas” function is not activated. Otherwise, a safety stop 1 is triggered before the space limit. (>>> 2.5.8 "Braking before restricted areas" Page 28) 20/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 WARNING Risk of fatal injury due to unmonitored robot components Cartesian monitoring spaces are only monitored against the spheres used to model the active safety-oriented tool. Robot components situated outside the tool spheres are not monitored and a space violation by these components is not detected. Death, injuries or damage to property may result. • Design and configure Cartesian monitoring spaces and tool spheres in such a manner that the unmonitored robot components do not pose any threat. The cell area is configured in the WORLD coordinate system as a convex polygon with 3 ... 10 corners. A convex polygon is a polygon consisting of at least 3 different corners. The line segments between any 2 corners must not be outside the polygon. Triangles and squares are examples of convex polygons. Fig. 2-4: Example of convex polygon 1 Convex polygon with 6 corners 2 Non-convex polygon with 6 corners Example The diagram shows an example of a configured cell area. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 21/304 Product description KUKA.SafeOperation 3.6 Product description KUKA.SafeOperation 3.6 Fig. 2-5: Example of a cell area 2.5.4 1 Cell area 2 Spheres on safety-oriented tool 3 Robot Cartesian workspaces Description The safety-oriented tool on the mounting flange of the robot is modeled using up to 12 configurable spheres; when the robot moves, these spheres move with it. These spheres are simultaneously monitored against the activated Cartesian workspaces and must move within the workspaces. If the “Braking before restricted areas” function is active, the spheres are additionally monitored at the fictitious STOP 1 - DRS end position. At this fictitious end position, they must move within the workspaces. (>>> 2.5.8 "Braking before restricted areas" Page 28) If a sphere violates the limit of a workspace at the actual position, e.g. when the monitoring space is activated via an input, the following reactions are triggered: • A safety-oriented output is reset (state: “logic 0”). The safety-oriented outputs are set if a monitoring space is not violated (state: “logic 1”). If interface XG13 is used, safety-oriented outputs are only available for monitoring spaces 1 … 6. • The robot is stopped (precondition: parameter Stop at boundaries is activated for the space). • Monitoring of the space-specific velocity is activated (precondition: Space violated is set for the space at parameter Vmax valid if). If a sphere violates the limit of a workspace at the fictitious STOP 1 DRS end position, the following reactions are triggered: 22/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 • The robot is stopped (precondition: parameter Stop at boundaries is activated for the space). WARNING Risk of fatal injury due to unmonitored robot components Cartesian monitoring spaces are only monitored against the spheres used to model the active safety-oriented tool. Robot components situated outside the tool spheres are not monitored and a space violation by these components is not detected. Death, injuries or damage to property may result. • Design and configure Cartesian monitoring spaces and tool spheres in such a manner that the unmonitored robot components do not pose any threat. Example The diagram shows an example of a Cartesian workspace. Fig. 2-6: Example of a Cartesian workspace 2.5.5 1 Workspace 2 Spheres on safety-oriented tool 3 Robot Cartesian protected spaces Description The safety-oriented tool on the mounting flange of the robot is modeled using up to 12 configurable spheres; when the robot moves, these spheres move with it. These spheres are simultaneously monitored against the activated Cartesian protected spaces and must move outside the protected spaces. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 23/304 Product description KUKA.SafeOperation 3.6 KUKA.SafeOperation 3.6 Product description If the “Braking before restricted areas” function is active, the spheres are additionally monitored at the fictitious STOP 1 - DRS end position. At this fictitious end position, they must move outside the protected spaces. (>>> 2.5.8 "Braking before restricted areas" Page 28) The length, width and height of a protected space must not fall below the predefined minimum value. This value depends on the global maximum Cartesian velocity and the radius of the smallest sphere of the safety-oriented tool. (>>> "Minimum protected space dimensions" Page 93) If a sphere violates the limit of a protected space at the actual position, e.g. when the monitoring space is activated via an input, the following reactions are triggered: • A safety-oriented output is reset (state: “logic 0”). The safety-oriented outputs are set if a monitoring space is not violated (state: “logic 1”). If interface XG13 is used, safety-oriented outputs are only available for monitoring spaces 1 … 6. • The robot is stopped (precondition: parameter Stop at boundaries is activated for the space). • Monitoring of the space-specific velocity is activated (precondition: Space violated is set for the space at parameter Vmax valid if). If a sphere violates the limit of a protected space at the fictitious STOP 1 - DRS end position, the following reactions are triggered: • The robot is stopped (precondition: parameter Stop at boundaries is activated for the space). WARNING Risk of fatal injury due to unmonitored robot components Cartesian monitoring spaces are only monitored against the spheres used to model the active safety-oriented tool. Robot components situated outside the tool spheres are not monitored and a space violation by these components is not detected. Death, injuries or damage to property may result. • Design and configure Cartesian monitoring spaces and tool spheres in such a manner that the unmonitored robot components do not pose any threat. Example The diagram shows an example of a Cartesian protected space. 24/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Product description KUKA.SafeOperation 3.6 Fig. 2-7: Example of a Cartesian protected space 2.5.6 1 Protected space 2 Spheres on safety-oriented tool 3 Robot Axis-specific workspaces Description The axis limits can be set and monitored individually for each axis via the software. 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. A maximum of 8 axes or, in the case of kinematic systems with master/ slave axes, a maximum of 8 drives can be configured for each monitoring space. If the “Braking before restricted areas” function is active, an additional check is carried out to ascertain whether the axis position at the fictitious STOP 1 - DRS end position is inside the permissible range. (>>> 2.5.8 "Braking before restricted areas" Page 28) If the robot violates an axis limit with the actual position, e.g. when the monitoring space is activated via an input, the following reactions are triggered: • A safety-oriented output is reset (state: “logic 0”). The safety-oriented outputs are set if a monitoring space is not violated (state: “logic 1”). If interface XG13 is used, safety-oriented outputs are only available for monitoring spaces 1 … 6. • The robot is stopped (precondition: parameter Stop at boundaries is activated for the space). KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 25/304 Product description KUKA.SafeOperation 3.6 • Monitoring of the space-specific velocity is activated (precondition: Space violated is set for the space at parameter Vmax valid if). If the robot violates an axis limit with the fictitious STOP 1 - DRS end position, the following reactions are triggered: • The robot is stopped (precondition: parameter Stop at boundaries is activated for the space). Example The diagram 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. 2-8: Example of an axis-specific workspace 2.5.7 1 Workspace 3 Stopping distance 2 Robot 4 Protected space Axis-specific protected spaces Description The axis limits can be set and monitored individually for each axis via the software. The resulting axis range is the protected range of an axis within which the robot may not move. The individual axis ranges together make up the overall protected space, which may consist of up to 8 axis ranges. A maximum of 8 axes or, in the case of kinematic systems with master/ slave axes, a maximum of 8 drives can be configured for each monitoring space. If the “Braking before restricted areas” function is active, an additional check is performed to establish whether the axis position at the fictitious STOP 1 - DRS end position is outside the protected area. (>>> 2.5.8 "Braking before restricted areas" Page 28) If the robot violates an axis limit with the actual position, e.g. when the monitoring space is activated via an input, the following reactions are triggered: 26/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 • A safety-oriented output is reset (state: “logic 0”). The safety-oriented outputs are set if a monitoring space is not violated (state: “logic 1”). If interface XG13 is used, safety-oriented outputs are only available for monitoring spaces 1 … 6. • The robot is stopped (precondition: parameter Stop at boundaries is activated for the space). • Monitoring of the space-specific velocity is activated (precondition: Space violated is set for the space at parameter Vmax valid if). If the robot violates an axis limit with the fictitious STOP 1 - DRS end position, the following reactions are triggered: • The robot is stopped (precondition: parameter Stop at boundaries is activated for the space). WARNING Risk of fatal injury due to axes that can rotate more than 360° In the case of axes that can rotate more than 360°, the configured axis ranges refer to the position of the axis (including sign) and not to the sector of a circle. This means that they can pass through the protected space. Death, severe injuries or damage to property may result. • Do not configure protected spaces for axes that can rotate more than 360°. Instead, configure a suitable workspace. If, for example, a protected space of +90° to +270° is configured for axis A1, the robot can move through the protected space in the other direction from -90° to -185°. In this case, it is advisable to configure a workspace from -90° to +90°. Fig. 2-9: Example of a protected space through which the robot can move 1 Workspace 3 Protected space 2 Robot 4 Protected space through which the robot can move KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 27/304 Product description KUKA.SafeOperation 3.6 Product description KUKA.SafeOperation 3.6 Example The diagram 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° ... +185° by means of software limit switches. The protected space is configured from -110° ... 10°. This results in 2 permissible motion ranges for the robot, separated by the configured protected space. Fig. 2-10: Example of an axis-specific protected space 1 Permissible range 1 4 Protected space 2 Robot 5 Permissible range 2 3 Stopping distance 2.5.8 Braking before restricted areas Description The “Braking before restricted areas” function changes the way the robot behaves at the limits of the monitoring spaces and of the cell area. With the “Braking before restricted areas” function, the fictitious STOP 1 DRS end position based on the actual position is monitored in addition to the actual position. If this end point violates a monitoring space, this indicates an impending violation of this monitoring space by the robot. In this case, a safety stop 1 DRS is triggered, bringing the robot to a standstill at the precalculated end point. Due to the small safety margin in the precalculation, the robot can generally be stopped before the monitoring space. 28/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 A safety stop 1 DRS is a safely monitored drive ramp stop. This usually deviates from the programmed path. If the safety controller detects a violation of the monitored braking ramp, a safety stop 0 is triggered. As the stopping distance of the robot deviates significantly from the stopping distance of the drive ramp stop in this instance, this case must be taken into consideration in the risk assessment of the cell. Possible reasons for an escalation of this nature are, for example: • Power failure • Controller fault • Operation outside of the specification limits • Hardware fault at the time the drive ramp stop is executed Example The figures show the behavior of the robot at the limits of a Cartesian and axis-specific monitoring space when “Braking before restricted areas” is activated. Fig. 2-11: Braking before Cartesian space limit 1 Anticipated stop position of current position 2 Anticipated stop position of current position with safety margin 3 Actual stop with end point before monitoring space Fig. 2-12: Braking before axis-specific space limit 1 Anticipated stop position of current position 2 Anticipated stop position of current position with safety margin 3 Actual stop with end point before monitoring space KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 29/304 Product description KUKA.SafeOperation 3.6 Product description KUKA.SafeOperation 3.6 2.5.9 Space-specific velocity Description For Cartesian and axis-specific monitoring spaces, a Cartesian velocity can be defined which is monitored if the space is violated or not violated. A safety-oriented TCP is defined for every safety-oriented tool. This safety-oriented TCP is monitored against a configured velocity limit. If the safety-oriented TCP exceeds the velocity limit, the robot is stopped safely. Example The diagram shows an example of a Cartesian workspace. If the safetyoriented TCP on the safety-oriented tool exceeds the velocity limit inside the workspace, the robot is stopped with a safety stop 0. Fig. 2-13: Example of a Cartesian protected space 2.5.10 1 Workspace 2 Spheres on safety-oriented tool 3 Robot Reference stop A reference stop can be activated for monitoring spaces. (= function Stop if mastering test not yet done) If the reference stop is activated and the following conditions are met, the robot can only be moved in T1 mode: • Monitoring space is activated. • Mastering test requested internally. If the reference stop is activated and the following preconditions are met, the robot stops with a safety stop 1: • Monitoring space is activated. 30/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 • Mastering test requested internally. • Operating mode T2, AUT or AUT EXT To be able to move the robot again in the stop-triggering operating modes, the following possibilities are available: • Perform mastering test in T1 mode. • Deactivate monitoring spaces. • Deactivate reference stop. 2.6 Safety-oriented tools Description Up to 16 safety-oriented tools can be defined. A safety-oriented TCP is defined for each safety-oriented tool and monitored against the configured velocity limits. A safety-oriented tool can be modeled using up to 12 configurable spheres. These spheres are monitored against the limits of the Cartesian monitoring spaces. The number of configurable spheres is limited to 96. For example, it is possible to have up to 8 safety-oriented tools with a maximum number of 12 spheres per tool. The sphere radius must not fall below the predefined minimum value. This radius is dependent on the global maximum Cartesian velocity. (>>> "Minimum sphere radius" Page 93) The safety-oriented tools are activated using safety-oriented inputs. Only 1 safety-oriented tool may be active at any one time. If discrete safety interface XG13 or none of the safety interfaces specified in (>>> 2.3 "Safety interfaces" Page 15) is used, tool 1 is always active. The tool cannot be activated via a safety-oriented input. An automated, safely monitored tool change is thus not possible. The safety-oriented TCP for the velocity monitoring can be freely configured in the safety configuration. It is independent of the current TCP that is set in the KUKA System Software with the variable $TOOL. WARNING Risk of fatal injury due to unmonitored robot components Cartesian monitoring spaces are only monitored against the spheres used to model the active safety-oriented tool. Robot components situated outside the tool spheres are not monitored and a space violation by these components is not detected. Death, injuries or damage to property may result. • Design and configure Cartesian monitoring spaces and tool spheres in such a manner that the unmonitored robot components do not pose any threat. Example The diagram shows an example of a safety-oriented tool. 2 spheres and a safety-oriented TCP are defined on the safety-oriented tool of the robot by means of the FLANGE coordinate system. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 31/304 Product description KUKA.SafeOperation 3.6 Product description KUKA.SafeOperation 3.6 Fig. 2-14: Safety-oriented tool 2.7 Velocity monitoring functions Axis velocities and Cartesian velocities can be subjected to safety-oriented monitoring. Axis velocity The velocity of every axis is monitored against a limit value: • Limit value for reduced axis velocity (optional) • Limit value for maximum axis velocity for T1 mode Monitoring of the maximum axis velocity in T1 mode is part of the standard safety configuration and always active. • Limit value for maximum axis velocity (valid globally for every axis) Cartesian velocity The Cartesian velocity at the safety-oriented TCP of the active safety-oriented tool is monitored. The velocity monitoring is always relative to $WORLD: • Limit value for the reduced velocity at the safety-oriented TCP (optional) • Limit value for the reduced velocity at the safety-oriented TCP for T1 mode • Limit value for the global maximum velocity at the safety-oriented TCP and at the sphere center points of the safety-oriented tool (not spacedependent) • Space-specific velocity (>>> 2.5.9 "Space-specific velocity" Page 30) 32/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Stop reactions Stop reaction Description Safety stop 0 The stop is triggered if a monitoring In automatic operation, the robot exfunction is already activated and the ceeds the activated limit value for robot then exceeds the monitoring reduced axis velocity. limit. Safety stop 1 The stop is triggered if a monitoring function is just being activated and the robot has already exceeded the monitoring limit. 2.8 Example The safe reduced velocity, for which the limit value has already been exceeded by the robot, is activated by a safety mat. Safe operational stop for axis groups The global safe operational stop is one of the standard safety functions. If this function is activated via the safety interface, the standstill of all axes of the kinematic system is monitored. The axes may still move within the configured axis angle or distance tolerances. The tolerances can be configured individually for each axis. With KUKA.SafeOperation 3.6, the safe operational stop can additionally be configured for up to 6 axis groups. An axis group comprises the axes that are to be monitored when the safe operational stop is activated for this axis group. Before monitoring is activated, the corresponding axes must be stopped under program control. The safe operational stop for axis groups is activated via safety-oriented inputs. If none of the safety interfaces specified in (>>> 2.3 "Safety interfaces" Page 15) is used, the safe operational stop for axis groups is not available. A maximum of 8 axes or, in the case of kinematic systems with master/ slave axes, a maximum of 8 drives can be configured for each axis group. If the safe operational stop is activated for an axis group, the standstill of the axes for which it has been configured is monitored using safe technology. The axes may still move within the configured axis angle or distance tolerances. If the safe operational stop is violated, i.e. if the position tolerance for an axis is exceeded or the velocity of an axis exceeds the maximum permitted level, a safety stop 0 is triggered in response. The safety stop 0 affects all axes, not just those for which the operational stop is configured. This means that an unintended motion of an axis which is relevant for the safe operational stop causes the machine to stop. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 33/304 Product description KUKA.SafeOperation 3.6 Product description KUKA.SafeOperation 3.6 34/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Safety KUKA.SafeOperation 3.6 3 Safety 3.1 General 3.1.1 Disclaimer The device described in this document is either an industrial robot or a component thereof. Components of the industrial robot: • • • • • Manipulator Robot controller Teach pendant Connecting cables External axes (optional) e.g. linear unit, turn-tilt table, positioner • Software • Options, accessories The industrial robot is built using state-of-the-art technology and in accordance with the recognized safety rules. Nevertheless, misuse of the industrial robot may constitute a risk to life and limb or cause damage to the industrial robot and to other material property. The industrial robot may only be used in perfect technical condition in accordance with its intended use and only by safety-conscious persons who are fully aware of the risks involved in its operation. Use of the industrial robot is subject to compliance with this document and with the declaration of incorporation supplied together with the industrial robot. Any functional disorders, especially those affecting safety, must be rectified immediately. Safety information Information about safety may not be construed against the manufacturer. Even if all safety instructions are followed, this is not a guarantee that the industrial robot will not cause personal injuries or material damage. No modifications may be carried out to the industrial robot without the authorization of the manufacturer. Unauthorized modifications will result in the loss of warranty and liability claims. Additional components (tools, software, etc.), not supplied by the manufacturer, may be integrated into the industrial robot. The user is liable for any damage these components may cause to the industrial robot or to other material property. In addition to the Safety chapter, this document contains further safety instructions. These must also be observed. 3.1.2 EC declaration of conformity and declaration of incorporation The industrial robot constitutes partly completed machinery as defined by the EC Machinery Directive. The industrial robot may only be put into operation if the following preconditions are met: KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 35/304 Safety KUKA.SafeOperation 3.6 • The industrial robot is integrated into a complete system. or: The industrial robot, together with other machinery, constitutes a complete system. or: All safety functions and safeguards required for operation in the complete machine as defined by the EC Machinery Directive have been added to the industrial robot. • The complete system complies with the EC Machinery Directive. This has been confirmed by means of a conformity assessment procedure. EC declaration of conformity The system integrator must issue an EC declaration of conformity for the complete system in accordance with the Machinery Directive. The EC declaration of conformity forms the basis for the CE mark for the system. The industrial robot must always be operated in accordance with the applicable national laws, regulations and standards. The robot controller has a CE mark in accordance with the EMC Directive and the Low Voltage Directive. Declaration of incorporation The partly completed machinery is supplied with a declaration of incorporation in accordance with Annex II B of the Machinery Directive 2006/42/EC. The assembly instructions and a list of essential requirements complied with in accordance with Annex I are integral parts of this declaration of incorporation. The declaration of incorporation declares that the start-up of the partly completed machinery is not allowed until the partly completed machinery has been incorporated into machinery, or has been assembled with other parts to form machinery, and this machinery complies with the terms of the EC Machinery Directive, and the EC declaration of conformity is present in accordance with Annex II A. 3.1.3 Terms in the “Safety” chapter STOP 0, STOP 1 and STOP 2 are the stop definitions according to EN 60204-1:2018. Term Description Axis range Range within which the axis may move The axis range must be defined for each axis. Stopping distance Stopping distance = reaction distance + braking distance The stopping distance is part of the danger zone. Workspace Area within which the robot may move. The workspace is derived from the individual axis ranges. AUT Automatic mode Operating mode for program execution. The robot moves at the programmed velocity. AUT EXT Automatic mode, external Operating mode for program execution. The robot is moved at the programmed velocity by a higher-level controller. 36/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 User The user of the industrial robot can be the management, employer or delegated person responsible for use of the industrial robot. Service life The service life of a safety-relevant component begins at the time of delivery of the component to the customer. The service life is not affected by whether the component is used or not, as safety-relevant components are also subject to aging during storage. Danger zone The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). KSS KUKA System Software KUKA smartPAD see “smartPAD” KUKA smartPAD-2 see “smartPAD” Manipulator The robot arm and the associated electrical installations Safety zone The safety zone is situated outside the danger zone. Safe operational stop The safe operational stop is a standstill monitoring function. It does not execute a stop, but rather monitors whether the axes are at a standstill. If these are moved during the safe operational stop, a safety STOP 0 is triggered. The safe operational stop can also be triggered externally. When a safe operational stop is triggered, the robot controller sets an output to the field bus. The output is set even if not all the axes were stationary at the time of triggering, thereby causing a safety STOP 0 to be triggered. Safety STOP 0 A stop that is triggered and executed by the safety controller. The safety controller immediately switches off the drives and the power supply to the brakes. Note: This stop is called “safety stop 0” in this document. Safety STOP 1 A stop that is triggered and monitored by the safety controller. The braking operation is carried out by the non-safety-oriented section of the robot controller and monitored by the safety controller. • T1: The power supply to the brakes is switched off (SBC/Safe Brake Control signal) as soon as all axes are at a standstill or after 680 ms at the latest. 200 ms after SBC, the drives are switched off. • T2, AUT (KSS), AUT EXT (KSS), EXT (VSS): The drives are switched off after the configured braking time (default: 1.5 s). The power supply to the brakes is switched off 200 ms beforehand. The safety STOP 1 can also be triggered externally. Note: This stop is called “safety stop 1” in this document. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 37/304 Safety KUKA.SafeOperation 3.6 Safety KUKA.SafeOperation 3.6 Safety STOP 1 – Drive Ramp Stop Only relevant for safety options with BBRA (braking before restricted areas): A stop that is triggered and monitored by the safety controller. The braking operation is carried out by the non-safety-oriented section of the robot controller and monitored by the safety controller. • The power supply to the brakes is switched off (SBC/Safe Brake Control signal) as soon as the robot stops or, at the latest, after the configured braking time (default: 1.5 s) plus an oscillation time of 500 ms. 200 ms after SBC, the drives are switched off. Note: This stop is called “Safety stop 1 DRS” in this document. Safety STOP 2 A stop that is triggered and monitored by the safety controller. The braking operation is carried out by the non-safety-oriented section of the robot controller and monitored by the safety controller. • T1: Safe standstill monitoring is activated as soon as all axes are at a standstill or after 680 ms at the latest. • T2, AUT (KSS), AUT EXT (KSS), EXT (VSS): After the configured braking time (default: 1.5 s), safe standstill monitoring is activated for all axes. The safety STOP 2 can also be triggered externally. Note: This stop is called “safety stop 2” in this document. Safety options Generic term for options which make it possible to configure additional safe monitoring functions in addition to the standard safety functions. Example: SafeOperation smartPAD Teach pendant for the robot controller The smartPAD has all the operator control and display functions required for operating and programming the industrial robot. For robot controllers of the KR C5 series with KUKA System Software or VW System Software, the model KUKA smartPAD-2 is used. Stop category 0 The drives are deactivated immediately and the brakes are applied. The manipulator and any external axes (optional) perform path-oriented braking. Note: This stop category is called “STOP 0” in this document. Stop category 1 The manipulator and any external axes (optional) perform pathmaintaining braking. The drives are only disconnected once the machine has come to a standstill. Note: This stop category is called “STOP 1” in this document. Stop category 1 – Drive Ramp Stop The manipulator and any external axes (optional) perform path-oriented braking. The drives are only disconnected once the machine has come to a standstill. Note: This stop category is called “STOP 1 - DRS” in this document. 38/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Stop category 2 The drives are not deactivated and the brakes are not applied. The manipulator and any external axes (optional) are braked with a path-maintaining braking ramp. Note: This stop category is called “STOP 2” in this document. System integrator (plant integrator) The system integrator is responsible for safely integrating the industrial robot into a complete system and commissioning it. T1 Test mode, Manual Reduced Velocity (<= 250 mm/s) T2 Test mode, Manual High Velocity (> 250 mm/s permissible) VSS VW System Software External axis Motion axis which is not part of the manipulator but is controlled by the robot controller, e.g. KUKA linear unit, turn-tilt table, positioner. 3.2 Personnel The following persons or groups of persons are defined for the industrial robot: • User • Personnel Qualification of personnel Work on the system must only be performed by personnel that is able to assess the tasks to be carried out and detect potential hazards. Death, severe injuries or damage to property may otherwise result. The following qualifications are required: • Adequate specialist training, knowledge and experience • Knowledge of the relevant operating or assembly instructions, knowledge of the relevant standards • All persons working with the industrial robot must have read and understood the industrial robot documentation, including the safety chapter. User The user must observe the labor laws and regulations. This includes e.g.: • The user must comply with his monitoring obligations. • The user must carry out briefing at defined intervals. • The user must comply with the regulations relating to personal protective equipment (PPE). Personnel Personnel must be instructed, before any work is commenced, in the type of work involved and what exactly it entails as well as any hazards which may exist. Instruction must be carried out regularly. Instruction is also required after particular incidents or technical modifications. Personnel includes: • System integrator • Operators, subdivided into: ‒ Start-up, maintenance and service personnel KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 39/304 Safety KUKA.SafeOperation 3.6 Safety KUKA.SafeOperation 3.6 ‒ Operating personnel ‒ Cleaning personnel System integrator The industrial robot is safely integrated into a complete system by the system integrator. The system integrator is responsible for the following tasks: • • • • • • • Installing the industrial robot Connecting the industrial robot Performing the risk assessment Implementing the required safety functions and safeguards Issuing the EC declaration of conformity Affixing the CE mark Creating the operating instructions for the system Operators The operator must meet the following preconditions: • The operator must be trained for the work to be carried out. • Work on the system must only be carried out by qualified personnel. These are people who, due to their specialist training, knowledge and experience, and their familiarization with the relevant standards, are able to assess the work to be carried out and detect any potential hazards. 3.3 Workspace, safety zone and danger zone Workspaces are to be restricted to the necessary minimum size. The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). The danger zone must be protected by means of physical safeguards to prevent danger to persons or the risk of material damage. The safeguards (e.g. safety gate) must be located outside the danger zone. In the case of a stop, the manipulator and external axes (optional) are braked and come to a stop within the danger zone. There must be no shearing or crushing hazards at the loading and transfer areas. If there are no physical safeguards present, the requirements for collaborative operation in accordance with EN ISO 10218 must be met. 3.3.1 Determining stopping distances The system integrator’s risk assessment may indicate that the stopping distances must be determined for an application. In order to determine the stopping distances, the system integrator must identify the safety-relevant points on the programmed path. When determining the stopping distances, the robot must be moved with the tool and loads which are also used in the application. The robot must be at operating temperature. This is the case after approx. 1 h in normal operation. During execution of the application, the robot must be stopped at the point from which the stopping distance is to be calculated. This process must 40/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 be repeated several times with a safety stop 0 and a safety stop 1. The least favorable stopping distance is decisive. A safety stop 0 can be triggered by a safe operational stop via the safety interface, for example. If a safety option is installed, it can be triggered, for instance, by a space violation (e.g. the robot exceeds the limit of an activated workspace in Automatic mode). A safety stop 1 can be triggered by pressing the EMERGENCY STOP device on the smartPAD, for example. 3.4 Triggers for stop reactions: KSS Stop reactions of the industrial robot are triggered in response to operator actions or as a reaction to monitoring functions and error messages. The following table shows the different stop reactions according to the operating mode that has been set. Trigger T1, T2 AUT, AUT EXT Start key released STOP 2 - STOP key pressed STOP 2 Drives OFF STOP 1 $MOVE_ENABLE input drops out STOP 2 Power switched off via main switch or device switch STOP 0 Or power failure Internal error in non-safety-oriented part of the robot controller STOP 0 or STOP 1 (dependent on the cause of the error) Operating mode changed during operation Safety stop 2 Safety gate opened (operator safety) - Safety stop 1 Enabling switch released (internal or external enabling) Safety stop 2 - Internal enabling switch pressed down fully or error Safety stop 1 - External enabling switch pressed down fully or error Safety stop 2 - E-STOP pressed Safety stop 1 Error in safety controller or periphery of the safety controller Safety stop 0 * In the KR C5 series, the “pressed down fully” position is not communicated to the robot controller as a specific “panic position” signal for external enabling, but only as “enabling not present”. This triggers a safety stop 2. 3.5 Triggers for stop reactions: VSS Stop reactions of the industrial robot are triggered in response to operator actions or as a reaction to monitoring functions and error messages. The following table shows the different stop reactions according to the operating mode that has been set. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 41/304 Safety KUKA.SafeOperation 3.6 Safety KUKA.SafeOperation 3.6 Trigger T1, T2 EXT Start key released STOP 2 - STOP key pressed STOP 2 Drives OFF STOP 1 Power switched off via main switch or device switch STOP 0 Or power failure Internal error in non-safety-oriented part of the robot controller STOP 0 or STOP 1 (dependent on the cause of the error) Operating mode changed during operation Safety stop 2 Safety gate opened (operator safety) - Safety stop 1 Enabling switch released (internal or external enabling) Safety stop 2 - Internal enabling switch pressed down fully or error Safety stop 1 - External enabling switch pressed down fully or error Safety stop 2 - E-STOP pressed Safety stop 1 Error in safety controller or periphery of the safety controller Safety stop 0 * In the KR C5 series, the “pressed down fully” position is not communicated to the robot controller as a specific “panic position” signal for external enabling, but only as “enabling not present”. This triggers a safety stop 2. 3.6 Safety functions 3.6.1 Overview of the safety functions The following safety functions are always present on the industrial robot: • Operator safety (= connection for the monitoring of physical safeguards) • EMERGENCY STOP device on the smartPAD • External EMERGENCY STOP device • Enabling device on the smartPAD • External enabling device • Velocity monitoring in T1 Depending on the hardware configuration, the following safety functions are present on the industrial robot: • • • • • External safety stop, STOP 1 External safety stop, STOP 2 External safe operational stop EMERGENCY STOP device (additional local device) Peripheral contactor US2 The safety functions of the industrial robot meet the following requirements: 42/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 • Category 3 and Performance Level d in accordance with EN ISO 13849-1 The requirements are only met on the following conditions, however: • The EMERGENCY STOP device is pressed at least once every 12 months. • The enabling device is checked at least once every 12 months. (>>> "Function test" Page 47) • Peripheral contactor US2 is checked at least once every 12 months (if used). • The testing of the safety functions is carried out in accordance with the maintenance table. For maintenance table, see chapter “Maintenance” in the documentation of the hardware components used. DANGER Risk of fatal injury due to non-operational safety functions or external safeguards In the absence of operational safety functions or safeguards, the industrial robot can cause death, severe injuries or damage to property. • If safety functions or safeguards are dismantled or deactivated, do not operate the industrial robot. Integrate industrial robot into safety system of the overall system During system planning, the safety functions of the overall system must be planned and designed. Death, severe injuries or damage to property may otherwise result. • The industrial robot must be integrated into the safety system of the overall system. 3.6.2 Safety controller The safety controller is a unit inside the control PC. It links safety-relevant signals and safety-relevant monitoring functions. Safety controller tasks: • • • • • • 3.6.3 Switching off the drives; applying the brakes Monitoring the braking ramp Standstill monitoring (after the stop) Velocity monitoring in T1 Evaluation of safety-relevant signals Setting of safety-oriented outputs “Operator safety” signal: KSS The “operator safety” signal is used for monitoring physical safeguards, e.g. safety gates. Automatic operation is not possible without this signal. In the event of a loss of signal during automatic operation (e.g. safety gate is opened), the manipulator stops with a safety stop 1. Operator safety is not active in modes T1 (Manual Reduced Velocity) and T2 (Manual High Velocity). KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 43/304 Safety KUKA.SafeOperation 3.6 Safety KUKA.SafeOperation 3.6 WARNING Danger to life and limb due to resumption of automatic operation without adequate checking Following loss of the “Operator safety” signal, it must not be possible to restart automatic operation by merely closing the safeguard. Otherwise, for example, the safety gate could close unintentionally, thereby causing automatic operation to resume while there are persons in the danger zone. Death, severe injuries or damage to property may result. • Automatic operation must not be resumed until the safeguard has been closed and the closing has been acknowledged. • The acknowledgement must be designed in such a way that an actual check of the danger zone can be carried out first. Acknowledgement that is automatically and directly triggered by closure of the safeguard is not permitted. • If closure is acknowledged by a device (e.g. by the PLC), the system integrator must ensure that the acknowledgement is preceded by an actual check of the danger zone. 3.6.4 “Operator safety” signal: VSS The “Operator safety” signal is used for monitoring physical safeguards, e.g. safety gates. Automatic operation is not possible without this signal. In the event of a loss of signal during automatic operation (e.g. safety gate is opened), the manipulator stops with a safety stop 1. In Manual Reduced Velocity (T1) mode, operator safety can be overridden with the E2/E22 key. In Manual High Velocity (T2) mode, operator safety can be overridden with the E2/E22+E7 key. WARNING Danger to life and limb due to resumption of automatic operation without adequate checking Following loss of the “Operator safety” signal, it must not be possible to restart automatic operation by merely closing the safeguard. Otherwise, for example, the safety gate could close unintentionally, thereby causing automatic operation to resume while there are persons in the danger zone. Death, severe injuries or damage to property may result. • Automatic operation must not be resumed until the safeguard has been closed and the closing has been acknowledged. • The acknowledgement must be designed in such a way that an actual check of the danger zone can be carried out first. Acknowledgement that is automatically and directly triggered by closure of the safeguard is not permitted. • If closure is acknowledged by a device (e.g. by the PLC), the system integrator must ensure that the acknowledgement is preceded by an actual check of the danger zone. 3.6.5 EMERGENCY STOP device The EMERGENCY STOP device for the industrial robot is the EMERGENCY STOP device on the smartPAD. The device must be pressed in the event of a hazardous situation or emergency. Reactions of the industrial robot if the EMERGENCY STOP device is pressed: 44/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 • The manipulator and any external axes (optional) are stopped with a safety stop 1. Before operation can be resumed, the EMERGENCY STOP device must be turned to release it. WARNING Danger to life and limb due to tools and equipment without EMERGENCY STOP If tools and other equipment connected to the robot are not integrated into the EMERGENCY STOP circuit, this can result in death, severe injuries or damage to property. • Integrate tools and other equipment into the EMERGENCY STOP circuit if they could constitute a potential hazard. There must always be at least one external EMERGENCY STOP device installed. This ensures that an EMERGENCY STOP device is available even when the smartPAD is disconnected. 3.6.6 Logging off from the higher-level safety controller If the robot controller is connected to a higher-level safety controller, this connection will inevitably be terminated in the following cases: • Switching off the voltage via the main switch or device switch of the robot controller Or power failure • Shutdown of the robot controller via the smartHMI • Activation of a WorkVisual project in WorkVisual or directly on the robot controller • Changes to Start-up > Network configuration • Changes to Configuration > Safety configuration • I/O drivers > Reconfigure • Restoration of an archive Effect of the interruption: • If a discrete safety interface is used, this triggers an EMERGENCY STOP for the overall system. • If the Ethernet interface is used, the KUKA safety controller generates a signal that prevents the higher-level controller from triggering an EMERGENCY STOP for the overall system. Take Ethernet safety interface into consideration in risk assessment Failure to take the Ethernet safety interface into consideration in the risk assessment may result in death, severe injuries or damage to property. • In his risk assessment, the system integrator must take into consideration whether the fact that switching off the robot controller does not trigger an EMERGENCY STOP of the overall system could constitute a hazard and, if so, how this hazard can be countered. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 45/304 Safety KUKA.SafeOperation 3.6 Safety KUKA.SafeOperation 3.6 WARNING Danger to life and limb due to smartPAD on controller that has been switched off If a robot controller is switched off, the EMERGENCY STOP device on the smartPAD is not operational. There is a risk of operational and nonoperational EMERGENCY STOP devices becoming interchanged. Death, severe injuries or damage to property may result. • Cover smartPADs on controllers that have been switched off or remove them from the system. 3.6.7 External EMERGENCY STOP device Every operator station that can initiate a robot motion or other potentially hazardous situation must be equipped with an EMERGENCY STOP device. The system integrator is responsible for ensuring this. There must always be at least one external EMERGENCY STOP device installed. This ensures that there is an EMERGENCY STOP device available, even if the smartPAD has been disconnected. External EMERGENCY STOP devices are connected via the customer interface. 3.6.8 Enabling device The enabling devices of the industrial robot are the enabling switches on the smartPAD. For robot controllers of the KR C5 series, the model smartPAD-2 is used. It has 4 enabling switches. The enabling switches have 3 positions: • Not pressed • Center position • Fully pressed (panic position) In the test modes, the manipulator can only be moved if at least one of the enabling switches is held in the center position. It is possible to hold several enabling switches in the center position simultaneously. This makes it possible to adjust grip from one enabling switch to another one. In the test modes, the manipulator can be stopped in the following ways: • Press at least one enabling switch down fully. Pressing an enabling switch down fully triggers a safety stop 1. • Or release all enabling switches. Releasing all (!) enabling switches held in the center position triggers a safety stop 2. WARNING Danger to life and limb due to lack of reaction when an enabling switch is released Releasing one of multiple enabling switches held in the center position does not trigger a stop reaction. If multiple switches are held in the center position, the robot controller cannot distinguish whether one of them was intentionally released or if it was unintentionally released as the result of an accident. • Create awareness for the hazard. 46/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 If an enabling switch malfunctions (e.g. jams in the center position), the industrial robot can be stopped using one of the following methods: • Press another enabling switch down fully. • Actuate the EMERGENCY STOP device. • Release the Start key. WARNING Danger to life and limb due to manipulation of enabling switches The enabling switches must not be held down by adhesive tape or other means or tampered with in any other way. Death, severe injuries or damage to property may result. • Carry out a visual inspection of the enabling switches. • Rectify tampering or remove any foreign bodies. Function test The function of the enabling switches must be tested in the following cases: • Following initial start-up or recommissioning of the industrial robot • After a software update • After disconnecting and reconnecting a smartPAD (the same smartPAD or another one) • The test must be carried out at least once every 12 months. To test, perform the following steps separately for each enabling switch: 1. Move the manipulator in a test mode. 2. While the manipulator is moving, press the enabling switch down fully and hold it down for 3 seconds. The test is passed in the following case: • The manipulator stops. • And: No error message for the enabling device is displayed (Enabling switch error or similar). If the test has not been passed for one or more enabling switches, the smartPAD must be exchanged and the test must be performed again. 3.6.9 External enabling device External enabling devices are required if it is necessary for more than one person to be in the danger zone of the industrial robot. The function of the external enabling switches must be tested at least once every 12 months. Which interface can be used for connecting external enabling devices is described in the “Planning” chapter of the robot controller operating instructions and assembly instructions. 3.6.10 Velocity monitoring in T1 The axis-specific velocity is safely monitored in T1 mode. The Cartesian velocity is safely monitored in T1 if the associated setting is activated in the safety configuration. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 47/304 Safety KUKA.SafeOperation 3.6 Safety KUKA.SafeOperation 3.6 Axis-specific monitoring If an axis exceeds its velocity limit, a safety stop 0 is triggered. • Default limit value for rotational axes: 30°/s • Default limit value for linear axes: 250 mm/s The axis-specific monitoring can be configured via the parameter Maximum velocity T1. Further information about this can be found in the Operating and Programming Instructions for System Integrators documentation for the System Software. Cartesian monitoring The Cartesian monitoring refers to the velocity at the flange. If a limit value is exceeded, a safety stop 0 is triggered. • Default limit value: 250 mm/s If an additional safety option (e.g. SafeOperation) is used, the limit value can be configured. It can be reduced, but not increased. 3.7 Additional protective equipment 3.7.1 Jog mode In the operating modes T1 (Manual Reduced Velocity) and T2 (Manual High Velocity), the robot controller can only execute programs in jog mode. This means that it is necessary to hold down an enabling switch and the Start key in order to execute a program. • Releasing the enabling switch triggers a safety stop 2. • Pressing the enabling switch down fully (panic position) triggers a safety stop 1. • Releasing the Start key triggers a STOP 2. 3.7.2 Software limit switches The axis ranges of all manipulator and positioner axes are limited by means of adjustable software limit switches. These software limit switches only serve as machine protection and must be adjusted in such a way that the manipulator/positioner cannot hit the mechanical end stops. The software limit switches are set during commissioning of an industrial robot. Further information is contained in the operating and programming instructions. 3.7.3 Mechanical end stops Depending on the robot variant, the axis ranges of the main and wrist axes of the manipulator are partially limited by mechanical end stops. Additional mechanical end stops can be installed on the external axes. 48/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 WARNING Danger to life and limb following collision with obstacle If the manipulator or an external axis hits an obstruction or a mechanical end stop or mechanical axis limitation, the manipulator can no longer be operated safely. Death, injuries or damage to property may result. • Put manipulator out of operation. • KUKA must be consulted before it is put back into operation. 3.7.4 Mechanical axis limitation (optional) Some manipulators can be fitted with adjustable mechanical axis limitation systems in axes A1 to A3. The axis limitation systems restrict the working range to the required minimum. This increases personal safety and protection of the system. In the case of manipulators that are not designed to be fitted with mechanical axis limitation, the workspace must be laid out in such a way that there is no danger to persons or material property, even in the absence of mechanical axis limitation. If this is not possible, the workspace must be limited by means of photoelectric barriers, photoelectric curtains or mechanical limitations on the system side. There must be no shearing or crushing hazards at the loading and transfer areas. This option is not available for all robot models. Information on specific robot models can be obtained from the manufacturer. 3.7.5 Options for moving the manipulator without drive energy Qualification of personnel with regard to behavior in emergency situations In emergencies or other exceptional situations, it may be necessary to move the manipulator without drive energy. • Personnel must be trained in how to move the manipulator without drive energy. Description The following options may be available for moving the manipulator without drive energy after an accident or malfunction: • Release device (optional) The release device can be used for the main axis drive motors and, depending on the robot variant, also for the wrist axis drive motors. • Brake release device (option) The brake release device is designed for robot variants whose motors are not freely accessible. • Moving the wrist axes directly by hand There is no release device available for the wrist axes of variants in the low payload category. This is not necessary because the wrist axes can be moved directly by hand. Information about the options available for the various robot models and about how to use them can be found in the assembly and operating instructions for the robot or can be requested from the manufacturer. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 49/304 Safety KUKA.SafeOperation 3.6 Safety KUKA.SafeOperation 3.6 NOTICE Damage to property due to moving the manipulator without drive energy Moving the manipulator without drive energy can damage the motor brakes of the axes concerned. • Only move the manipulator without drive energy in emergencies, e.g. for rescuing persons. • Perform brake test. • The motor must be replaced if the brake has been damaged. 3.7.6 Labeling on the industrial robot All plates, labels, symbols and marks constitute safety-relevant parts of the industrial robot. They must not be modified or removed. Labeling on the industrial robot consists of: • • • • • • Identification plates Warning signs Safety symbols Designation labels Cable markings Rating plates Further information is contained in the technical data of the operating instructions or assembly instructions of the components of the industrial robot. 3.7.7 External safeguards The access of persons to the danger zone of the industrial robot must be prevented by means of safeguards. It is the responsibility of the system integrator to ensure this. If there are no physical safeguards present, the requirements for collaborative operation in accordance with EN ISO 10218 must be met. Physical safeguards must meet the following requirements: • They meet the requirements of EN ISO 14120. • They prevent access of persons to the danger zone and cannot be easily circumvented. • They are sufficiently fastened and can withstand all forces that are likely to occur in the course of operation, whether from inside or outside the enclosure. • They do not, themselves, represent a hazard or potential hazard. • Prescribed clearances, e.g. to danger zones, are adhered to. Safety gates (maintenance gates) must meet the following requirements: • They are reduced to an absolute minimum. • The interlocks (e.g. safety gate switches) are linked to the operator safety input of the robot controller via safety gate switching devices or safety PLC. • Switching devices, switches and the type of switching conform to the requirements of Performance Level d and category 3 according to EN ISO 13849-1. 50/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 • Depending on the hazard situation: the safety gate is additionally safeguarded by means of a locking mechanism that only allows the gate to be opened if the manipulator is safely at a standstill. • The button for acknowledging the safety gate is located outside the space limited by the safeguards. Further information is contained in the corresponding standards and regulations. These also include EN ISO 14120. Other safety equipment Other safety equipment must be integrated into the system in accordance with the corresponding standards and regulations. 3.7.8 “Drives ready” lamp If the system is to comply with ANSI/UL 1740, the system integrator must integrate a “Drives ready” lamp into the system. An interface is available for the lamp connection. The “Drives ready” lamp must always be functionally tested before entering the danger zone. If the test is not passed, the danger zone must not be entered except to work on the lamp. More information about the “Drives ready” lamp, the associated interface and testing can be found in the assembly instructions for the robot controller. 3.8 Operating mode selection: KSS Operating modes The industrial robot can be operated in the following modes: • • • • Manual Reduced Velocity (T1) Manual High Velocity (T2) Automatic (AUT) Automatic External (AUT EXT) Do not change the operating mode while a program is running. If the operating mode is changed during program execution, the industrial robot is stopped with a safety stop 2. Operating Use mode Velocities T1 For test operation, programming and teaching • Program verification: Programmed velocity, maximum 250 mm/s • Jog mode: Jog velocity, maximum 250 mm/s T2 For test operation • Program verification: Programmed velocity • Jog mode: Not possible KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 51/304 Safety KUKA.SafeOperation 3.6 Safety KUKA.SafeOperation 3.6 Operating Use mode Velocities AUT For industrial robots without higher-level controllers • Program operation: Programmed velocity • Jog mode: Not possible AUT EXT For industrial robots with higher-level controllers, e.g. PLC • Program operation: Programmed velocity • Jog mode: Not possible Mode selector switch The user can change the operating mode via the connection manager. The connection manager is a view that is called by means of the mode selector switch on the smartPAD. The mode selector switch may be one of the following variants: • With key It is only possible to change operating mode if the key is inserted. • Without key WARNING Danger to life and limb due to mode selector switch without access restriction If the smartPAD is equipped with a mode selector switch without a key, all persons can operate the mode selector switch, irrespective of their field of activity or qualifications. Death, severe injuries or damage to property may result. • An additional device must be installed to ensure that the mode selector switch can only be operated by a restricted group of people. • The device itself must not trigger motions of the industrial robot or other hazards. 3.9 Overview of operating modes and safety functions: KSS The following table indicates the operating modes in which the safety functions are active. 3.10 Safety functions T1 T2 AUT AUT EXT Operator safety - - active active EMERGENCY STOP device active active active active Enabling device active active - - Reduced velocity during program verification active - - - Jog mode active active - - Software limit switches active active active active Interface for “Drives ready” lamp active active active active Operating mode selection: VSS Operating modes The industrial robot can be operated in the following modes: 52/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Safety KUKA.SafeOperation 3.6 • Manual Reduced Velocity (T1) • Manual High Velocity (T2) • Automatic External (EXT) Do not change the operating mode while a program is running. If the operating mode is changed during program execution, the industrial robot is stopped with a safety stop 2. Operating Use mode Velocities T1 For test operation, programming and teaching • Program verification: Programmed velocity, maximum 250 mm/s • Jog mode: Jog velocity, maximum 250 mm/s T2 For test operation • Program verification: Programmed velocity • Jog mode: Not possible EXT For industrial robots with higher-level controllers, e.g. PLC • Program operation: Programmed velocity • Jog mode: Not possible Mode selector switch The user can change the operating mode via the connection manager. The connection manager is a view that is called by means of the mode selector switch on the smartPAD. Bypassing In order to be able to move the manipulator in operating mode T1 or T2 with the safety gate open, the following keys are available: Active key Authorization E2/E22 Authorization to move in T1 with the safety gate open E2/E22 and E7 Authorization to move in T2 with the safety gate open WARNING Danger to life and limb of persons in danger zone in T2 In T2, the robot moves at the programmed velocity. Death, severe injuries or damage to property may result. • There must be no persons in the danger area. Use E keys in a safety-conscious manner Keys E2/E22 and E7 must be used in a safety-conscious manner. Death, severe injuries or damage to property may otherwise result. • It is the responsibility of the user or system integrator to determine which key may be used and when. The applicable laws, regulations and standards must be taken into consideration. • The keys may only be used by qualified personnel. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 53/304 Safety KUKA.SafeOperation 3.6 Active key Program execution possible? T1 T2 T1 T2 Open No No No No Closed Yes No Yes Yes Open Yes No Yes No Closed No No No No Open Yes No No Yes Closed No No No No Safety gate No key active E2/E22 E2/E22 and E7 3.11 Jogging possible? Overview of operating modes and safety functions: VSS The following table indicates the operating modes in which the safety functions are active. Safety measures T1 T2 EXT Operator safety Active * Active ** Active EMERGENCY STOP device Active Active Active Enabling device Active Active - Reduced velocity during program verification Active - - Jog mode Active Active - Software limit switches Active Active Active * In T1 mode, operator safety can be bypassed with the E2/E22 key. ** In T2 mode, operator safety can be bypassed with the E2/E22+E7 key. 3.12 Safety measures 3.12.1 General safety measures The industrial robot may only be used in perfect technical condition in accordance with its intended use and only by safety-conscious persons. Operator errors can result in personal injury and damage to property. It is important to be prepared for possible movements of the industrial robot even after the robot controller has been switched off and locked out. Incorrect installation (e.g. overload) or mechanical defects (e.g. brake defect) can cause the manipulator or external axes to sag. If work is to be carried out on a switched-off industrial robot, the manipulator and external axes must first be moved into a position in which they are unable to move on their own, whether the payload is mounted or not. If this is not possible, the manipulator and external axes must be secured by appropriate means. DANGER Risk of fatal injury due to non-operational safety functions or external safeguards In the absence of operational safety functions or safeguards, the industrial robot can cause death, severe injuries or damage to property. • If safety functions or safeguards are dismantled or deactivated, do not operate the industrial robot. 54/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 DANGER Danger to life and limb of persons under the robot arm Sagging or falling parts can cause death or serious injuries. This applies at all times, e.g. also for assembly tasks or with the controller switched off. • Never loiter under the robot arm. WARNING Danger to life and limb due to incorrect loads Operating a robot with incorrect loads may result in death, severe injuries or damage to property. • Use correct load data. • Use only loads for which the robot is suitable. CAUTION Risk of burns from hot motors The motors reach temperatures during operation which can cause burns. • Avoid contact. • Take appropriate safety precautions, e.g. wear protective gloves. Implants WARNING Danger to life due to malfunction of implants caused by motors and brakes Electric motors and brakes generate electric and magnetic fields. The fields can cause malfunctions in active implants, e.g. pacemakers. • Affected persons must maintain a minimum distance of 300 mm from motors and brakes. This applies to both energized and deenergized motors and brakes. smartPAD The user must ensure that the industrial robot is only operated with the smartPAD by authorized persons. If more than one smartPAD is used in the overall system, it must be ensured that it is clearly recognizable which smartPAD is connected to which industrial robot. They must not be interchanged. WARNING Danger to life and limb due to disconnected smartPAD If a smartPAD is disconnected, its EMERGENCY STOP device is not operational. There is a risk of connected and disconnected smartPADs being interchanged. Death, injuries or damage to property may result. • Remove the disconnected smartPAD from the system immediately. • Store the disconnected smartPAD out of sight and reach of personnel working on the industrial robot. The enabling switches on the smartPAD must be subjected to a function test at least once every 12 months and in certain specific cases. (>>> "Function test" Page 47) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 55/304 Safety KUKA.SafeOperation 3.6 Safety KUKA.SafeOperation 3.6 Modifications After modifications to the industrial robot, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety functions must also be tested. New or modified programs must always be tested first in Manual Reduced Velocity mode (T1). After modifications to the industrial robot, existing programs must always be tested first in Manual Reduced Velocity mode (T1). This applies to all components of the industrial robot and includes e.g. modifications of the external axes or to the software and configuration settings. Faults In the case of faults on the industrial robot, the following safety measures must be implemented immediately: • Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again. • Indicate the fault by means of a label with a corresponding warning (tagout). • Keep a record of the faults. Carry out a functional test after the fault has been rectified. 3.12.2 IT security KUKA products must only be used in perfect technical condition in accordance with their intended use and only by safety-conscious persons. In particular, safety-conscious use includes being operated in an IT environment which meets the current security-relevant standards and for which there is an overall concept for IT security. Take measures to ensure IT security IT security involves not only aspects of information and data processing as such, but also affects at least the following areas: • Technology, organization, personnel, infrastructure KUKA urgently recommends that users implement an information security management system for their products which designs, coordinates and monitors the tasks related to information security. Sources for information about IT security for companies include: • Independent consulting firms • National cyber security authorities National authorities often make their recommendations available on the Internet. In addition to their official language, some national authorities provide their information in English. 3.12.3 Transportation Manipulator The prescribed transport position of the manipulator must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the robot. 56/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Avoid vibrations and impacts during transportation in order to prevent damage to the manipulator. Robot controller The prescribed transport position of the robot controller must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the robot controller. Avoid vibrations and impacts during transportation in order to prevent damage to the robot controller. External axis (optional) The prescribed transport position of the external axis (e.g. KUKA linear unit, turn-tilt table, positioner) must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the external axis. 3.12.4 Start-up and recommissioning: KSS/VSS KSS only: Changing default passwords The KUKA System Software is supplied with default passwords for the user groups. If the passwords are not changed, this enables unauthorized persons to log on. • Before start-up, change the passwords for the user groups. • Only communicate the passwords to authorized personnel. KSS and VSS: Before starting up systems and devices for the first time, a check must be carried out to ensure that the systems and devices are complete and operational, that they can be operated safely and that any damage is detected. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety functions must also be tested. WARNING Danger to life and limb due to incorrectly assigned cables The robot controller is preconfigured for the specific industrial robot. The manipulator and other components can receive incorrect data if they are connected to a different robot controller. Death, severe injuries or damage to property may result. • Only connect the manipulator to the corresponding robot controller. WARNING Risk of fatal injury due to non-configured external axes The robot controller cannot detect an external axis that is physically connected, but not configured correctly in the software. It cannot exert any torque nor any holding torque on this external axis. If the brakes release, uncontrolled motion can occur at this external axis as a result. Death, severe injuries or damage to property may result. • Ensure that external axes are correctly configured before an enabling switch is pressed and the brakes are thus released. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 57/304 Safety KUKA.SafeOperation 3.6 Safety KUKA.SafeOperation 3.6 Do not impair safety functions Additional components (e.g. cables and hoses) not supplied by KUKA may be integrated into the industrial robot. If the safety functions are not taken into consideration, this may result in death, severe injuries or damage to property. • Additional components must not impair or disable safety functions. NOTICE Damage to property due to condensation If the internal cabinet temperature of the robot controller differs greatly from the ambient temperature, condensation can form. This may result in damage to property. • Wait until the internal cabinet temperature has adapted to the ambient temperature in order to avoid condensation. Function test The following tests must be carried out before start-up and recommissioning: General test: It must be ensured that: • The industrial robot is correctly installed and fastened in accordance with the specifications in the documentation. • There is no damage to the robot that could be attributed to external forces. WARNING Danger to life and limb resulting from external forces The external application of force, such as an impact or a collision, can cause non-visible damage. For example, it can lead to a gradual loss of drive power from the motor, resulting in unintended movements of the manipulator. Death, severe injuries or damage to property may result from nonvisible damage. ‒ Check the robot for damage that could have been caused by external forces, e.g. dents or abrasion of paintwork. Check the motor and counterbalancing system particularly carefully. (Motor inspection not relevant for robots with internal motors.) ‒ In the case of damage, the affected components must be exchanged. • There are no foreign bodies or defective or loose parts on the industrial robot. • All required safety equipment is correctly installed and operational. • The power supply ratings of the industrial robot correspond to the local supply voltage and mains type. • The ground conductor and the equipotential bonding cable are sufficiently rated and correctly connected. • The connecting cables are correctly connected and the connectors are locked. Test of the safety functions: 58/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 A function test must be carried out for the following safety functions to ensure that they are functioning correctly: • • • • • • 3.12.4.1 Local EMERGENCY STOP device External EMERGENCY STOP device (input and output) Enabling device (in the test modes) Operator safety All other safety-relevant inputs and outputs used Other external safety functions Checking machine data and safety configuration WARNING Danger to life and limb due to incorrect data The industrial robot must not be moved if incorrect machine data or an incorrect controller configuration are loaded. Unforeseeable reactions may occur. Death, severe injuries or damage to property may result. • Only operate industrial robots with correct data. • Following the start-up procedure, the practical tests for the machine data must be carried out. The tool must be calibrated (either via an actual calibration or through numerical entry of the data). • Following modifications to the machine data, the safety configuration must be checked. • After activation of a WorkVisual project on the robot controller, the safety configuration must be checked. • If machine data are adopted when checking the safety configuration (regardless of the reason for the safety configuration check), the practical tests for the machine data must be carried out. • If the activation code of the safety configuration has changed, the safe axis monitoring functions must be checked. Information about checking the safety configuration and the safe axis monitoring functions is contained in the Operating and Programming Instructions for System Integrators. If the practical tests are not successfully completed in the initial start-up, KUKA Deutschland GmbH must be contacted. If the practical tests are not successfully completed during a different procedure, the machine data and the safety-relevant controller configuration must be checked and corrected. General practical test for 6-axis robots If practical tests are required for the machine data, this test must always be carried out. The following methods are available for performing the practical test: • TCP calibration with the XYZ 4-point method The practical test is passed if the TCP has been successfully calibrated. Or: 1. Align the TCP with a freely selected point. The point serves as a reference point. • The point must be located so that reorientation is possible. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 59/304 Safety KUKA.SafeOperation 3.6 Safety KUKA.SafeOperation 3.6 • The point must not be located on the Z axis of the FLANGE coordinate system. 2. Move the TCP manually at least 45° once in each of the A, B and C directions. The movements do not have to be accumulative, i.e. after motion in one direction it is possible to return to the original position before moving in the next direction. The practical test is passed if the TCP does not deviate from the reference point by more than 2 cm in total. General practical test for palletizing robots Palletizing robots, in this case, are either robots that can be used only as palletizers from the start or robots operated in palletizing mode. The latter must also be in palletizing mode during the practical test. If practical tests are required for the machine data, this test must always be carried out. First part: 1. Align the TCP with a freely selected point. The point serves as a reference point. 2. 3. 4. 5. • The point must be located so that reorientation is possible. • The point must not be located on the Z axis of the FLANGE coordinate system. Mark the starting position of the TCP. Also read and note the starting position from the Actual position – Cartesian display on the smartHMI. Jog the TCP in the X direction. The distance must be at least 20% of the robot’s maximum reach. Determine the exact length via the Actual position display. Measure the distance covered and compare it with the distance value displayed on the smartHMI. The deviation must be < 5%. Repeat steps 1 and 2 for the Y direction and Z direction. The first part of the practical test is passed if the deviation is < 5% in every direction. Second part: • Rotate the tool manually about A by 45°: once in the plus direction, once in the minus direction. At the same time, observe the TCP. The second part of the practical test is passed if the position of the TCP in space is not altered during the rotations. General practical test for SCARA robots If practical tests are required for the machine data, this test must always be carried out. First part: 1. Align the TCP with a freely selected point. The point serves as a reference point. • The point must be located so that reorientation is possible. • The point must not be on A4. 2. Mark the starting position of the TCP. Also read and note the starting position from the Actual position – Cartesian display on the smartHMI. 60/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 3. Jog the TCP in the Z direction. The distance must be at least 20% of the maximum travel. Determine the exact length via the Actual position display. 4. Measure the distance covered and compare it with the distance value displayed on the smartHMI. The deviation must be < 5%. The first part of the practical test is passed if the deviation is < 5%. Second part: • Rotate the tool manually by 45°: once in the plus direction, once in the minus direction. At the same time, observe the TCP. The second part of the practical test is passed if the position of the TCP in space is not altered during the rotations. Practical test for axes that are not mathematically coupled If practical tests are required for the machine data, this test must be carried out when axes are present that are not mathematically coupled. 1. Mark the starting position of the axis that is not mathematically coupled. Also read and note the start position from the Actual position display on the smartHMI. 2. Move the axis manually by a freely selected path length. Determine the path length from the Actual position display. • Move linear axes a specific distance. • Move rotational axes through a specific angle. 3. Measure the length of the path covered and compare it with the value displayed on the smartHMI. The practical test is passed if the values differ by no more than 5%. 4. Repeat the test for each axis that is not mathematically coupled. Practical test for robot on ROBROOT kinematic system If practical tests are required for the machine data, this test must be carried out if the robot is mounted on a mathematically coupled ROBROOT kinematic system, e.g. on a KL. • Move the axes of the ROBROOT kinematic system manually in Cartesian mode, individually and one after the other. The practical test is passed if the TCP does not move at the same time. Practical test for couplable axes If practical tests are required for the machine data, this test must be carried out when axes are present that can be physically coupled and uncoupled, e.g. a servo gun. 1. Physically uncouple the couplable axis. 2. Move all the remaining axes individually. The practical test is passed if it has been possible to move all the remaining axes. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 61/304 Safety KUKA.SafeOperation 3.6 Safety KUKA.SafeOperation 3.6 3.12.4.2 Start-up mode Description The industrial robot can be set to Start-up mode via the smartHMI user interface. In this mode, the manipulator can be moved in T1 without the external safeguards being put into operation. The safety interface used affects “Start-up” mode: • Discrete safety interface Start-up mode is always possible. • Ethernet safety interface The robot controller prevents or terminates Start-up mode if a connection to a higher-level safety system exists or is established. Effect When the Start-up mode is activated, all outputs are automatically set to the state “logic zero”. If the robot controller has a peripheral contactor (US2), and if the safety configuration specifies for this to switch in accordance with the motion enable, then the same also applies in Start-up mode. This means that if motion enable is present, the US2 voltage is switched on – even in Start-up mode. The maximum number of switching cycles of the peripheral contactors is 175 per day. Hazards Possible hazards and risks involved in using Start-up mode: • A person walks into the manipulator’s danger zone. • In a hazardous situation, a disabled external EMERGENCY STOP device is actuated and the manipulator is not shut down. Additional measures for avoiding risks in Start-up mode: • Cover disabled EMERGENCY STOP devices or attach a warning sign indicating that the EMERGENCY STOP device is out of operation. • If there is no safety fence, other measures must be taken to prevent persons from entering the manipulator’s danger zone, e.g. use of warning tape. Use Intended use of Start-up mode: • Start-up in T1 mode when the external safeguards have not yet been installed or put into operation. The danger zone must be delimited at least by means of warning tape. • Fault localization (periphery fault). • Use of Start-up mode must be minimized as much as possible. WARNING Risk of fatal injury due to non-operational external safeguards Use of Start-up mode disables all external safeguards. Death, severe injuries or damage to property may result. • There must be no persons in the danger zone of the manipulator while it is in Start-up mode. 62/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Misuse Any use or application deviating from the intended use is deemed to be misuse and is not allowed. It will result in the loss of warranty and liability claims. KUKA is not liable for any damage resulting from such misuse. 3.12.5 Manual mode General Manual mode is the mode for setup work. Setup work is all the tasks that have to be carried out on the industrial robot to enable automatic operation. Setup work includes: • • • • Jog mode Teaching Programming Program verification The following must be taken into consideration in manual mode: • New or modified programs must always be tested first in Manual Reduced Velocity mode (T1). • The manipulator, tooling or external axes (optional) must never touch or project beyond the safety fence. • Workpieces, tooling and other objects must not become jammed as a result of the industrial robot motion, nor must they lead to short-circuits or be liable to fall off. • All setup work must be carried out, where possible, from outside the safeguarded area. Setup work in T1 If it can be avoided, there must be no persons inside the safeguarded area. If it is necessary to carry out setup work from inside the safeguarded area, the following must be taken into consideration in the operating mode Manual Reduced Velocity (T1): • If it can be avoided, there must be no more than one person inside the safeguarded area. • If it is necessary for there to be several persons inside the safeguarded area, the following must be observed: ‒ Each person must have an enabling device. ‒ All persons must have an unimpeded view of the industrial robot. ‒ Eye-contact between all persons must be possible at all times. • The operator must be so positioned that he can see into the danger zone and get out of harm’s way. • Unexpected motions of the manipulator cannot be ruled out, e.g. in the event of a fault. For this reason, an appropriate clearance must be maintained between persons and the manipulator, including the tool. Guide value: 50 cm. The minimum clearance may vary depending on local circumstances, the motion program and other factors. The minimum clearance that is to apply for the specific application must be decided by the user on the basis of a risk assessment. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 63/304 Safety KUKA.SafeOperation 3.6 Safety KUKA.SafeOperation 3.6 Setup work in T2 If it is necessary to carry out setup work from inside the safeguarded area, the following must be taken into consideration in the operating mode Manual High Velocity (T2): • This mode may only be used if the application requires a test at a velocity higher than that possible in T1 mode. • Teaching and programming are not permissible in this operating mode. • Before commencing the test, the operator must ensure that the enabling devices are operational. • The operator must be positioned outside the danger zone. • There must be no other persons inside the safeguarded area. It is the responsibility of the operator to ensure this. 3.12.6 Simulation Simulation programs do not correspond exactly to reality. Robot programs created in simulation programs must be tested in the system in Manual Reduced Velocity mode (T1). It may be necessary to modify the program. 3.12.7 Automatic mode Automatic mode is only permissible in compliance with the following safety measures: • All safety equipment and safeguards are present and operational. • There are no persons in the system or the requirements for collaborative operation in accordance with EN ISO 10218 have been met. • The defined working procedures are adhered to. If the manipulator or an external axis (optional) comes to a standstill for no apparent reason, the danger zone must not be entered until an EMERGENCY STOP has been triggered. 3.12.8 Maintenance and repair After maintenance and repair work, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety functions must also be tested. The purpose of maintenance and repair work is to ensure that the system is kept operational or, in the event of a fault, to return the system to an operational state. Repair work includes troubleshooting in addition to the actual repair itself. The following safety measures must be carried out when working on the industrial robot: • Carry out work outside the danger zone. If work inside the danger zone is necessary, the user must define additional safety measures to ensure the safe protection of personnel. • Switch off the industrial robot and secure it (e.g. with a padlock) to prevent it from being switched on again. If it is necessary to carry out work with the robot controller switched on, the user must define additional safety measures to ensure the safe protection of personnel. 64/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 • If it is necessary to carry out work with the robot controller switched on, this may only be done in operating mode T1. • Label the system with a sign indicating that work is in progress. This sign must remain in place, even during temporary interruptions to the work. • The EMERGENCY STOP devices must remain active. If safety functions or safeguards are deactivated during maintenance or repair work, they must be reactivated immediately after the work is completed. DANGER Danger to life and limb due to live parts The robot system must be disconnected from the mains power supply prior to work on live parts. It is not sufficient to trigger an EMERGENCY STOP or safety stop, because parts remain live. Death or severe injuries may result. • Before commencing work on live parts, turn off the main switch and secure it against being switched on again. If the controller variant in question does not have a main switch (e.g. KR C5 micro), turn off the device switch then disconnect the power cable and secure it so it cannot be reconnected. • Then check to ensure that the system is deenergized. • Inform the individuals involved that the robot controller is switched off. (e.g. by affixing a warning sign) Faulty components must be replaced using new components with the same article numbers or equivalent components approved by KUKA Deutschland GmbH for this purpose. Cleaning and preventive maintenance work is to be carried out in accordance with the operating instructions. Robot controller Even when the robot controller is switched off, parts connected to peripheral devices may still carry voltage. The external power sources must therefore be switched off if work is to be carried out on the robot controller. The ESD regulations must be adhered to when working on components in the robot controller. Voltages in excess of 50 V (up to 780 V) can be present in various components for several minutes after the robot controller has been switched off! To prevent life-threatening injuries, no work may be carried out on the industrial robot in this time. On robot controllers with transformers, the transformers must be disconnected before working on components in the robot controller. Water and dust must be prevented from entering the robot controller. Counterbalancing system Some robot variants are equipped with a hydropneumatic, spring or gas cylinder counterbalancing system. • Counterbalancing system classified below category I: Is subject to the Pressure Equipment Directive but exempt from application of the Pressure Equipment Directive according to Art. 4, para. 3 and therefore not CE marked. • Counterbalancing system classified as category I or higher: Is subject to the Pressure Equipment Directive and CE marked as a component (see rating plate of the counterbalancing system). The KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 65/304 Safety KUKA.SafeOperation 3.6 KUKA.SafeOperation 3.6 Safety pressure equipment is placed on the market in conjunction with partly completed machinery. Conformity is expressed on the declaration of incorporation according to the Machinery Directive. The user must comply with the applicable national laws, regulations and standards pertaining to pressure equipment. • In Germany, the counterbalancing system is work equipment according to the German Ordinance on Industrial Safety and Health (BetrSichV). Inspection intervals in Germany in accordance with the Ordinance on Industrial Safety and Health, Sections 14 and 15. Inspection by the user before commissioning at the installation site. • Inspection intervals in all other countries must be researched and observed. As a rule, however, at least the maintenance intervals specified by KUKA must be observed. These must not be exceeded. The following safety measures must be carried out when working on the counterbalancing system: • The assemblies supported by the counterbalancing systems must be secured. • Work on the counterbalancing systems must only be carried out by qualified personnel. Hazardous substances The following safety measures must be carried out when handling hazardous substances: • Avoid prolonged and repeated intensive contact with the skin. • Avoid breathing in oil spray or vapors. • Clean skin and apply skin cream. Use current safety data sheets Knowledge of the safety data sheets of the substances and mixtures used is a prerequisite for the safe use of KUKA products. Death, injuries or damage to property may otherwise result. • Request up-to-date safety data sheets from the manufacturers of hazardous substances regularly. 3.12.9 Decommissioning, storage and disposal The industrial robot must be decommissioned, stored and disposed of in accordance with the applicable national laws, regulations and standards. 3.12.10 Safety measures for single point of control Overview If certain components are used on the industrial robot, safety measures must be taken to ensure complete implementation of the principle of “single point of control” (SPOC). The relevant components are: • • • • • 66/304 | www.kuka.com Submit interpreter PLC OPC server Remote control tools Tools for configuration of bus systems with online functionality KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Safety KUKA.SafeOperation 3.6 • KUKA.RobotSensorInterface • KUKA.DeviceConnector (not KUKA.DeviceConnector pre-installed) Since only the system integrator knows the safe states of actuators in the periphery of the robot controller, it is his task to set these actuators to a safe state, e.g. in the event of an EMERGENCY STOP. Further safety measures for Single Point of Control Depending on the specific application, further safety measures may be required to ensure complete implementation of the principle of “single point of control”. Failure to take this precaution into consideration may result in death, injuries or damage to property. • Check whether further safety measures are required; if so, implement them. T1, T2 In modes T1 and T2, the components referred to above may only access the industrial robot if the following signals have the following states: Signal State required for SPOC $USER_SAF TRUE $SPOC_MOTION_ENABLE TRUE Submit interpreter, PLC If motions, (e.g. drives or grippers) are controlled with the submit interpreter or the PLC via the I/O system, and if they are not safeguarded by other means, then this control will take effect even in T1 and T2 modes or while an EMERGENCY STOP is active. If variables that affect the robot motion (e.g. override) are modified with the submit interpreter or the PLC, this takes effect even in T1 and T2 modes or while an EMERGENCY STOP is active. • In T1 and T2, the system variable $OV_PRO must not be written to by the submit interpreter or the PLC. OPC server, KUKA.DeviceConnector, remote control tools These components can be used with write access to modify programs, outputs or other parameters of the robot controller, without this being noticed by any persons located inside the system. Safety measure: If these components are used, outputs that could cause a hazard must be determined in a risk assessment. These outputs must be designed in such a way that they cannot be set without being enabled. This can be done using an external enabling device, for example. Tools for configuration of bus systems If these components have an online functionality, they can be used with write access to modify programs, outputs or other parameters of the robot controller, without this being noticed by any persons located inside the system. • WorkVisual from KUKA • Tools from other manufacturers Safety measure: KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 67/304 KUKA.SafeOperation 3.6 Safety In the test modes, programs, outputs or other parameters of the robot controller must not be modified using these components. 68/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 4 Technical data 4.1 Service life Technical data KUKA.SafeOperation 3.6 The maximum permissible service life of safety-relevant hardware components is 20 years. Once this time has been reached, the safety-relevant hardware components must be exchanged. 4.2 Reference switch Basic data Designation Values Ambient temperature -25 °C … +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 or HIGH level UB(HIGH) for pulsed voltage 20 … 33 V LOW level UB(LOW) for pulsed voltage 0 … 5 V Required pulse duty factor T(HIGH):T(LOW) for pulsed voltage Min. 4:1 Supported pulse duration T(LOW) for pulsed voltage 0.1 … 20 ms Protection rating IP67 Operating current (power consumption) without load 5 mA Permissible load current max. 250 mA Permissible switching frequency max. 500 Hz Permissible switching distance at the proximity switch surfaces 0 … 4 mm Short circuit and overload protection, pulsed Yes Outputs • PNP • LOW-active • Dual-channel LED function indicator Yes Hysteresis when installed 0.2 … 1 mm EMC conformity IEC 60947-5-2 KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 69/304 Technical data KUKA.SafeOperation 3.6 Pulse duty factor Fig. 4-1: Pulse duty factor for pulsed voltage Hole pattern Fig. 4-2: Hole pattern, reference switch 70/304 | www.kuka.com 1 Holes for fastening (2x Ø6.6 mm) 2 Holes for roll pins (2x Ø4 mm) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 4.3 Technical data KUKA.SafeOperation 3.6 Reference cable XG42 - XS Ref Fig. 4-3: Connector pin allocation for reference cable XG42 - XS Ref Fig. 4-4: Wiring diagram for reference cable XG42 - XS Ref KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 71/304 Technical data KUKA.SafeOperation 3.6 4.4 Circuit diagram of reference switch XS Ref Fig. 4-5: Circuit digram of reference switch XS Ref 1 72/304 | www.kuka.com Switching element, channel A 2 Switching element, channel B KST SafeOperation 3.6 V3 | Issued: 10.10.2022 4.5 Technical data KUKA.SafeOperation 3.6 Hole pattern for actuating plate Actuating plate, straight Fig. 4-6: Hole pattern for actuating plate, straight 1 Thread for fastening (2x M6) 2 Holes for fastening (2x Ø9 mm) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 73/304 Technical data KUKA.SafeOperation 3.6 Actuating plate, angled Fig. 4-7: Hole pattern for actuating plate, angled 1 74/304 | www.kuka.com Hole for fastening KST SafeOperation 3.6 V3 | Issued: 10.10.2022 5 Installation The option package can either be installed on the robot controller via the smartHMI or via WorkVisual. 5.1 System requirements Hardware • KR C5 robot controller Software Robot controller: • KUKA System Software 8.7 • If the Ethernet safety interface EtherNet IP/CIP Safety is used: ‒ KUKA.EtherNet/IP M/S 5.1 • If the Ethernet safety interface PROFINET/PROFIsafe is used: ‒ KUKA.PROFINET M/S 6.0 Laptop/PC: • WorkVisual 6.0 Compatibility KUKA.SafeOperation 3.6 must not be installed on a robot controller together with the following safety options: • KUKA.SafeRangeMonitoring 3.6 • KUKA.SafeVelocityMonitoring 3.6 • KUKA.SafeSingleBrake 3.6 5.2 Installing via WorkVisual 5.2.1 Installing or updating KUKA.SafeOperation 3.6 Description The option package is installed in WorkVisual and added to the project. During project deployment, the option package is automatically installed on the robot controller. In the case of an update, the existing configuration is automatically adopted. If this is not desired, the existing version must first be uninstalled. It is advisable to archive all relevant data before updating a software package. Precondition • • • • • User group “Expert” or higher T1 or T2 mode No program is selected. Network connection between PC and robot controller The option package is available as a KOP file. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 75/304 Installation KUKA.SafeOperation 3.6 Installation KUKA.SafeOperation 3.6 Procedure 1. 2. 3. 4. Install the KUKA.SafeOperation 3.6 option package in WorkVisual. Load the active project from the robot controller. Insert the KUKA.SafeOperation 3.6 option package into the project. Configure the option package in WorkVisual as required. (>>> 7.6 "Editing the local safety configuration in WorkVisual" Page 131) 5. Deploy the project from WorkVisual to the robot controller and activate it. 6. The request for confirmation Do you want to activate the project […]? is displayed on the smartHMI. The active project is overwritten during activation. If no relevant project will be overwritten: Answer the query with Yes. 7. An overview with the changes and a request for confirmation are displayed on the smartHMI. Answer this with Yes. The option package is installed and the message Reconfiguration in progress ... is displayed. When the message disappears, reconfiguration is completed. Information about procedures in WorkVisual is contained in the KUKA.WorkVisual documentation. LOG file A LOG file is created under C:\KRC\ROBOTER\LOG. 5.2.2 Uninstalling KUKA.SafeOperation 3.6 Description The option package can be uninstalled via WorkVisual. It is advisable to archive all relevant data before uninstalling a software package. Preparation • Deactivate safe monitoring. If the safe monitoring is not deactivated on the robot controller, the configured safety monitoring functions will remain active after the software has been uninstalled. Safe monitoring can only be deactivated by the user group “Safety maintenance” or higher. (>>> 7.14 "Deactivating safe monitoring" Page 192) Precondition • • • • • User group “Expert” or higher T1 or T2 mode No program is selected. Safe monitoring has been deactivated. Network connection between PC and robot controller Procedure 1. Load the project from the robot controller. 76/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 2. Remove the KUKA.SafeOperation 3.6 option package from the project. A window with modifications is displayed. 3. Deploy the project from WorkVisual to the robot controller and activate it. 4. The request for confirmation Do you want to activate the project […]? is displayed on the smartHMI. The active project is overwritten during activation. If no relevant project will be overwritten: Answer the query with Yes. 5. An overview with the changes and a request for confirmation are displayed on the smartHMI. Answer this with Yes. The option package is uninstalled and the message Reconfiguration in progress ... is displayed. When the message disappears, reconfiguration is completed. Information about procedures in WorkVisual is contained in the KUKA.WorkVisual documentation. LOG file A LOG file is created under C:\KRC\ROBOTER\LOG. 5.3 Installing via smartHMI 5.3.1 Installing or updating KUKA.SafeOperation 3.6 It is advisable to archive all relevant data before updating a software package. In the case of an update, the existing configuration is automatically adopted. If this is not desired, the existing version must first be uninstalled. Precondition • User rights: Function group General configuration But at least the user group “Expert” • T1 or T2 mode • No program is selected. • USB stick with the option package (KOP file) NOTICE Data loss due to USB sticks from third-party manufacturers Data may be lost if USB sticks from manufacturers other than KUKA are used for activities on the robot controller. • For activities on the robot controller requiring a USB stick, use a KUKA stick. The KUKA sticks are validated for use with the robot controller. Procedure 1. Connect the USB stick to the robot controller or smartPAD. 2. In the main menu, select Start-up > Additional software. 3. Press New software: The entry KUKA.SafeOperation 3.6 must be displayed in the Name column and drive E:\ or K:\ in the Path column. If not, press Refresh. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 77/304 Installation KUKA.SafeOperation 3.6 Installation KUKA.SafeOperation 3.6 4. If the specified entries are now displayed, continue with step 5. Otherwise, the path from which the software is to be installed must be configured first: 5. 6. 7. 8. a. Press the Configure button. b. Select a line in the Installation paths for options area. Note: If the line already contains a path, this path will be overwritten. c. Press Path selection. The available drives are displayed. d. If the stick is connected to the robot controller: Select E:\. If the stick is connected to the smartPAD: K:\ instead of E:\ e. Press Save. The Installation paths for options area is displayed again. It now contains the new path. f. Mark the line with the new path and press Save again. Activate the check mark at KUKA.SafeOperation 3.6 and press Install. Confirm the installation query with OK. The request for confirmation Do you want to activate the project […]? is displayed on the smartHMI. The active project is overwritten during activation. If no relevant project will be overwritten: Answer the query with Yes. An overview with the changes and a request for confirmation are displayed on the smartHMI. Answer this with Yes. The option package is installed and the message Reconfiguration in progress ... is displayed. When the message disappears, reconfiguration is completed. Remove the stick. LOG file A LOG file is created under C:\KRC\ROBOTER\LOG. 5.3.2 Uninstalling KUKA.SafeOperation 3.6 It is advisable to archive all relevant data before uninstalling a software package. Preparation • Deactivate safe monitoring. If the safe monitoring is not deactivated on the robot controller, the configured safety monitoring functions will remain active after the software has been uninstalled. Safe monitoring can only be deactivated by the user group “Safety maintenance” or higher. (>>> 7.14 "Deactivating safe monitoring" Page 192) Precondition • User rights: Function group General configuration • T1 or T2 mode • Safe monitoring has been deactivated. Procedure 1. In the main menu, select Start-up > Additional software. 78/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 2. Activate the check mark at KUKA.SafeOperation 3.6 and press Uninstall. Answer the request for confirmation with Yes. 3. The request for confirmation Do you want to activate the project […]? is displayed on the smartHMI. The active project is overwritten during activation. If no relevant project will be overwritten: Answer the query with Yes. 4. An overview with the changes and a request for confirmation are displayed on the smartHMI. Answer this with Yes. The option package is installed and the message Reconfiguration in progress ... is displayed. When the message disappears, reconfiguration is completed. LOG file A LOG file is created under C:\KRC\ROBOTER\LOG. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 79/304 Installation KUKA.SafeOperation 3.6 Installation KUKA.SafeOperation 3.6 80/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 6 Operation 6.1 User groups Operation KUKA.SafeOperation 3.6 Description The configuration of the safety functions of the System Software and the installed safety option is assigned to defined user groups. Access cannot be influenced via function groups. The user rights of the safety recovery technician are restricted by the installation of a safety option. • Safety recovery technician The safety recovery technician can activate an existing safety configuration of the robot using the corresponding activation code. He cannot edit or modify the safety configuration. • Safety maintenance technician Like the administrator, the safety maintenance technician can perform all functions including those of the safety systems. He can edit and modify the safety configuration. The safety maintenance technician must be specially trained in the safety configuration. • Administrator Like the safety maintenance technician, the administrator can perform all functions including those of the safety systems. He can edit and modify the safety configuration. The administrator must be specially trained in the safety configuration if he wishes to edit and modify the safety configuration. Additionally, in the rights management, the administrator can modify which rights a user group has. Safety configuration by qualified personnel only The safety configuration may only be edited and modified by specially trained personnel. Death, severe injuries or damage to property may otherwise result. We recommend training courses at KUKA College for training personnel. Information about the training program can be found at www.kuka.com or can be obtained directly from our subsidiaries. Passwords The user groups are protected by means of a password. The default password for all groups is “kuka”. Changing the default passwords before start-up If the passwords are not changed, this enables unauthorized persons to log on. In particular, the change of password must ensure that only authorized and trained persons can modify the safety configuration. • Before start-up, change the passwords for the user groups. • Only communicate the passwords to authorized personnel. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 81/304 Operation KUKA.SafeOperation 3.6 6.2 Displaying user rights Description If tasks belonging to the standard functions of the system software are assigned to a function group, this is specified. In the case of tasks that are not assigned to any function group, the permanently assigned, minimum required user group is specified. In the rights management, the user can view what user group is currently assigned to what function group, i.e. the minimum user group required to execute a function from a function group. Procedure 1. In the main menu, select Start-up > Rights management. The Rights management window opens. 2. Select the Function groups tab. 6.3 Opening the safety configuration Description On opening, the safety configuration checks whether there are any relevant deviations between the data in the robot controller and those in the safety controller. • If there are no deviations, the safety configuration opens directly. • If there are deviations, the troubleshooting wizard is opened. A description of the problem and a list of possible causes is displayed. The user can select the applicable cause. The wizard then suggests a solution. Further information about checking the safety configuration is contained in the Operating and Programming Instructions for System Integrators. Procedure 1. In the main menu, select Configuration > Safety configuration. 2. Only for the “Administrator” user group: Confirm the safety message with OK. 6.4 Overview of buttons The following buttons are available: Button Description Reset all to defaults Resets all parameters of the safety configuration to the default values. Reset changes Resets all changes since the last time the configuration was saved. Revision log The log of changes to the safety configuration is displayed. View The safety-relevant machine data are displayed. Properties The properties of a monitoring space or safety-oriented tool can be defined. Export Parts of the safety configuration can be exported into an XML file (XML export). 82/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Button Description Import Parts of the safety configuration can be imported as an XML file (XML export). Communication parameters The safety ID of the PROFINET device can be changed. Note: Further information is contained in the Operating and Programming Instructions for System Integrators. Global parameters The global parameters of the safety configuration can be defined. Hardware options The hardware settings can be defined. Note: Further information is contained in the Operating and Programming Instructions for System Integrators. Check machine data It is possible to check whether the machine data of the safety configuration are up to date. Safe operational stop The safe operational stop can be defined. Save Saves and activates the safety configuration for the robot. Touch-up Saves the current robot position as a corner of a cell area. OR Saves the current axis angle as the lower limit or upper limit of the axis-specific monitoring space. Touch-up reference position Saves the current robot flange position or the position of the for group axes of a reference group as a reference position. Cell configuration The cell area can be defined. Back Back to the tab 6.5 Displaying information about the safety configuration Procedure • In the main menu, select Configuration > Safety configuration. Description The Common tab contains the following information: Parameter Description Robot Serial number of the robot Safety controller • Installed safety option version • Safety controller version (internal) Parameter data set • Activation code of the safety configuration • Time stamp of the safety configuration (date and time last saved) • Safety configuration version Machine data Time stamp of the safety-relevant machine data (date and time last saved) Brake test State of the brake test • Deactivated: No axis is tested. • Activated: One or more axes are tested. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 83/304 Operation KUKA.SafeOperation 3.6 Operation KUKA.SafeOperation 3.6 Parameter Description Current configuration • Name of the safety interface • State of Cartesian monitoring (= velocity monitoring in T1) ‒ Activated, Deactivated • State of safe monitoring • • • • 6.6 ‒ Activated, Deactivated Number of velocity-monitored axes Number of monitoring spaces Number of protected spaces Number of safety-oriented tools Displaying the revision log Description Every modification to the safety configuration and every saving operation are automatically logged. The log can be displayed on the smartHMI. Procedure 1. In the main menu, select Configuration > Safety configuration. 2. On the Common tab, press Revision log. 6.7 Displaying machine data Description The safety-relevant machine data can be displayed on the smartHMI. Procedure 1. In the main menu, select Configuration > Safety configuration. 2. On the Common tab, press View. 6.8 Importing the safety configuration (XML import) Description Parts of the safety configuration can be imported as an XML file. The importable parameters depend on the installed safety option: SafeOperation SafeRange Monitoring SafeVelocity Monitoring SafeSingle Brake Cell configuration Cartesian monitoring spaces Axis-specific monitoring spaces Tools* Global parameters 84/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 SafeOperation SafeRange Monitoring SafeVelocity Monitoring SafeSingle Brake If KUKA.SafeVelocityMonitoring is installed, only tool 1 is available. The safety-oriented TCP of the tool can be configured. * In order to generate an XML file for importing, the user has the following options: • Export the current safety configuration of the robot controller to an XML file and edit it. In this way it is possible to ensure that the format of the XML file is correct for a subsequent import. (>>> 6.9 "Exporting the safety configuration (XML export)" Page 87) • Generate the XML file on the basis of the XML schema C:\KRC \SmartHMI\Schemes\SafetyConfigImport.xsd, e.g. using a script programmed by the user. The following points must be observed when editing the XML files: • The XML schema defines the structure of the XML file for the import. For individual parameters, the XML schema allows higher values than the installed version of the safety option. • The XML file to be imported should only contain parameters and values which are supported by the current safety option. If this is not the case, it can prevent the XML import from occurring. It is also possible to import safety configurations in WorkVisual. Further information about the XML import can be found in the WorkVisual documentation. The SCG format can be used for the complete import of the safety configuration. Further information about the SCG import can be found in the WorkVisual documentation. Precondition • • • • Safety option is installed. User group “Safety maintenance” or higher T1 or T2 mode No program is selected. Procedure 1. In the main menu, select Configuration > Safety configuration. 2. 3. 4. 5. The Safety configuration window opens. Press Import. The available drives are displayed. Navigate to the directory where the XML file to be imported is located. Select the XML file and press Next. The parameters configured in the XML file are compared with the current parameters of the safety configuration. If notification, warning or error messages occur, these are displayed in the Safety configuration window. To continue with the XML import, press Next. The Next button is deactivated in the event of error messages. Analyze errors and cancel the XML import. • Rectify the error in the XML file and repeat the XML import. • OR: Select the correct XML file and repeat the XML import. 6. A tree view provides an overview of the parameters to be imported. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 85/304 Operation KUKA.SafeOperation 3.6 KUKA.SafeOperation 3.6 Operation (>>> "Parameter display" Page 86) By default, only those nodes which contain changes to the current safety configuration are expanded in the tree view. The parameters which are changed by the XML import are displayed in blue text. 7. Check the parameters. If not all of the required safety functions are configured correctly, or if the wrong XML file was selected, cancel the XML import. • Rectify the error in the XML file and repeat the XML import. • OR: Select the correct XML file and repeat the XML import. 8. Press Import. The safety configuration is imported. 9. Save safety configuration. (>>> 7.5.11 "Saving the safety configuration" Page 131) 10. If plausibility errors are detected while saving, the user is informed of this by a dialog. Close the dialog with OK. 11. Rectify errors directly in the safety configuration and save the safety configuration. OR Rectify the error in the XML file, repeat the XML import and save the safety configuration. Following a change to the safety configuration, safety acceptance must be carried out and documented by means of checklists. Parameter display The display with the overview of the parameters to be imported has the following columns: Column Description Parameter name Name of the parameter in the Safety configuration window Result Value of the parameter following import of the safety configuration Current Value of the parameter in the current safety configuration Imported Value of the parameter in the XML file to be imported The column is hidden when the display opens. The following buttons are available for changing the display: Button Description Display import column Displays or hides the Imported column. Check box active: Column is displayed. Check box not active: Column is hidden. 86/304 | www.kuka.com Collapse all All nodes in the tree view are collapsed. Expand all All nodes in the tree view are expanded. Expand changes Only those nodes which contain changes to the current safety configuration are expanded in the tree view. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 6.9 Operation KUKA.SafeOperation 3.6 Exporting the safety configuration (XML export) Description Parts of the safety configuration can be exported into an XML file: • • • • Cell configuration Monitoring spaces Tools Global parameters The XML file always contains all the parameters which are contained in the exported parts of the safety configuration. Exporting is always possible, irrespective of whether a safety option is installed or not. However, an export only makes sense if a safety option is installed. The current safety configuration of the robot controller is exported. If the safety configuration contains unsaved changes, these are also exported. If invalid values are entered in the safety configuration, the export is aborted with an error message (plausibility error). It is also possible to export safety configurations in WorkVisual. Further information about the XML export can be found in the WorkVisual documentation. The SCG format can be used for the complete export of the safety configuration. Further information about the SCG export can be found in the WorkVisual documentation. Procedure 1. In the main menu, select Configuration > Safety configuration. The Safety configuration window opens. 2. Press Export. The available drives are displayed. 3. Select the desired file path and press Export. The safety configuration is saved in an XML file. The file name is generated automatically. 6.10 Safe robot retraction in case of space violation Description If the robot has violated a monitoring space, it is stopped by the safety controller (precondition: function Stop at boundaries is active). The robot must be moved out of the violated space in T1 mode. After a “Stop at boundaries”, the robot can only be moved in T1 mode. No other operating mode can be set until the robot has left the violated space. If the space is violated in T2 or Automatic mode, only a status message is displayed. The status message indicates which space has been violated. If the space is violated in T1 mode, the acknowledgement message Ackn.: Stop because workspace exceeded is additionally displayed. Precondition • Operating mode T1 KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 87/304 Operation KUKA.SafeOperation 3.6 Procedure 1. When the acknowledgement message is displayed, confirm it with OK. 2. Press and hold down the enabling switch. 3. Move the robot out of the violated space: • Using the jog keys (manual mode) • Using the Start and Start backwards keys (program mode) The status message is cleared when the robot has left the violated space. 88/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 7 Start-up and configuration 7.1 System safety instructions During system planning, the safety functions must be planned. Required safety functions that are not implemented with the SafeOperation safety option must be implemented using different safety measures. Including stopping distances in the risk assessment The stopping distance when a safety function is triggered varies according to the specific robot type. Failure to take this into consideration when parameterizing the safety functions may result in death, severe injuries or damage to property. • The system integrator must include the stopping distances in the risk assessment and parameterize the safety functions accordingly. Further information about the stopping distances and stopping times can be found in the assembly instructions of the relevant robot. WARNING Serious system errors, severe damage to the robot and injury or death can result from not carrying out the risk analysis. Risk analysis must be carried out before start-up and after any safety-relevant modification. • Define axes that must be tested in the brake test. • Determine brake test cycle time. • Determine axis-specific and Cartesian limit values for the reduced velocity. • Define axis-specific and Cartesian monitoring spaces. • Define axes that must be configured for a safe operational stop. WARNING Incorrect configuration of the safe monitoring functions may result in death or severe injuries and major damage to property. Consequently, safety options may not be operated until after safety acceptance has been carried out in accordance with the checklists. The checklists must be completed fully and confirmed in writing. (>>> 11.1 "Checklists for safety acceptance" Page 269) WARNING If safe monitoring is deactivated, the configured safety monitoring functions are inactive. WARNING Serious injury and severe damage to the robot can be caused by changing the machine data. Modifying the machine data may deactivate monitoring functions. Machine data may only be modified by authorized personnel. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 89/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 7.2 Jogging the robot without a higher-level safety controller Description To jog the robot without a higher-level safety controller, Start-up mode must first be activated. The robot can then be jogged in T1 mode. Start-up mode has the following effect on the safety configuration: • Tool 1 is always active in Start-up mode. • In Start-up mode, all safety monitoring functions that can be activated via safety-oriented inputs are deactivated. (>>> 8.1.1 "KUKA.SafeOperation via Ethernet safety interface" Page 197) • The following safety monitoring functions remain active in Start-up mode: ‒ ‒ ‒ ‒ Monitoring of the cell area Monitoring of global maximum Cartesian velocity Monitoring of global maximum axis velocity Workspace monitoring functions that are configured as always active ‒ Monitoring of the workspace-specific velocity in workspaces that are configured as always active ‒ Velocity monitoring in T1 Observe the safety instructions relating to Start-up mode. External safeguards are disabled in Start-up mode. • The safety instructions relating to Start-up mode must be observed. (>>> 3.12.4.2 "Start-up mode" Page 62) Precondition • User rights: Function group Start-up mode • If an Ethernet safety interface is used: No connection to a higher-level safety controller • T1 mode Procedure • In the main menu, select Start-up > Service > Start-up mode. Menu Description Start-up mode is active. Touching the menu item deactivates the mode. Start-up mode is not active. Touching the menu item activates the mode. 90/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 7.3 Overview: start-up and configuration Step 1 Description Set up brake test. (>>> 7.8 "Brake test" Page 149) 2 If a reference switch is being used for the mastering test: 1. Select reference position. (>>> 7.7.1.2 "Selecting a reference position" Page 135) 2. Install reference switch and actuating plate. (>>> 7.7.1.3 "Installing the reference switch and actuating plate" Page 137) 3. Connect reference switch. (>>> 7.7.1.4 "Connecting the reference switch" Page 138) 3 If a safety PLC is being used: • Configure the communication via the interface to the higher-level controller. (>>> 8 "Interfaces to the higher-level controller" Page 193) 4 Master the robot. Note: Further information about mastering is contained in the operating and programming instructions for the System Software. 5 Activate safe monitoring. (>>> 7.5.1 "Activating safe monitoring" Page 97) 6 Configure global parameters: • Mastering type • Mastering test input • Cartesian velocity monitoring functions (>>> 7.5.2 "Configuring global parameters" Page 97) 7 Configure monitoring spaces. (>>> 7.5.4 "Configuring a cell area" Page 105) (>>> 7.5.5 "Configuring a Cartesian monitoring space" Page 107) (>>> 7.5.6 "Configuring an axis-specific monitoring space" Page 111) 8 Configure axis monitoring. (>>> 7.5.7 "Configuring axis-specific velocity monitoring functions and braking time" Page 115) (>>> 7.5.8 "Configuring safe operational stop for axis groups" Page 122) 9 Configure safety-oriented tools. (>>> 7.5.3 "Configuring a safety-oriented tool" Page 101) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 91/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Step Description 10 If a reference switch is being used for the mastering test: • Program a mastering test. (>>> 7.7.1.6 "Teaching positions for the mastering test" Page 140) 11 If a reference switch is being used for the mastering test: • Configure the reference position and reference groups. (>>> 7.5.10 "Configuring the reference position and reference group" Page 128) (>>> 7.7.1.5 "Configuring the reference groups to be checked in file" Page 139) 12 If a reference switch is being used for the mastering test and the reference switch is actuated by a ferromagnetic part of the tool, or following a tool change or replacement: • Check the correctness of the reference position. (>>> 7.7.1.7 "Checking the reference position (actuation with tool)" Page 142) 13 Save safety configuration. (>>> 7.5.11 "Saving the safety configuration" Page 131) 14 Perform mastering test. (>>> 7.7.1.8 "Performing a mastering test manually" Page 143) 15 Carry out safety acceptance. (>>> 7.10 "Safety acceptance overview" Page 177) (>>> 7.11 "Checking the safety functions for correct operation" Page 178) (>>> 7.12 "Checking the values for the safe axis monitoring functions" Page 190) 16 If a new safety configuration is activated: • Compare the activation code displayed when the safety configuration is archived with the activation code documented in the checklist for safety functions. (>>> 7.13 "Activating the safety configuration" Page 191) 7.4 Information about the safety configuration WARNING Risk of fatal injury due to unmonitored robot components Cartesian monitoring spaces are only monitored against the spheres used to model the active safety-oriented tool. Robot components situated outside the tool spheres are not monitored and a space violation by these components is not detected. Death, injuries or damage to property may result. • Design and configure Cartesian monitoring spaces and tool spheres in such a manner that the unmonitored robot components do not pose any threat. 92/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Minimum sphere radius The sphere radius must not fall below the predefined minimum value. This radius is dependent on the global maximum Cartesian velocity. The minimum sphere radius is calculated as follows: • rmin [mm] >= 0.5 * (maximum Cartesian velocity [mm/s] * 0.012 s) The smallest possible radius is 10 mm. A radius smaller than 10 mm cannot be configured, even if the calculation gives a smaller value. If values that are too small are configured, a message is displayed when saving and the configuration is prevented from being saved. Minimum protected space dimensions The length, width and height of a protected space must not fall below the predefined minimum value. This value depends on the global maximum Cartesian velocity and the radius of the smallest sphere of the safety-oriented tool. The minimum space dimensions (= minimum length, width and height) are calculated as follows: • amin [mm] ≥ 0.018 s * maximum Cartesian velocity [mm/s] − 2 * rsphere [mm] A precondition for a correct result is that the sphere radius has been configured correctly. (>>> "Minimum sphere radius" Page 93) The smallest permissible length, width and height is 10 mm. Values smaller than 10 mm cannot be configured, even if the calculation gives a smaller value. If values that are too small are configured, a message is displayed when saving and the configuration is prevented from being saved. 7.4.1 Safe definition of Cartesian protected spaces Here, different constellations are covered which can cause a protected space violation to not be detected: • Narrow protected spaces • Motion across corners Narrow protected spaces With narrow protected spaces, there is a risk that the robot may be able to move through the protected space without the space violation being detected. The risk is partially reduced by the specified minimum value for the sphere radius and space dimensions. To further reduce the risk, the following rules must be observed in the configuration of protected spaces: • An area to be protected must always lie completely within a protected space, i.e. be enclosed by the protected space. • Shielding an area to be protected using a narrow protected space (e.g. by replicating a light curtain) is not permitted. • The stopping distances of the robot must also be taken into account when defining a protected space. The protected space must overlap with the area to be protected on all sides so that the robot can under no circumstances enter the area to be protected. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 93/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Fig. 7-1: Definition of protected space 1 Area to be protected 2 Protected space shields the area to be protected (not allowed) 3 Protected space encloses the entire area to be protected Motion across corners If a sphere is moved across the corner of a protected space at a high velocity, there is a risk of the space violation not being detected. To ensure that a signal is always reliably triggered on violation of an alarm space, this space must be made large enough to ensure that its full width, length or height is passed through. Fig. 7-2: Protected space as an alarm space 94/304 | www.kuka.com 1 Target area 2 Sphere moves across corner of protected space (signal not triggered) 3 Protected space is passed through completely (signal reliably triggered) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 7.4.2 Safe definition of Cartesian protected spaces for BBRA Description When the “Braking before restricted areas” function is used, it must additionally be taken into account that it is only the start and end points of the fictitious braking path that are checked and not the entire fictitious braking path. In the event of an unfavorable combination of protected space configuration and path, this can cause the protected space to be violated by the actual position without prior detection of an impending violation via the fictitious STOP 1 - DRS end position. Example In this example, the fictitious STOP 1 - DRS end position is situated outside the protected space. For this reason, the impending space violation cannot be detected. The robot is stopped at the space limit due to the monitoring of the actual position and executes a drive ramp stop in accordance with the precalculated path. The braking path passes through the protected space and the robot comes to a standstill again outside the protected space. Fig. 7-3: Unfavorable combination of protected space configuration and path 1 Protected space 2 Tool sphere path at actual position (orange) 3 Tool sphere path at fictitious STOP 1 - DRS end position (blue) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 95/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 4 Drive ramp stop at space limit; braking path passes through protected space (green line) 7.4.3 Unexpected protected space violation at space corners At the corners of a Cartesian protected space, unexpected space violations can occur even though the tool sphere is clearly outside the space boundary. The following figure (>>> Fig. 7-4) depicts the closest path along which a tool sphere can theoretically move about a Cartesian protected space. It can be moved along this closest path and reoriented without violating the protected space. Fig. 7-4: Path of a tool sphere along the space surface 1 Protected space 2 Tool spheres 3 Tool spheres reoriented The monitoring responds earlier than expected at the corners because of the virtually expanded space boundaries. Depending on the radius of the tool sphere, the protected space is expanded virtually on all sides (X, Y, Z) by precisely this radius. In the figure (>>> Fig. 7-5), a simplified depiction is used. Only the space expansion in the directions X and Y is shown. As long as the tool sphere infringes the expanded space boundaries in only one direction, the protected space is not violated. If, however, the expanded protected space is infringed in 2 planes simultaneously, this is evaluated as a space violation. 96/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Start-up and configuration KUKA.SafeOperation 3.6 Fig. 7-5: Protected space violation at space corners 1 Protected space 2 Protected space expanded by the radius of the tool sphere 3 Space violation in the X direction 4 Space violation in the Y direction 7.5 Configuring safety monitoring functions 7.5.1 Activating safe monitoring Configuration of the safety monitoring functions is only possible if safe monitoring has been activated. Precondition • User group Safety Maintenance Technician or higher • T1 or T2 mode Procedure 1. 2. 3. 4. 7.5.2 Open the safety configuration. Press Global parameters. Set the check mark at Safe monitoring. Save the safety configuration or continue configuration. Configuring global parameters Precondition • • • • User group “Safety maintenance” or higher T1 or T2 mode Safety configuration is open. Safe monitoring is active. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 97/304 Start-up and configuration KUKA.SafeOperation 3.6 Procedure • Press Global parameters and set parameters. 1. If the mastering test is to be performed via an external system, select the mastering type External confirmation. 2. A safety notification is displayed. Confirm with OK. The external mastering confirmation is activated and the Reference position tab is deactivated. Once the external mastering confirmation has been activated, responsibility for confirmation of the mastering lies outside the robot controller. The safety maintenance technician must ensure that the mastering test on the external system is correctly executed and confirmed. Parameters Fig. 7-6: Global parameters 98/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Parameter Description Safe monitoring Check box active: Safe monitoring is activated. Check box not active: Safe monitoring is not activated. Default: Safe monitoring not activated. Mastering type Reference switch = mastering test is carried out via KUKA reference switch. External confirmation = mastering test is performed via external system and with external mastering confirmation. Default: Reference switch Mastering test input Mastering type Reference switch: at cabinet = reference switch is connected via interface XG42. via bus interface = reference switch is connected via Ethernet safety interface. Default: at cabinet Mastering type External confirmation: at cabinet = mastering is confirmed via interface XG42. via bus interface = mastering is confirmed via Ethernet safety interface. Default: at cabinet Maximum Cartesian velocity Limit value for global maximum Cartesian velocity (not space-dependent) • 0.5 … 30,000 mm/s Default: 10,000 mm/s Reduced Cartesian velocity Limit value for safely reduced Cartesian velocity • 0.5 … 30,000 mm/s Default: 30,000 mm/s Reduced Cartesian velocity T1 Limit value for safely reduced Cartesian velocity in T1 mode • 0.5 … 250 mm/s Default: 250 mm/s Cartesian monitoring This parameter is always present, irrespective of whether a safety option is used or not. Default: active (>>> 7.5.2.1 "Switching safe Cartesian monitoring on/off" Page 99) 7.5.2.1 Switching safe Cartesian monitoring on/off Description Safe Cartesian monitoring refers to both KUKA kinematic systems as well as customer kinematic systems (CKs). KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 99/304 Start-up and configuration KUKA.SafeOperation 3.6 KUKA.SafeOperation 3.6 Start-up and configuration As a rule, the settings for safe Cartesian monitoring must not be changed on the controller. The reason is that WorkVisual projects almost always have only one possible setting: either active or inactive. They can only be transferred to the robot controller if the setting is correct. The setting for safe Cartesian monitoring can, however, be changed on the robot controller in the following cases: • If simulated axes are used, active monitoring can be deactivated. This is the only case in which the user can decide whether to operate the kinematic system with or without monitoring. • If the robot controller indicates via a message that monitoring is not possible. If simulated axes are used and monitoring is active in WorkVisual, it can only first be determined during the test on the robot controller whether the kinematic system can be moved. (It is not possible to determine this before in WorkVisual.) If the kinematic system cannot be moved, a message is generated which indicates that Cartesian monitoring is not possible. WARNING Danger to life and limb due to missing risk assessment To operate a kinematic system for which safe Cartesian monitoring is not possible, this monitoring can be deactivated. Failure to identify risks that may result from the deactivation may result in death or severe injuries. • Before deactivating the safe Cartesian monitoring, perform a risk assessment. Precondition • User group “Safety maintenance” or higher • T1 or T2 mode • No program is selected. Procedure 1. In the main menu, select Configuration > Safety configuration. The Safety configuration window opens. 2. On the Common tab, press Global parameters. 3. Remove the check mark at Cartesian monitoring: and press Save. 4. Answer the request for confirmation with Yes. The controller is reconfigured. 5. Once the reconfiguration has been completed, the following message is displayed: The changes were saved successfully. Confirm the message with OK. The Cartesian monitoring: check box refers to all Cartesian safety functions, including safe Cartesian monitoring in T1 mode. The check box is always present, irrespective of whether a safety option is used or not. There is always a basic, non-safe limitation of the speed in T1 mode to <= 250 mm/s as well as a safe monitoring of the axis-specific speed. They are not influenced by the setting Cartesian monitoring:. 100/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 7.5.3 Start-up and configuration KUKA.SafeOperation 3.6 Configuring a safety-oriented tool Precondition • • • • User group “Safety maintenance” or higher T1 or T2 mode Safety configuration is open. Safe monitoring is active. Procedure 1. Select the Tools tab and select a tool from the list. The parameters of the safety-oriented tool are displayed. 2. Activate safety-oriented tool. To do so, set the check mark at Activation. 3. Enter a name for the tool (max. 24 characters). 4. Define the safety-oriented TCP of the tool. 5. Press Properties. The Properties of {0} window opens. 6. Press the “plus” key of the external axis to configure a tool sphere. The parameters of the sphere are displayed. 7. Monitoring of the first sphere of the first tool to be configured is activated as standard. Activate monitoring for all other spheres and tools. To do so, set the check mark at Monitoring. 8. Enter the coordinates of the center of the sphere and the radius of the sphere. 9. Repeat steps 6 to 8 to define additional spheres for the safety-oriented tool. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 101/304 Start-up and configuration KUKA.SafeOperation 3.6 Parameters Fig. 7-7: Tool and TCP 102/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Parameter Description Activation Activation of the safety-oriented tool Check box active: Safety-oriented tool is activated. Check box not active: Safety-oriented tool is not activated. Default tool 1: Activated Default tool 2 … 16: Not activated Note: If discrete safety interface XG13 or none of the safety interfaces specified in the product description is used, tool 1 is always active. The tool cannot be activated via a safety-oriented input. An automated, safely monitored tool change is thus not possible. (>>> 2.3 "Safety interfaces" Page 15) TCP X, Y, Z X, Y and Z coordinates of the safety-oriented TCP for velocity monitoring • -10 000 mm … +10 000 mm Default: 0 mm KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 103/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Properties Fig. 7-8: Tool properties The following buttons are available: Button Description Plus key Adds a tool sphere and displays its parameters. Delete key Deletes the selected tool sphere. Parameter Description Monitoring Check box active: Sphere is monitored. Check box not active: Sphere is not monitored. X, Y, Z X, Y and Z coordinates of the sphere center point relative to the FLANGE coordinate system • -10,000 mm … +10,000 mm Default: 0 mm 104/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Parameter Description Radius Radius of the sphere on the safety-oriented tool • 0 … 10,000 mm Default: 250 mm The sphere radius must not fall below the predefined minimum value. This radius is dependent on the global maximum Cartesian velocity. (>>> "Minimum sphere radius" Page 93) 7.5.4 Configuring a cell area Precondition • • • • User group “Safety maintenance” or higher T1 or T2 mode Safety configuration is open. Safe monitoring is active. Procedure 1. Select the Monitoring spaces tab and press Cell configuration. The Cell configuration window opens. 2. Enter the upper and lower bounds of the cell area. 3. Select a corner from the list. The parameters of the corner are displayed. 4. Activate the corner of the cell area if necessary. Set the check mark for the corner to do so. Corners 1 to 4 are activated as standard. 5. Move the robot to one corner of the cell area. 6. Press Touch-up. The X and Y coordinates of the corner are saved. The taught point refers to $WORLD and the tool $TOOL that is being used. 7. Repeat steps 3 to 6 to define further corners. There must be at least 3 corners activated. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 105/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Parameters Fig. 7-9: Cell area configuration Parameter Description Reference system Reference coordinate system • $WORLD Z min Lower limit of the cell area • -100,000 mm … +100,000 mm Default: -30,000 mm Z max Upper limit of the cell area • -100,000 mm … +100,000 mm Default: 30,000 mm 106/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Parameter Description Activated Check box active: Corner of cell area is activated. (corner) Check box not active: Corner of cell area is not activated. Default corner 1 to 4: Activated Default corner 5 to 10: Not activated X, Y (corner) X, Y coordinate of corner 1 to 10 relative to the WORLD coordinate system • -100,000 mm … +100,000 mm Default corner 1 or 4: +100,000 mm Default corner 2 or 3: -100,000 mm Default corner 5 to 10: 0 mm 7.5.5 Configuring a Cartesian monitoring space Precondition • • • • User group “Safety maintenance” or higher T1 or T2 mode Safety configuration is open. Safe monitoring is active. Procedure 1. Select the Monitoring spaces tab and select the monitoring space from the list. The parameters of the monitoring space are displayed. 2. Enter the name of the monitoring space (max. 24 characters). 3. Select the space type Cartesian space and set the parameters of the monitoring space. 4. Press Properties. The Cartesian properties of {0} window is opened. 5. Select the reference coordinate system and enter Cartesian positions. Parameters Fig. 7-10: Cartesian space KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 107/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Parameter Description Type Type of monitoring space Workspace = The safety-oriented tool must move within the configured limits of the monitoring space. (Space violation if the safety-oriented tool leaves the monitoring space.) Protected space = The safety-oriented tool must move outside the configured limits of the monitoring space. (Space violation if the safetyoriented tool enters the monitoring space.) Default: Workspace Activation Activating the monitoring space always off = monitoring space is not active. always active = monitoring space is always active. by input = monitoring space is activated by a safety-oriented input. Note: If safety interface XG13 is used, safetyoriented inputs are only available for monitoring spaces 12 … 16. (>>> 8.2 "KUKA.SafeOperation via interface XG13" Page 205) Note: If none of the safety interfaces specified in the product description is used, the monitoring spaces cannot be activated via an input (only static spaces possible). (>>> 2.3 "Safety interfaces" Page 15) Default: always off Space type Type of monitoring space Cartesian space = Cartesian monitoring space Axis space = axis-specific monitoring space Default: Cartesian space Stop at boundaries A stop is triggered if the space is violated. Check box active: Robot stops if the monitoring space limits are exceeded. Check box not active: Robot does not stop if the monitoring space limits are exceeded. Default: Robot stops at boundaries. V max Limit value of the space-specific velocity • 0.5 … 30 000 mm/s Default: 30 000 mm/s 108/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Parameter Description Vmax valid if Validity of the space-specific velocity not used = space-specific velocity is not monitored. Space not violated = space-specific velocity is monitored if the monitoring space is not violated. Space violated = space-specific velocity is monitored if the monitoring space is violated. Default: not used Stop if mastering test not yet done Activating reference stop Check box active: Reference stop is activated for the monitoring space. Check box not active: Reference stop is not activated for the monitoring space. Default: Reference stop activated. Properties Fig. 7-11: Cartesian properties KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 109/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Parameter Description Reference system Reference coordinate system • $WORLD • $ROBROOT Default: $WORLD Space dimensions Length, width and height of the monitoring space (display only) The length, width and height of a protected space must not fall below the predefined minimum value. This value depends on the global maximum Cartesian velocity and the radius of the smallest sphere of the safety-oriented tool. (>>> "Minimum protected space dimensions" Page 93) Origin X, Y, Z Offset of the origin of the Cartesian monitoring space in X, Y and Z relative to the selected reference coordinate system. • -100,000 mm … +100,000 mm Default: 0 mm Origin A, B, C Orientation in A, B and C at the origin of the Cartesian monitoring space relative to the selected reference coordinate system. Origin A, C: • -180° … +180° Origin B: • -90° … +90° Default: 0° Distance to origin XMin, YMin, ZMin Minimum X, Y and Z coordinates of the Cartesian monitoring space relative to the origin • -100,000 mm … +100,000 mm Default: 0 mm Distance to origin XMax, YMax, ZMax Maximum X, Y and Z coordinates of the Cartesian monitoring space relative to the origin • -100,000 mm … +100,000 mm Default: 0 mm Example The example shows a Cartesian monitoring space whose origin is offset in the X, Y and Z directions (yellow arrow) relative to the $ROBROOT system. The orientation A, B, C at the origin of the Cartesian monitoring space is identical to the orientation at the origin of $ROBROOT. 110/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Start-up and configuration KUKA.SafeOperation 3.6 Fig. 7-12: Example of a Cartesian monitoring space 7.5.6 Configuring an axis-specific monitoring space Precondition • • • • User group “Safety maintenance” or higher T1 or T2 mode Safety configuration is open. Safe monitoring is active. Procedure 1. Select the Monitoring spaces tab and select the monitoring space from the list. The parameters of the monitoring space are displayed. 2. Enter the name of the monitoring space (max. 24 characters). 3. Select the space type Axis space and set the parameters of the monitoring space. 4. Press Properties. The Axis-specific properties of {0} window opens. 5. Select axis from the list. The axis-specific properties are displayed. 6. Activate the monitoring of axis limits by setting the check mark at Monitoring. 7. Move the axis to the upper axis limit in axis-specific mode. 8. Press Touch-up to save the current axis position. 9. Move the axis to the lower axis limit in axis-specific mode. 10. Press Touch-up to save the current axis position. 11. Repeat steps 5 to 10 to define the axis limits for additional axis ranges. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 111/304 Start-up and configuration KUKA.SafeOperation 3.6 A maximum of 8 axes or, in the case of kinematic systems with master/ slave axes, a maximum of 8 drives can be configured for each monitoring space. Parameters Fig. 7-13: Axis space Parameter Description Type Type of monitoring space Workspace = The axes must move within the configured limits of the monitoring space. (Space violation if the axes leave the monitoring space.) Protected space = The axes must move outside the configured limits of the monitoring space. (Space violation if the axes enter the monitoring space.) Default: Workspace Activation Activating the monitoring space inactive = monitoring space is not active. always active = monitoring space is always active. by input = monitoring space is activated by a safety-oriented input. Note: If safety interface XG13 is used, safetyoriented inputs are only available for monitoring spaces 12 … 16. (>>> 8.2 "KUKA.SafeOperation via interface XG13" Page 205) Note: If none of the safety interfaces specified in the product description is used, the monitoring spaces cannot be activated via an input (only static spaces possible). (>>> 2.3 "Safety interfaces" Page 15) Default: always off Space type Type of monitoring space Cartesian space = Cartesian monitoring space Axis space = axis-specific monitoring space Default: Cartesian space 112/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Parameter Description Stop at boundaries A stop is triggered if the space is violated. Check box active: Robot stops if the monitoring space limits are exceeded. Check box not active: Robot does not stop if the monitoring space limits are exceeded. Default: Robot stops at boundaries. V max Limit value of the space-specific velocity • 0.5 … 30 000 mm/s Default: 30 000 mm/s Vmax valid if Validity of the space-specific velocity not used = space-specific velocity is not monitored. Space not violated = space-specific velocity is monitored if the monitoring space is not violated. Space violated = space-specific velocity is monitored if the monitoring space is violated. Default: not used Stop if mastering test not yet done Activating reference stop Check box active: Reference stop is activated for the monitoring space. Check box not active: Reference stop is not activated for the monitoring space. Default: Reference stop activated. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 113/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Properties Fig. 7-14: Axis-specific properties Parameter Description Monitoring Activation of monitoring Check box active: Monitoring is activated. Check box not active: Monitoring is not activated. Default: Monitoring is not activated. Lower limit Lower limit of the axis-specific monitoring space (lower axis limit) • Rotational axes: -360° … +360° Default: -360° • Linear axes: -30,000 mm … +30,000 mm Default: -30,000 mm The lower limit of an axis-specific workspace must be at least 0.5° or 1.5 mm less than the upper limit. (>>> "Minimum size of a protected space" Page 115) 114/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Parameter Description Current position Axis-specific actual position (display only) • Red: axis position not allowed, as monitoring space is violated • Green: axis position allowed Upper limit Upper limit of the axis-specific monitoring space (upper axis limit) • Rotational axes: -360° … +360° Default: 360° • Linear axes: -30,000 mm … +30,000 mm Default: 30,000 mm The upper limit of an axis-specific workspace must be at least 0.5° or 1.5 mm greater than the lower limit. (>>> "Minimum size of a protected space" Page 115) Minimum size of a protected space An axis-specific protected space must not fall below the predefined minimum size. This is dependent on the maximum axis velocity. The minimum size for the axis-specific protected space is equal to the distance that the relevant axis can travel at maximum axis velocity in an interval of 18 ms. If the minimum size of the configured axis limits is not reached, a message is displayed when saving and the configuration is prevented from being saved. Icons Icon Description Icon for rotational and infinitely rotating axes Icon for linear axes Icon for simulated axes Icon for decouplable axes 7.5.7 Configuring axis-specific velocity monitoring functions and braking time Description The axis velocity can be monitored against various different limit values: • Limit value for the reduced axis velocity (activated by means of the safety-oriented input VRED) If none of the safety interfaces specified in the product description is used, this monitoring function is dispensed with, as the input VRED is not available. (>>> 2.3 "Safety interfaces" Page 15) • Limit value for maximum axis velocity in T1 • Limit value for maximum axis velocity (valid globally for every axis) Furthermore, the braking ramp of an axis can be changed using the braking time parameter. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 115/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Monitoring of the braking ramp and the maximum axis velocity in T1 is part of the standard safety configuration and always active. The parameters can also be modified if safe monitoring is deactivated. Precondition • • • • User group “Safety maintenance” or higher T1 or T2 mode Safety configuration is open. To modify option-specific monitoring functions: Safe monitoring is active. Procedure 1. Select the Axis monitoring tab. 2. Edit the parameters of the standard safety configuration as required. 3. If necessary, activate monitoring of the safely reduced axis velocity for one axis. To do so, select the desired axis and set the check mark at Monitoring. 4. Change the limit value for the safely reduced axis velocity if necessary. 5. Modify the maximum velocity for rotational axes and linear axes (valid globally for every axis). 116/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Start-up and configuration KUKA.SafeOperation 3.6 Parameters Fig. 7-15: Axis monitoring Parameter Description Monitoring Activation of monitoring Check box active: axis is monitored. Check box not active: axis is not monitored. Default: axis is not monitored. Braking time Duration of the axis-specific braking ramp monitoring for safety stop 1 and safety stop 2 • 500 … 15,000 ms Default: 1,500 ms (>>> 7.5.7.1 "Parameter: Braking time" Page 119) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 117/304 Start-up and configuration KUKA.SafeOperation 3.6 Parameter Description Maximum velocity T1 Maximum axis velocity in T1 • Rotational axes: 1.0 … 100.00°/s Default: 30°/s • Linear axes: 1.0 … 1,500 mm/s Default: 250 mm/s This parameter enables a servo gun, for example, to be calibrated in T1 with a higher velocity than 250 mm/s. Note: The Cartesian velocities at the flange and at the TCP are monitored independently of this parameter and cannot exceed 250 mm/s. (>>> 7.5.7.2 "Parameter: Maximum velocity T1" Page 121) Reduced velocity Limit value for safely reduced axis velocity • Rotational axes: 0.5 … 5,000 °/s Default: 5,000°/s • Linear axes: 1.5 … 10,000 mm/s Default: 10,000 mm/s Maximum velocity rotational axis Limit value for global maximum velocity for rotational axes • 0.5 … 5,000 °/s Default: 1,000°/s The axis-specific protected space is dependent on the global maximum axis velocity. A defined minimum size for the axisspecific protected space is derived from the global maximum axis velocity; the size must not fall below this value. If this minimum value is violated, a message is displayed. Maximum velocity translational axis Limit value for global maximum velocity for translational axes • 0.5 … 30,000 mm/s Default: 5,000 mm/s The axis-specific protected space is dependent on the global maximum axis velocity. A defined minimum size for the axisspecific protected space is derived from the global maximum axis velocity; the size must not fall below this value. If this minimum value is violated, a message is displayed. Icons Icon Description Icon for rotational and infinitely rotating axes Icon for linear axes Icon for simulated axes Icon for decouplable axes 118/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 7.5.7.1 Parameter: Braking time Description If a safety stop 1 or 2 occurs, the safety controller monitors the braking process. Among other things, it monitors whether the axis-specific velocity remains below its monitoring ramp. If the velocity is too high, i.e. if the ramp is violated, then the safety controller triggers a safety stop 0. The ramp monitored in T1 mode cannot be changed and applies for the braking process from the configured maximum T1 velocity of the respective axis down to standstill. The monitoring ramp valid in the other operating modes can be adapted using the Braking time parameter. The parameter Braking time modifies the monitoring ramp. It does not modify the actual time required by the kinematic system for braking. The safety controller also monitors the braking ramp for axes which are configured as couplable or grouped together in coupling groups. To be able to alter the configured braking time for this monitoring function, the coupling must be temporarily canceled. The coupling of the axes can be canceled and set again in WorkVisual. Information about this can be found in the WorkVisual documentation. WARNING Only increase the default time if it is necessary to do so. This might be required, for example, in the case of very heavy machines and/or very heavy loads, as these cannot stop within the default time. The safety maintenance technician must check whether and to what extent the Braking time value needs to be modified in each specific application. He must also check whether the modification makes additional safety measures necessary, e.g. installation of a gate lock. The monitoring ramp (for all modes apart from T1) is determined as follows: • The ramp starts at 106% of the rated speed of the axis. This value remains constant for the first 300 ms. • Similarly, a constant value of 10.6% of the rated speed of the axis applies for the last 300 ms of the configured braking time. • Over the intervening time, the permissible velocity is reduced linearly from 106% to 10.6% of the rated speed of the axis. • Allowance for the brake closing time for safety stop 1: 200 ms before the configured braking time elapses, the brake is commanded to close (SBC) and the drives enable signal (AF) is canceled. • In the event of a safety stop 2, the standstill monitoring is activated after completion of the braking process, but no later than after the configured braking time. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 119/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Fig. 7-16: Monitoring ramp for safety stop 1 1 Velocity profile during braking (example) 2 Monitoring ramp for braking time TBT 3 Brake closing time TBCT is taken into account within the monitoring ramp n Percentage of the rated speed of the axis t (s) Time (in seconds) T0 The moment when safety stop 1 or 2 is initiated TBT Braking time Default value of Braking time parameter: 1.5 s TBCT Brake closing time: 0.2 s Signals: FF Motion enable AF Drives enable SBC Safe Brake Control STO Safe Torque Off Limitations Braking time can be configured separately for each axis. At the moment of braking, however, the value used for all axes is always the highest value entered. Recommendation: for greater transparency, enter the same value for all axes. 120/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Value increased If the value Braking time is increased, this has the following consequences: The monitoring ramp becomes longer and flatter, i.e. monitoring is now less strict. It is now less likely that the braking process will violate the ramp. Fig. 7-17: Example: Value is increased 1 Velocity profile during braking (example) 2 Monitoring (lower Braking time value) 3 Monitoring (higher Braking time value) Value reduced If the value “Braking time” is reduced, this has the following effect: The monitoring ramp becomes shorter and steeper, i.e. monitoring is now stricter. There is now a higher probability that a braking process will violate the ramp. 7.5.7.2 Parameter: Maximum velocity T1 Description The safety controller monitors whether the maximum velocity in T1 remains below the configured values even for axes which are configured as couplable or grouped together in coupling groups. To be able to alter the configured values for these axes, the coupling must be temporarily canceled. The coupling of the axes can be canceled and set again in WorkVisual. Information about this can be found in the WorkVisual documentation. WARNING Only alter the default value of Maximum velocity T1 if it is necessary to do so. This can be the case, for example, when positioning welding guns if these are to be moved at process velocity in T1 mode. The safety maintenance technician must check whether and to what extent the value needs to be modified in each specific application. He must also check whether the modification makes additional safety measures necessary, e.g. installation of a gate lock. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 121/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 WARNING Following modifications to the Maximum velocity T1 parameter, the new value must be checked. The new value must also be checked if it is smaller than the previous value. (>>> 7.11.7 "Checking axis-specific velocity limits" Page 184) 7.5.8 Configuring safe operational stop for axis groups Description Safe operational stop can be configured for up to 6 axis groups (situations). A maximum of 8 axes or, in the case of kinematic systems with master/slave axes, a maximum of 8 drives can be configured for each axis group. The safe operational stop for axis groups is activated via safety-oriented inputs. If none of the safety interfaces specified in the product description is used, the safe operational stop for axis groups is not available. (>>> 2.3 "Safety interfaces" Page 15) Forces acting on the robot in the production process may result in a violation of the safe operational stop, e.g. when loading a workpiece into a gripper. To remedy this, the position tolerance for the affected axis must be increased. Preparation The safety controller monitors whether the position tolerance is observed in the event of a safe operational stop even for axes which are configured as couplable or grouped together in coupling groups. • To be able to alter the configured values for these axes, the coupling must be temporarily canceled. The coupling of the axes can be canceled and set again in WorkVisual. Information about this can be found in the WorkVisual documentation. Precondition • • • • User group “Safety maintenance” or higher T1 or T2 mode Safety configuration is open. Safe monitoring is active. Procedure 1. Select the Axis monitoring tab and press Safe operational stop. The Safe operational stop window opens. 2. Select axis from the list. 3. Enter the position tolerance for this axis. The position tolerance configured here also applies to the global safe operational stop, with which all axes are monitored. The global safe operational stop is one of the standard safety functions. The position tolerances can also be modified if safe monitoring is deactivated. 4. Activate one or more axis groups in which the axis is to be monitored by activating the corresponding check box (set the check mark). 122/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 5. Repeat steps 2 to 4 to define further monitoring functions. Parameters Fig. 7-18: Safe operational stop Parameter Description Monitoring in axis groups 1-6 Safe operational stop for axis group 1 … 6 Check box active: Axis is monitored in axis group. Check box not active: Axis is not monitored in axis group. Default: No monitoring Position tolerance Tolerance for standstill monitoring in the case of safe operational stop. The axis may still move within this tolerance when a safe operational stop is active. • Rotational axes: 0.001° … 1° Default: 0.01° • Linear axes: 0.003 - 3 mm Default: 0.1 mm KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 123/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Icons Icon Description Icon for rotational and infinitely rotating axes Icon for linear axes Icon for simulated axes Icon for decouplable axes 7.5.9 Activating “Braking before restricted areas” Description The “Braking before restricted areas” function changes the way the robot behaves at the limits of the monitoring spaces and of the cell area. With the “Braking before restricted areas” function, the fictitious STOP 1 DRS end position based on the actual position is monitored in addition to the actual position. If this end point violates a monitoring space, this indicates an impending violation of this monitoring space by the robot. In this case, a safety stop 1 DRS is triggered, bringing the robot to a standstill at the precalculated end point. Due to the small safety margin in the precalculation, the robot can generally be stopped before the monitoring space. A safety stop 1 DRS is a safely monitored drive ramp stop. This usually deviates from the programmed path. If the safety controller detects a violation of the monitored braking ramp, a safety stop 0 is triggered. As the stopping distance of the robot deviates significantly from the stopping distance of the drive ramp stop in this instance, this case must be taken into consideration in the risk assessment of the cell. Possible reasons for an escalation of this nature are, for example: • Power failure • Controller fault • Operation outside of the specification limits • Hardware fault at the time the drive ramp stop is executed Example The figures show the behavior of the robot at the limits of a Cartesian and axis-specific monitoring space when “Braking before restricted areas” is activated. Fig. 7-19: Braking before Cartesian space limit 124/304 | www.kuka.com 1 Anticipated stop position of current position 2 Anticipated stop position of current position with safety margin KST SafeOperation 3.6 V3 | Issued: 10.10.2022 3 Actual stop with end point before monitoring space Fig. 7-20: Braking before axis-specific space limit 1 Anticipated stop position of current position 2 Anticipated stop position of current position with safety margin 3 Actual stop with end point before monitoring space Precondition • • • • • User group “Safety maintenance” or higher T1 or T2 mode Safety configuration is open. Safe monitoring is active. The braking ramps of the axes have been verified by KUKA or by the user / safety maintenance technician. • If the braking ramps have been verified by the user / safety maintenance technician: The function has been enabled in the machine data of the kinematic system in WorkVisual. WARNING Whether a KUKA kinematic system supports BBRA is stored in the machine data. If this is the case, the set braking ramps of this kinematic system have been checked by KUKA and verified as suitable for BBRA. • For kinematic systems with a variable mounting position, the verification applies exclusively to the “Floor” mounting position. The braking ramps must be verified separately for the use of BBRA in other mounting positions. • For kinematic systems with a fixed mounting position, the verification applies exclusively to the defined mounting position. The verification refers to motions of the kinematic system without the influence of a ROBROOT kinematic system, e.g. a linear axis. If the robot is expanded with a ROBROOT kinematic system, the values are only valid if no simultaneous motions (robot kinematic system plus ROBROOT kinematic system) are executed. Simultaneous motions may cause the BBRA braking ramp monitoring to be violated. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 125/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Before KUKA kinematic systems are used with BBRA in normal operation, they should be verified by KUKA. KUKA cannot verify the braking ramps of third-party kinematic systems, e.g. linear axes. In order to enable these for BBRA nevertheless, the user/safety maintenance technician can mark such a kinematic system as verified in the machine data. For verification purposes, it is necessary to check whether the axis is able to execute the ramp indicated in the safety configuration in all anticipated situations. This can also include superposed motions of KUKA kinematic systems and third-party kinematic systems, for example. (>>> 7.11.9 "Checking the values for the maximum braking ramp" Page 187) Further information about editing the machine data of a kinematic system is contained in the WorkVisual documentation. Procedure 1. Select the Braking before restricted areas tab. 2. Set the check mark next to the Activate braking before restricted areas check box. 126/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Start-up and configuration KUKA.SafeOperation 3.6 Parameters Fig. 7-21: Braking before restricted areas Parameter Description Drive ramp stop group Synchronously braking axes belong to a drive ramp stop group (display only) Braking ramp of drive unit Maximum possible braking ramp for an axis (display only) Activate braking before restricted areas Activating the “Braking before restricted areas” function Check box active: Function is activated. Check box not active: Function is not activated. Default: Function is not activated. Icons Icon Description Icon for rotational and infinitely rotating axes Icon for linear axes Icon for simulated axes KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 127/304 Start-up and configuration KUKA.SafeOperation 3.6 Icon Description Icon for decouplable axes 7.5.10 Configuring the reference position and reference group Precondition • • • • • User group “Safety maintenance” or higher T1 or T2 mode Safety configuration is open. Safe monitoring is active. Mastering type Reference switch is configured. Procedure 1. Select the tool and base for Cartesian jogging. 2. Select the Reference position tab. 3. If external axes are configured, enter for each external axis the number of the reference group to which it is to be assigned. 4. Move all axes of reference group 1 to the corresponding reference position. 5. On the tab, select one of the axes of reference group 1. 6. Press Touch-up reference position for group to accept the reference position for the axes in reference group 1. The coordinates of the Cartesian reference position are displayed in the configuration window. 7. If present, move external axes in reference group 2 to the corresponding reference position and save with Touch-up reference position for group. 8. If present, move external axes in reference group 3 to the corresponding reference position and save with Touch-up reference position for group. 128/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Start-up and configuration KUKA.SafeOperation 3.6 Parameters Fig. 7-22: Reference position KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 129/304 Start-up and configuration KUKA.SafeOperation 3.6 Parameter Description Reference group Each axis that is to be subjected to safe monitoring must be assigned to a reference group. There are 3 reference groups: • Reference group 1 Robot axes and external axes on which a robot is installed are always assigned to reference group 1. Such external axes include KLs, for example, that serve as a carrier kinematic system for the robot. • Reference group 2, 3 Only external axes can be assigned to reference groups 2 and 3. There must be no robot installed on them. Default: 1 Reference position Axis-specific coordinates of the reference position To monitor the mastering, the axis angles of the robot axes are defined for a specific Cartesian reference position. During the mastering test, the robot moves to the Cartesian reference position and the actual position of the axes is compared with the setpoint position. • Rotational axes: -360° … +360° Default: 45° • Linear axes: -30,000 mm … +30,000 mm Default: 1,000 mm Current position Axis-specific actual position (display only) • Red: reference position not allowed, as too near mastering position • Green: reference position allowed Mastering position The axis angles at the mastering position are defined in the machine data (display only). Cartesian reference position X, Y, Z X, Y and Z coordinates of the Cartesian reference position relative to the WORLD coordinate system (display for reference group 1) The coordinates of the Cartesian reference position refer to the center point of the mounting flange. • -30,000 mm … +30,000 mm Default: 0 mm Icons Icon Description Icon for rotational and infinitely rotating axes Icon for linear axes Icon for simulated axes Icon for decouplable axes 130/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 7.5.11 Saving the safety configuration WARNING Serious injury and severe damage to the robot can be caused by an error during saving or a failed reinitialization. If an error message is displayed after saving, the safety configuration must be checked and saved again. Precondition • User group “Safety maintenance” or higher • Safety configuration is open. • Safety configuration is completed. Procedure 1. Click on Save and answer the request for confirmation with Yes. The safety configuration is saved on the hard drive and the activation code of the safety configuration is saved to the RDC. The robot controller is automatically reinitialized. 2. The activation code of the safety configuration is displayed on the Common tab. Note the activation code in the checklist for safety functions. (>>> 11.1.3 "Checklist: Safety functions" Page 270) 7.6 Editing the local safety configuration in WorkVisual Description Instead of using the smartHMI, the safety configuration can be created and edited entirely in WorkVisual. The tabs in WorkVisual are the same as those on the smartHMI. Precondition • The safety option is installed in WorkVisual. • The project that is to be edited has been loaded and opened. • The safety option has been added to the project. Procedure 1. Set the robot controller as the active controller. 2. Select the menu sequence Editors > Safety configuration (local) or double-click on the Safety controller node in the Hardware view. The Local safety configuration window is opened. 3. Select the Global parameters area on the Common tab and activate the check box for Safe monitoring. 4. Edit the local safety configuration as required. 5. Save and close the local safety configuration. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 131/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 7.7 Mastering test Overview A mastering test checks at a suitable reference position whether the saved reference position of the motor of an axis corresponds to the actual mechanical position of the axis. The procedure used to perform the mastering test can be set in the safety configuration: • Mastering test via KUKA reference switch A reference switch is used for the mastering test. The robot moves to a taught reference position. The reference position is confirmed using the reference switch. • Mastering test via external system and with external mastering confirmation An independent, user-specific referencing system such as a tracker, navigation system or absolute encoder is used for external mastering confirmation. The robot moves to a reference position saved in the higher-level controller. The mastering test must be confirmed via a safe input signal of the robot controller. Safety risk due to mastering test that has not been performed/ confirmed The safety integrity of safety functions based on safe axis positions is limited if the mastering test is missing. The safety functions may behave differently from how they were configured, creating additional hazards in the system. • It is advisable to perform the mastering test as quickly as possible once this is requested by the robot controller. • The system integrator must determine, by means of a risk assessment, whether additional system-specific safety measures must be taken if the mastering test is missing, e.g. a reference stop. Request The following events cause a mastering test to be requested: • • • • Robot controller is rebooted (internal request) Robot is remastered (internal request) I/O driver is reconfigured (internal request) Only relevant for mastering test via reference switch: Input $MASTERINGTEST_REQ_EXT is set externally, e.g. by a PLC (external request) Monitoring time The robot controller generates the following message for an internal mastering test request: Mastering test required (internal). The robot can be moved for another 2 hours (monitoring time) without a mastering test and mastering confirmation. Once the monitoring time has elapsed, the robot stops with a safety stop 1 and the robot controller displays the following acknowledgement message: Ackn.: Mastering test time interval expired. Once the message has been acknowledged, the robot can be moved for another 2 hours. 132/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 7.7.1 Mastering test via reference switch Description In the mastering test, a specific reference position is addressed, and the reference switch is used to check whether the actual position of the robot and specific external axes correspond to the reference position taught in the safety configuration. Infinitely rotating axes are taken into consideration in the mastering test with modulo 360°, i.e. the reference position is always relative to the circle. If the deviation between the current position and the reference position is too great, the mastering test has failed. The robot stops with a safety stop 1 and can only be moved in T1 mode. Axes checked During a mastering test, the following axes are checked: • Robot and external axes that influence the Cartesian position of the robot flange • External axes which are monitored in axis-specific monitoring spaces NOTICE Damage to property due to incorrect mastering of non-referenced external axes The incorrect mastering of external axes which are not checked by the mastering test can result in damage to property. • Correct mastering of the external axes which have not been checked must be ensured by means other than the mastering test. Reference group Each axis that is to be subjected to safe monitoring must be assigned to a reference group. There are 3 reference groups: • Reference group 1 Robot axes and external axes on which a robot is installed are always assigned to reference group 1. Such external axes include KLs, for example, that serve as a carrier kinematic system for the robot. • Reference group 2, 3 Only external axes can be assigned to reference groups 2 and 3. There must be no robot installed on them. All axes of a reference group are mastered together. During the mastering test, all axes of a reference group must be in the reference position in order to actuate the reference switch. If not all the axes of a reference group are involved in actuating the reference switch, the position of the axes cannot be checked. Execution The mastering test is carried out using the program “masref_main.src”. It can be started in the following ways: KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 133/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 • Automatic Integrate “masref_main.src” into the application program in such a way that it is cyclically called as a subprogram. If a mastering test is requested, the robot detects this and starts the mastering test. • Manual For this, start the program “masref_main.src” manually. Ensure 2-channel referencing with external activation of the reference switch If the reference switch is activated via the bus interface, 1-channel referencing must be prevented. • The safety PLC may only set the Mastering test signal to LOW if both input channels have a low level. Overview Step 1 Description Select reference position. (>>> 7.7.1.2 "Selecting a reference position" Page 135) 2 Install reference switch and actuating plate. (>>> 7.7.1.3 "Installing the reference switch and actuating plate" Page 137) 3 Connect reference switch. (>>> 7.7.1.4 "Connecting the reference switch" Page 138) 4 Configure the input signal $MASTERINGTEST_REQ_EXT for the external mastering test request. This signal is declared in the file $machine.dat in the directory KRC:\ROBOTER\KRC\STEU\MADA and must be assigned to a suitable input. As standard, the signal is routed to $IN[1026]. 5 In the file “masref_user.dat” and in the safety configuration, configure the reference groups to be checked. (>>> 7.7.1.5 "Configuring the reference groups to be checked in file" Page 139) (>>> 7.5.10 "Configuring the reference position and reference group" Page 128) 6 Teach positions for the mastering test in the program “masref_user.src”. The reference position must be taught in the program “masref_user.src” and in the safety configuration. (>>> 7.7.1.6 "Teaching positions for the mastering test" Page 140) (>>> 7.5.10 "Configuring the reference position and reference group" Page 128) 7 Only if the reference switch is actuated by a ferromagnetic part of the tool or following a tool change or replacement: Check the correctness of the reference position. (>>> 7.7.1.7 "Checking the reference position (actuation with tool)" Page 142) 134/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Step 8 Description If the mastering test is to be executed automatically: Integrate “masref_main.src” into the application program in such a way that it is cyclically called as a subprogram. 9 If the mastering test is to be executed manually: Start the program “masref_main.src” manually. (>>> 7.7.1.8 "Performing a mastering test manually" Page 143) 7.7.1.1 Programs for the mastering test The following programs are used for the mastering test: Program Directory Description masref_main.src R1\System The program checks whether a mastering test is required and must be executed as soon as possible 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. The program calls the program “masref_user.src” that is used to address the reference position. masref_user.src R1\Program The program contains 3 subprograms for moving to reference positions 1 to 3 and 3 subprograms for the motion away from reference positions 1 to 3 after the mastering test has been performed. If the motion away from the reference position is not taught, the robot and external axes remain stationary after the mastering test. The robot controller generates an error message. 7.7.1.2 Selecting a reference position Description The reference position can be approached with the actuating plate or with a ferromagnetic part of the tool as follows: KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 135/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Fig. 7-23: Example position of reference switch actuating plate 1 Tool 2 Actuating plate 3 Reference switch 4 Mechanical mounting fixture for the reference switch 5 Actuated reference switch Selection criteria The reference run must be selected in accordance with the following criteria: • The position of the reference switch and actuating plate does not interfere with the work sequence of the robot. • The reference position is not a position in which the axes are in a singularity. • In the reference position, both proximity switch surfaces of the reference switch are actuated by the switching surface (actuating plate or tool). • In the case of actuation with a tool, it must be ensured that the actuation is only carried out at the intended reference position. For this, the reference position must be checked using the procedure described here: (>>> 7.7.1.7 "Checking the reference position (actuation with tool)" Page 142) ‒ Reason: In the event of a false positive mastering test, it is possible to exceed the configured safety-oriented space limits. ‒ The risk of a false positive mastering test is particularly high if the reference switch is actuated by a large ferromagnetic part of a tool. 136/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 • The reference switch must not be actuated continuously outside the context of the mastering test. The reference switch signal is monitored continuously. If the reference switch is actuated for longer than 5 minutes, a fault message is generated. • All axes of a reference group are in the reference position in order to actuate the reference switch. • In the reference position, the robot axes are at least ±5° (rotational axes) or ±15 mm (linear axes) away from the mastering position. • The position of the reference switch is within the motion range of the robot. 7.7.1.3 Installing the reference switch and actuating plate Precondition • The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. • The reference run has been selected in accordance with the required criteria. (>>> "Selection criteria" Page 136) Procedure 1. Prepare a mechanical mounting fixture for mounting the reference switch. 2. Attach the reference switch to the mounting fixture. 3. If the actuating plate is being used, fasten the actuating plate to the robot flange or tool. NOTICE To ensure that the reference position remains stable, the reference switch and actuating plate must be securely installed. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 137/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Example Fig. 7-24: Example of an actuating plate on the tool 1 Robot 2 Actuating plate on tool 3 Tool 4 Reference switch on mounting fixture 7.7.1.4 Connecting the reference switch WARNING Danger to life and limb due to incorrectly assigned cables The robot controller is preconfigured for the specific industrial robot. The manipulator and other components can receive incorrect data if they are connected to a different robot controller. Death, severe injuries or damage to property may result. • Only connect the manipulator to the corresponding robot controller. Only 1 reference switch can be connected directly to the robot controller. If multiple reference groups are required, the reference switches can be connected to the safety PLC and activated via the bus interface that is in use. The safety PLC must evaluate the reference switches and set the Mastering test input accordingly. Ensure 2-channel referencing with external activation of the reference switch If the reference switch is activated via the bus interface, 1-channel referencing must be prevented. • The safety PLC may only set the Mastering test signal to LOW if both input channels have a low level. 138/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Description The reference switch is connected to the robot controller with the reference cable XG42 - XS Ref. • XG42: Interface to robot controller • XS Ref: Interface to reference switch Bending radius The following bending radii must be observed when installing the reference cable: • Fixed installation: At least 5 x cable diameter • Cable carrier installation: At least 10 x cable diameter Precondition • The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. • The power cable is de-energized. • Observe the ESD guidelines. • Reference switch is installed. Procedure 1. Route the reference cable correctly. 2. Connect the reference cable. 7.7.1.5 Configuring the reference groups to be checked in file Description The reference groups to be checked must be configured in the file “masref_user.dat”. For this, the reference groups to be checked are entered in an array. The order in which the reference groups are entered determines the order in which they are subsequently called in the mastering test. Configuration file Directory C:\KRC\R1\Program File masref_user.dat Fold reference groups Array MASREFg_GroupSequence[3] Precondition • User group Expert Procedure 1. Open the file in the navigator. 2. Enter the numbers of the reference groups to be checked in the array. (0 means that no reference group will be checked here.) 3. Save and close the file. Example Reference groups 1 and 2 are called and checked in sequence during the mastering test. Reference group 3 is not required: KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 139/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 reference groups ... DECL GLOBAL CONST INT MASREFg_GroupSequence[3] ; contains reference groups to test MASREFg_GroupSequence[1]=1 MASREFg_GroupSequence[2]=2 MASREFg_GroupSequence[3]=0 The order in which the reference groups are called is irrelevant for the mastering test. It is equally permissible to call and check reference group 2 first and then reference group 1. reference groups ... DECL GLOBAL CONST INT MASREFg_GroupSequence[3] ; contains reference groups to test MASREFg_GroupSequence[1]=2 MASREFg_GroupSequence[2]=1 MASREFg_GroupSequence[3]=0 7.7.1.6 Teaching positions for the mastering test Description The following points must be taught for each reference group: • Movement to the reference switch • Reference position The reference position must additionally be taught in the safety configuration. • Movement away from the reference switch Precondition • User rights of the following function groups: ‒ ‒ ‒ ‒ ‒ Critical KRL program changes Program selection and deselection Block selection General configuration Jogging with the jog keys Or alternatively: Jogging using the 6D mouse ‒ Teach local points But at least the user group “Safety maintenance” • The reference switch is installed and connected. • T1 or T2 mode Procedure 1. Open the program “masref_user.src”. 2. Insert a HALT statement in the subprograms MASREFSTARTGX() and MASREFBACKGX() of the current reference group. 3. Close the program “masref_user.src”. 4. Set the variable MASREF_GroupNumber to the value of the current reference group, e.g. 1. 140/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 5. 6. 7. 8. 9. • Via the variable display, Module: /R1/masref_main • Or directly in the file R1/System/masref_main.dat in the fold reference groups Select the program “masref_main.src”. Perform block selection to the subprogram RunTest_Group(MASREF_GroupNumber). Press the Start key. The subprogram MASREFSTARTGX() of the program “masref_user.src” is called. In the subprogram MASREFSTARTGX(), program a motion to a point approx. 10 cm before the reference switch and teach the required points. Program a LIN motion to the reference switch so that it is actuated. This position is the reference position. The distance from the reference switch must not exceed 2 mm in the reference position. If the distance is greater, the reference switch will not be actuated. 10. Teach the reference position. 11. Do not move the robot. 12. Teach the reference position in the safety configuration. (>>> 7.5.10 "Configuring the reference position and reference group" Page 128) 13. Return to the subprogram MASREFSTARTGX() and perform a block selection to the END line. 14. Press the Start key. The subprogram MASREFBACKGX() of the program “masref_user.src” is called. 15. In the subprogram MASREFBACKGX(), program the motion away from the reference position and teach the required points. 16. Deselect the program “masref_main.src” and save the changes. 17. For further reference groups (2, 3), repeat the sequence from step 1. 18. For automatic operation, delete all HALT statements from the program “masref_user.src” once again. 19. Cyclically call the program “masref_main.src” at a suitable point and enable execution of the mastering test after an internal request. Program 1 GLOBAL DEF 2 Teach path 3 4 END 5 6 GLOBAL DEF 7 Teach path 8 9 END 10 11 GLOBAL DEF 12 Teach path 13 14 END 15 16 GLOBAL DEF 17 Teach path 18 KST SafeOperation 3.6 V3 | Issued: 10.10.2022 MASREFSTARTG1() and reference position for group 1 MASREFSTARTG2() and reference position for group 2 MASREFSTARTG3() and reference position for group 3 MASREFBACKG1() back for group 1 www.kuka.com | 141/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 19 END 20 21 GLOBAL DEF 22 Teach path 23 24 END 25 26 GLOBAL DEF 27 Teach path 28 29 END 7.7.1.7 MASREFBACKG2() back for group 2 MASREFBACKG3() back for group 3 Line Description 2 Program the motion to the reference position of reference group 1 and teach the reference position. 7 Program the motion to the reference position of reference group 2 and teach the reference position. 12 Program the motion to the reference position of reference group 3 and teach the reference position. 17 Teach the motion away from the reference position of reference group 1. 22 Teach the motion away from the reference position of reference group 2. 27 Teach the motion away from the reference position of reference group 3. Checking the reference position (actuation with tool) WARNING Danger to life and limb due to false positive mastering test In the case of improper actuation with a tool, e.g. if the reference switch is actuated by a large ferromagnetic part of a tool, it is possible that the actuation may occur at a position other than the intended reference position. A false positive mastering test such as this makes it possible to exceed the configured safety-oriented space limits. Death, severe injuries or damage to property may result. • It must be ensured that actuation is only carried out at the intended reference position. The reference position must be checked in the following cases: ‒ For start-up and recommissioning after the reference position has been (re-)taught ‒ For recommissioning following a tool change or replacement If the check with the new tool reveals that actuation no longer occurs at the taught reference position, the following possible solutions are available: ‒ Adapt the reference position to the new tool and reteach it. ‒ Remount the tool in such a way that actuation is carried out at the taught reference position. (>>> "Procedure" Page 143) Precondition • User rights of the following function groups: 142/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 ‒ ‒ ‒ ‒ ‒ • • • • Critical KRL program changes Program selection and deselection Block selection General configuration Jogging with the jog keys Or alternatively: Jogging using the 6D mouse The reference switch is installed and connected. The reference position has been taught in the program “masref_user.src”. The reference position has been taught in the safety configuration. T1 or T2 mode Procedure 1. Open the program “masref_user.src”. 2. In the subprogram MASREFSTARTGX() of the current reference group, insert a HALT statement immediately before the END line. 3. Close the program “masref_user.src”. 4. Set the variable MASREF_GroupNumber to the value of the current reference group, e.g. 1. • Via the variable display, Module: /R1/masref_main • Or directly in the file R1/System/masref_main.dat in the fold reference groups 5. Select the program “masref_main.src”. 6. Perform block selection to the subprogram RunTest_Group(MASREF_GroupNumber). 7. Press the Start key. The subprogram MASREFSTARTGX() of the program “masref_user.src” is called and the robot moves to the reference position. 8. Jog each axis individually in the positive and negative directions using the jog keys and observe when the reference switch is no longer actuated. 9. Analyze the axis-specific tolerances determined in this way for the mastering test relative to the application and select a different reference position if necessary. 10. For further reference groups (2, 3), repeat the sequence from step 1. 11. For automatic operation, delete all HALT statements from the program “masref_user.src” once again. 7.7.1.8 Performing a mastering test manually Precondition • User rights: Function group Program selection and deselection • The reference switch is installed and connected. If the reference switch is connected to the robot controller via interface XG42, the mastering test can be executed in Start-up mode. • The reference groups to be checked have been configured in the file “masref_user.dat”. • The reference groups to be checked have been configured in the safety configuration. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 143/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 • The reference position has been taught in the program “masref_user.src”. • The reference position has been taught in the safety configuration. • T1 or T2 mode WARNING The robot moves in T2 mode at the programmed velocity 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. Procedure • Select the program “masref_main.src” and execute it through to the end of the program. 7.7.2 System variables for mastering test 7.7.2.1 $MASTERINGTEST_ACTIVE Description Activation status of the mastering test The variable specifies whether a mastering test is currently being performed. Writability The system variable is write-protected. Syntax state = $MASTERINGTEST_ACTIVE Explanation of the syntax Element Description state Type: BOOL • TRUE: Mastering test is active. • FALSE: No mastering test is active. 7.7.2.2 $MASTERINGTEST_GROUP Description Number of the reference group in reference position The variable specifies the reference group that is currently in the reference position. Each axis that is to be subjected to safe monitoring must be assigned to a reference group. There are 3 reference groups: • Reference group 1 Robot axes and external axes on which a robot is installed are always assigned to reference group 1. Such external axes include KLs, for example, that serve as a carrier kinematic system for the robot. 144/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 • Reference group 2, 3 Only external axes can be assigned to reference groups 2 and 3. There must be no robot installed on them. All axes of a reference group are mastered together. Writability The system variable is write-protected. Syntax number = $MASTERINGTEST_GROUP Explanation of the syntax Element Description Number Type: INT • 0: No reference group in position • 1 … 3: Reference group with this number in position 7.7.2.3 $MASTERINGTEST_REQ_INT Description Internal request for mastering test The variable specifies whether the internal safety controller has requested the mastering test. The safety controller requests the mastering test after the following events: • The robot controller is rebooted. • The robot is remastered. • I/O driver is reconfigured. Writability The system variable is write-protected. Syntax state = $MASTERINGTEST_REQ_INT Explanation of the syntax Element Description state Type: BOOL • TRUE: Mastering test is requested. • FALSE: Mastering test is not requested. 7.7.2.4 $MASTERINGTEST_REQ_EXT Description External request for mastering test The variable specifies whether the mastering test has been requested externally, e.g. by a safety PLC. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 145/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 The input signal for the external request is declared in the file …\STEU \MADA\$machine.dat in the corresponding directory and must be assigned to a suitable input. As standard, the signal is routed to $IN[1026]. Writability The system variable is write-protected. Syntax state = $MASTERINGTEST_REQ_EXT $IN[number] Explanation of the syntax Element Description state Type: BOOL • TRUE: Mastering test is requested. • FALSE: Mastering test is not requested. Number Type: INT Number of the input $IN that is declared in the file $machine.dat for the external request Default: 1026 7.7.2.5 $MASTERINGTEST_SWITCH_OK Description Check of the function of the reference switch The variable specifies whether the reference switch functioned correctly during the mastering test. The state of the variable only changes if the following condition is met: • If the mastering test is active and a dual-channel error has occurred at the safety-oriented input signal JR ‒ Follow-up message: Error at mastering reference switch In the case of a dual-channel error, the level at the reference switch changes from HIGH to LOW and the variable is set to FALSE. The state of the variable dose not change if the following condition is met: • If the reference switch is actuated outside of the mastering test for at least 5 minutes, the variable remains TRUE. ‒ Follow-up message: Level at mastering reference switch is unexpectedly "low" • If the reference switch is disconnected, the variable remains TRUE. ‒ Follow-up message: Level at mastering reference switch is unexpectedly "low" Writability The system variable is write-protected. Syntax state = $MASTERINGTEST_SWITCH_OK 146/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Start-up and configuration KUKA.SafeOperation 3.6 Explanation of the syntax Element Description state Type: BOOL • TRUE: Reference switch OK • FALSE: Error at reference switch 7.7.3 Mastering test with external mastering confirmation Description If the mastering test is configured with external mastering confirmation, the mastering cannot be verified using one of the reference positions saved in the safety configuration. There is no KRL program to perform the mastering test. The system integrator himself must check the mastering in the higher-level controller as part of a safety function and must confirm the successful mastering test via a safe input signal of the robot controller. In the event that the higher-level controller recognizes a mastering error or the mastering test fails, appropriate measures must be taken on the robot controller, e.g. cancel the motion enable. Signals Safe input EJB (external mastering confirmation) is provided for external mastering confirmation via the higher-level controller. The EJB signal is available via the following interfaces: • Ethernet safety interface • Interface XG42 combined with safety interface XG13 In order to confirm mastering, a positive pulse must be created at input EJB. The pulse must be at least 350 ms long and must not exceed 5 s. If the EJB signal switches from “logic 0” to “logic 1” and switches back to “logic 0” within the time frame, the mastering test is successfully confirmed. The higher-level controller can determine whether mastering confirmation is required via the safe output signals RR (robot referenced) and SO (safety option active). If safe output RR is “logic 0”, the mastering test must be confirmed. However, output RR is also “logic 0” in the following cases: • The robot controller is switched off or is not yet fully booted (ready for operation). • The safety option is not active because safe monitoring is deactivated. It is advisable to poll the safe output SO (safety option active). When using an Ethernet safety interface, it is also possible to poll the safe output signal PSA (safety interface active). When safe output SO or PSA is “logic 1”, the state of safe output RR is also valid. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 147/304 Start-up and configuration KUKA.SafeOperation 3.6 Fig. 7-25: Connection of higher-level controller (example) 1 Higher-level controller 3 Pulse generator 2 “Mastering OK” signal 4 Robot controller Overview The following steps are required in order to carry out external mastering confirmation: Step 7.7.3.1 Description 1 Define the reference position and save it in the higher-level controller. 2 When the mastering test is requested, address the reference position via the robot controller (via a user-created KRL program). 3 Compare the setpoint position of the robot and external axes with the reference position saved in the higher-level controller to check whether the positions match. 4 If the position comparison is successful, confirm the mastering test via the higher-level controller. Send the confirmation pulse at safe input EJB to the robot controller. 5 If the position comparison fails, the robot must no longer be moved. Take appropriate measures on the robot controller via the higher-level controller, e.g. cancel the motion enable. Signal diagram: external mastering confirmation Description The signal diagram applies in the following case: • The safe output signal RR is evaluated by the higher-level controller. • The mastering test is requested by the robot controller. The RR signal switches from “logic 1” to “logic 0”. • The higher-level controller confirms the successful mastering test with the pulse signal EJB. 148/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 • The RR signal switches from “logic 0” to “logic 1”. The message Mastering test successfully carried out is displayed. Fig. 7-26: Signal diagram: external mastering confirmation 1 Mastering test requested 2 External mastering confirmation starts 3 Successful mastering test is confirmed Errors The following situations can lead to incorrect mastering confirmation: • The pulse at safe input EJB is created by the higher-level controller even though no mastering confirmation is required. Safe output RR is already “logic 1”. • The duration of the pulse is longer than 5 seconds. • Safe input EJB is already “logic 1” when the robot controller is started. In these situations, safe output RR switches to “logic 0” and the message Mastering test failed is displayed. A renewed pulse at safe input EJB will result in successful mastering confirmation. 7.7.3.2 Safety acceptance: checking the external mastering confirmation All steps of the function sequence implemented on the external system for the mastering test must be checked by the safety maintenance technician during safety acceptance as part of a positive test. In addition to the positive test, the potential errors to be assumed for the external system must be analyzed at the system level, and corresponding error control tests must be carried out. In the event of an error, no correct mastering may be confirmed, i.e. the EJB signal must not be set. 7.8 Brake test 7.8.1 Overview of the brake test Description Each robot axis has at least one holding brake integrated into the motor. The brake test checks to see if the braking torque is sufficiently high, i.e. whether it exceeds a certain minimum value. The minimum value for the individual motor types is stored in the machine data and cannot be configured. (The brake test does not calculate the absolute value of the braking torque.) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 149/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 It is advisable to carry out the brake test when the robot is at operating temperature. This is the case after approx. 1 h in normal operation. Operating modes The brake test can be performed in all operating modes. Activation + configuration • The “brake test” functionality is automatically active if a safety option is installed and safe monitoring is activated. • If the brake test is not automatically active, the user has the option of manually activating it (in WorkVisual or on the robot controller). • The axes to be checked in the brake test can be configured (in WorkVisual or on the robot controller). • The cycle time can be configured (in WorkVisual or on the robot controller). If the brake test is not automatically active, the operator must carry out a hazard assessment to determine whether it is necessary to activate the brake test for the specific application. If the brake test is active, the operator must perform a hazard assessment to determine the following: • Which axes need to be tested • What cycle time needs to be defined It is irrelevant whether the brake test is automatically active or it is activated manually. The hazard assessment is required in both cases. Request Events which request the execution of a brake test If the brake test is active, the following events request the execution of a brake test: • Input $BRAKETEST_REQ_EX is set externally, e.g. by a PLC (external request) • Robot controller boots with a cold start (internal request) • Brake test cycle time has elapsed (internal request) The default cycle time is 46 h. It elapses when the drives have been in servo-control for a total of 46 h. • Status message from the automatic brake check: Brake defective, {Axis} permanently under servo control Response following a request 1. If a request is present, the robot controller generates the following message: Brake test required. The robot can be moved for another 2 hours. (This is referred to as the monitoring time) 2. The brake test must be performed within the monitoring time. Once the brake test has been performed successfully, the cycle time restarts. 3. If the brake test is not performed, the robot stops once the monitoring time expires. The robot controller generates the following acknowledgement message: Cyclical check for brake test request not made. The message cannot be acknowledged externally (by the PLC), but must be acknowledged on the smartPAD. 150/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Once the message has been acknowledged, the robot can be moved for another 2 hours. At the time of the brake test, a simulation can be switched on, for example via $SIMULATED_AXIS, $SIMULATED_COOP_ROBOTS or $SERVO_SIM. The simulated axes are not included in the brake test. Simulated axes must be removed from the simulation and tested before the end of the cycle time. Otherwise, the robot stops and the robot controller generates the following acknowledgement message: Cyclical check for brake test request not made. Once the message has been acknowledged, the robot can be moved for another 2 hours. Active and requested axes “Active axes” are those axes selected in the Active Configuration column in the Brake test configuration window. “Requested axes” are the active axes for which there is currently a brake test request. 7.8.2 Sequence when testing a brake The brake test checks the brakes to be tested one after the other. 1. From the start position of the brake test, the axis to be tested moves in the direction in which the software limit switch is situated further away, and then moves back. The gravitation and friction of the axis to be tested are determined during this motion. Rotational axes move a maximum of 5° in the direction of the software limit switch; linear axes a maximum of 10 cm. 2. When the axis has returned to its start position, the brake closes and the motor torque exerted against the closed brake is increased. The results of the brake test are shown in the message window. 3. If a brake has been identified as being defective, the robot moves to the parking position following confirmation. If a brake has reached the wear limit, the robot controller indicates this by means of a message. A worn brake will soon be identified as defective. Until then, the robot can be moved without restrictions. If an axis is equipped with additional brakes, the main brake is tested first. 7.8.3 Programs for the brake test The programs are located in the directory C:\KRC\ROBOTER\KRC\R1\TP \BrakeTest. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 151/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Program Description BrakeTestReq.src Performing the brake test cyclically (via program): • All requested axes can be tested in one cycle using the program. For this purpose, the program is called without parameters. • A selection of the requested axes can also be tested using the program. The desired axes are transferred as parameters when calling the program. This enables the brake test to be divided into multiple shorter cycles. Note: This allows, for example, small breaks in the application to be utilized for testing individual axes. (>>> 7.8.5.1 "Performing a brake test for requested axes (cyclically via program)" Page 161) BrakeTestReq.src can also be selected manually. All active axes are tested. (>>> 7.8.5.2 "Performing a brake test for active axes (manually)" Page 163) BrakeTestAxes.src With the program, axes for which there is no brake test request can be tested. In particular, it also enables the testing of axes which cannot be activated for the brake test and thus cannot be tested via BrakeTestReq.src. Couplable axes fall into this category, for example. (>>> 7.8.5.3 "Performing a brake test for further axes (e.g. couplable axes)" Page 165) BrakeTestPark.src The parking position of the robot must be taught in this program. If, during the brake test, a brake has been identified as being defective, the robot is moved to the parking position following confirmation. BrakeTestStart.src The start position of the brake test can be taught in this program. The robot starts the brake test from this position. If the start position is not taught, the robot performs the brake test at the actual position. BrakeTestBack.src The end position of the brake test can be taught in this program. 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. 7.8.4 Overview of the brake test setup Step Description In WorkVisual or on the robot controller: 1 Activate the brake test; define the cycle time and axes • On the robot controller: (>>> 7.8.4.1 "Activating the brake test, defining the cycle time and axes" Page 153) • In WorkVisual: Information about activating the brake test in WorkVisual is contained in the WorkVisual documentation. On the robot controller: 2 Configure input and output signals for the brake test. (>>> 7.8.4.3 "Configuring input and output signals for the brake test" Page 155) 152/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Step 3 Description Teach positions for the brake test. (>>> 7.8.4.5 "Teaching positions for the brake test" Page 159) 4 Test the sequence. (>>> 7.8.4.6 "Testing the sequence in the case of defective brakes" Page 160) 7.8.4.1 Activating the brake test, defining the cycle time and axes Precondition • User group “Safety maintenance” or higher • T1 or T2 mode • No program is selected. Procedure 1. In the main menu, select Configuration > Brake test configuration. The Brake test configuration window opens. (>>> 7.8.4.2 "“Brake test configuration” window" Page 154) 2. If necessary, activate or deactivate the check box for Forcedin the Current configuration column. 3. Also make the desired settings for the cycle time and axes in the Current configuration column. 4. Press the Activate button. The message Reconfiguration in progress ... is displayed. The message disappears automatically when reconfiguration has been completed. The new settings for the brake test are now saved and valid. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 153/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 7.8.4.2 “Brake test configuration” window Fig. 7-27: “Brake test configuration” window Element Description Configurations are identical • LED lights up green: The settings in the Active Configuration and Current configuration columns are identical. • LED lights up red: The settings are not identical. Checksum Checksum of the brake test configuration in the corresponding column • Checksums in both columns are identical: The settings in the columns are identical. Corresponds to the green LED for Configurations are identical. • Checksums not identical: The settings are not identical. Corresponds to the red LED. Current configuration 154/304 | www.kuka.com The settings can be modified in this column. The most recent modifications are shown. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Element Description Active Configuration This column displays the valid settings. A check mark next to an axis means that the axis is selected for the brake test. This column is used for display purposes only. Modifications are not possible here. Forced • Check box not active: Automatic response of the brake test ‒ A safety option is installed and safe monitoring is active. The brake test is thus automatically active. ‒ Or: No safety option is installed or safe monitoring is not active. The brake test is thus automatically inactive. • Check box active: Forced response The brake test has been explicitly activated by the user (Here or in WorkVisual). It is active, irrespective of safety options or safe monitoring. Note: The Forced check box WITHOUT a check mark does not indicate whether the brake test is active or not! The state of the brake test is indicated in the Safety configuration window on the Common tab: • Activated: The brake test is active for at least one axis. • Deactivated: The brake test is not active for any axis. Cycle time [h] The cycle time specifies the interval at which the brake test is to be executed. • 1 … 1000 Default: 46. Unit: hours [Axis no.]:[Robot type] The robot axes and external axes for which the brake test is to be executed can be selected here. By default, all axes are selected. The following external axes cannot be selected: 1. External axes that are simulated 2. External axes that are configured as couplable 3. External axes with motors that are grouped together into a coupling group Activate Saves the settings of the Current configuration column. The system then automatically performs a reconfiguration. Once reconfiguration is completed, new settings are valid and are displayed in the Active Configuration column. Activate is only available if the 2 columns have different settings. Reset to active configuration Resets the Current configuration column to the settings from the Active Configuration column. Only available if the 2 columns have different settings. 7.8.4.3 Configuring input and output signals for the brake test Description All signals for the brake test are declared in the file $machine.dat in the directory KRC:\STEU\MADA. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 155/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 WARNING Danger to life and limb due to incorrectly used signals These signals are not redundant in design and can supply incorrect information. If they are used for safety-relevant applications, this may result in death, severe injuries or considerable damage to property. • Do not use these signals for safety-relevant applications. Precondition • User rights: Function group Critical KRL program changes Procedure 1. Open the file $machine.dat in the directory KRC:\STEU\MADA in the Navigator. 2. Assign inputs and outputs. 3. Save and close the file. $machine.dat Extract from the file $machine.dat (with default settings, without comments): ... SIGNAL SIGNAL ... SIGNAL SIGNAL SIGNAL SIGNAL ... $BRAKETEST_REQ_EX $IN[1026] $BRAKETEST_MONTIME FALSE $BRAKETEST_REQ_INT FALSE $BRAKETEST_WORK FALSE $BRAKES_OK FALSE $BRAKETEST_WARN FALSE Signals There is 1 input signal. By default, it is routed to $IN[1026]. The output signals are preset to FALSE. There is no need to assign output numbers to them. Signal Description $BRAKETEST_REQ_EX Input • TRUE = brake test is being requested externally (e.g. by PLC). The robot controller confirms the signal with $BRAKETEST_REQ_INT = TRUE and generates message 27004. • FALSE = brake test is not being requested externally. $BRAKETEST_MONTIME Output • TRUE = robot was stopped due to elapsed monitoring time. Acknowledgement message 27002 is generated. • FALSE = acknowledgement message 27002 is not active. (Not generated, or has been acknowledged.) 156/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Signal Description $BRAKETEST_REQ_INT Output • TRUE = message 27004 is active. The signal is not set to FALSE again until a brake test is carried out with a positive result, i.e. with message 27012. • FALSE = brake test is not requested (either internally or externally). $BRAKETEST_WORK Output • TRUE = brake test is currently being performed. • FALSE = brake test is not being performed. If no defective brakes have been detected, message 27012 is generated. Edge TRUE → FALSE: • Test was successfully completed. No brake is defective. Message 27012 is generated. • Or at least 1 defective brake was detected and the robot has moved to the parking position. • Or the program was canceled during execution of the brake test. $BRAKES_OK Output • Edge FALSE → TRUE: Output was set to FALSE by the previous brake test. The brake test was carried out again and no defective brake was detected. • Edge TRUE → FALSE: A brake has just been detected as defective. Message 27007 is generated. This signal does not take any couplable axes into account. $BRAKETEST_WARN Output • Edge FALSE → TRUE: At least 1 brake has been detected as having reached the wear limit. Message 27001 is generated at the same time. • Edge TRUE → FALSE: Output was set to TRUE by the previous brake test. The brake test was carried out again and no worn brake was detected. This signal does not take any couplable axes into account. Messages No. Message 27000 Test of brakes {Axis bit mask} not executed because axes are simulated 27001 Brake {Brake no.}{Axis no.} has reached the wear limit 27002 Cyclical check for brake test request not made 27003 Brake test for axes {Axis bit mask} required 27004 Brake test required 27007 Insufficient holding torque of brake {Brake no.}{Axis no.} 27009 Brake {Brake no.}{Axis no.} OK 27010 Unable to verify performance of brake {Brake}{Axis} 27012 Brake test successful KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 157/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 7.8.4.4 Signal diagram of the brake test – examples Example 1 The signal diagram for the brake test applies in the following case: • No brake has reached the wear limit. • No brake is defective. Fig. 7-28: Signal diagram: brakes OK Item Description 1 The brake test is requested. 2 Automatic call of the program BrakeTestReq.src Start of the brake test 3 The brake test is completed. Example 2 The signal diagram for the brake test applies in the following case: • Brake A2 is worn. • Brake A4 is defective. Fig. 7-29: Signal diagram: brakes not OK 158/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Item 1 Description The brake test is requested. $BRAKETEST_REQ_INT is not set to FALSE again until a brake test is carried out with a positive result. 2 Automatic call of the program BrakeTestReq.src Start of the brake test 7.8.4.5 3 Brake A2 is tested: brake is worn. 4 Brake A4 is tested: brake is defective. 5 The robot has been moved to the parking position or the program has been canceled. Teaching positions for the brake test Description Start position and end position The start position and end position can be taught. • If the start position is not taught, the robot performs the brake test at the actual position. • If the end position is not taught, the robot remains at the actual position after the brake test. Parking position A suitable parking position must be taught. If, during the brake test, a brake has been identified as being defective, the robot is moved to the parking position following confirmation. WARNING Danger to life and limb due to unfavorable parking position A defective brake may cause the robot to sag, even if it is already in the parking position. • Select the parking position where no persons are endangered if the robot sags. The transport position, for example, can be selected as the parking position. Further information about the transport position is contained in the robot operating or assembly instructions. Precondition • User rights of the following function groups: ‒ Jogging with the jog keys or alternatively Jogging using the 6D mouse ‒ Teach local points But at least the user group “Expert” • All output signals are assigned to outputs. • T1 mode Procedure Start position: 1. Open the program BrakeTestStart.src in the directory R1\TP\BrakeTest. 2. Teach the motions to the start position of the brake test. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 159/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 • The motions must be taught in such a way that the robot cannot cause a collision on the way to the start position. • In the start position, each robot axis to be tested must have a sufficient motion range. During the brake test, rotational axes move a maximum of 5° in the direction in which the software limit switch is situated further away; linear axes a maximum of 10 cm. 3. Save and close the program. End position: 1. Open the program BrakeTestBack.src in the directory R1\TP\BrakeTest. 2. Teach the motions from the start position to the end position of the brake test. The start and end position may be identical. 3. Save and close the program. Parking position: 1. Open the program BrakeTestPark.src in the directory R1\TP\BrakeTest. 2. Teach the motions from the end position to the parking position of the robot. 3. Save and close the program. Alternatively, the parking position can also be taught later when testing the sequence. (>>> 7.8.4.6 "Testing the sequence in the case of defective brakes" Page 160) 7.8.4.6 Testing the sequence in the case of defective brakes WARNING Danger to life and limb due to unfavorable parking position A defective brake may cause the robot to sag, even if it is already in the parking position. • Select the parking position where no persons are endangered if the robot sags. The transport position, for example, can be selected as the parking position. Further information about the transport position is contained in the robot operating or assembly instructions. Description The robot controller simulates a defective brake. Precondition • User rights: Function group Program selection and deselection But at least the user group “Expert” • In the start position, an adequate motion range is available for each axis to be tested. (Or, if no start position has been taught, in the actual position.) During the brake test, rotational axes move a maximum of 5° in the direction in which the software limit switch is situated further away; linear axes a maximum of 10 cm. 160/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Procedure 1. Select the program BrakeTestReq.src in the directory R1\TP\BrakeTest. The following message is displayed: Start key required 2. Press the Start key. The following message is displayed: Should the brake test be carried out manually or should the movement to the parking position be checked? 3. Select the answer Park pos.. 4. The BCO run is performed. The message Programmed path reached (BCO) is displayed. 5. Press the Start key. The following message is displayed: CAUTION! Braking effect of the holding brakes no longer sufficient to hold the robot safely. Triggering safety functions or switching off the drives can cause the robot to sag. Following confirmation, the parking position/wait position is addressed.. Confirm the message with Park pos.. • The robot moves to the parking position if the parking position has already been taught. • If the parking position has not yet been taught, the following message is displayed: Parking position is invalid. Move the robot to the correct position and press the “Touch Up” softkey. In this case, move the robot manually to the desired parking position and teach the position. 7.8.5 Performing a brake test 7.8.5.1 Performing a brake test for requested axes (cyclically via program) WARNING Danger to life and limb due to entering the danger zone prematurely A defective brake may cause the robot to sag. • Do not enter the danger zone until the robot has reached its parking position. NOTICE Damage to property during motion to the parking position If a brake is defective, the robot may sag when it is stopped. • Avoid stops during the motion to the parking position, as sagging could result in damage to property. In particular, it must be taken into consideration that certain actions trigger stops (e.g. E-STOP, opening safety gate, changing operating mode), as do certain monitoring functions (e.g. monitoring spaces). A defective brake can result in longer stopping distances. • Approach the parking position at low velocity. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 161/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Description With BrakeTestReq.src, the axes for which there is a brake test request can be tested. The axes can either be tested in a single cycle or the test can be divided into several shorter cycles. This allows, for example, small breaks in the application to be utilized for testing individual axes. Precondition To integrate the program: • User rights: Function group Critical KRL program changes Procedure Test in a single cycle: Integrate BrakeTestReq.src into a suitable program (e.g. into CELL.src or into the application program) in such a way that it is called cyclically as a subprogram. If a brake test is requested, BrakeTestReq.src detects the request and starts the brake test. • Call BrakeTestReq.src without parameters: BrakeTestReq() Further information: The axes are tested in a single cycle, from the lowest axis number to the highest. Alternative procedure Test divided into several shorter cycles: Integrate BrakeTestReq.src into a suitable program in such a way that it is called cyclically as a subprogram. If a brake test is requested, BrakeTestReq.src detects the request and starts the brake test. • When calling BrakeTestReq.src, transfer the axes to be tested as parameters. Further information: • One or more of the requested axes can be tested per cycle. The individual cycles do not have to follow one another directly. • The order of the cycles is irrelevant. A cycle to test A6, for example, can be called first. If multiple axes are tested in one cycle, however, the lowest axis will always be tested first. • In total, all requested axes must be tested. This must occur within the monitoring time. Parameter The axes to be tested can be transferred as an integer or as a bit mask. Bit 0 corresponds to A1; bit 1 to A2; …; bit 6 to A7/E1; …; bit 11 to A12/E6. Example for A1 and A3, as an integer: BrakeTestReq(5) Example for A1 and A3, as a bit mask: BrakeTestReq('b101') 162/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 No parameter or parameter “-1” means: all active axes. Example In this example, the lowest numbered axis from amongst the axes with a currently requested brake test is tested. Such an example can be integrated into the application cycle at a suitable point in order to test one axis per cycle. int axes_bit_mask, test_bit_mask, counter ... 1 axes_bit_mask = get_axesmask(#braketest_required) 2 test_bit_mask = 1 3 if axes_bit_mask > 0 then 4 for counter=1 to 12 5 if (axes_bit_mask B_AND test_bit_mask) > 0 THEN 6 counter = 13 7 else 8 test_bit_mask = test_bit_mask*2 9 endif 10 endfor 11 braketestreq(test_bit_mask) 12 endif ... 7.8.5.2 Line Description 1 Query for which axes the brake test is currently requested. 2 By way of preparation, set the lowest possible axis (in this case, A1) as the axis to be tested. 3 to 12 If there is a request for at least one axis, the IF block is executed. It contains a counting loop. 4 to 10 The counting loop is designed in such a way that, upon exiting it, test_bit_mask always corresponds to the lowest axis of all those to be tested. 6 Exit the counting loop. 11 Call the brake test for the axis to be tested test_bit_mask. Performing a brake test for active axes (manually) WARNING Danger to life and limb due to entering the danger zone prematurely A defective brake may cause the robot to sag. • Do not enter the danger zone until the robot has reached its parking position. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 163/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 NOTICE Damage to property during motion to the parking position If a brake is defective, the robot may sag when it is stopped. • Avoid stops during the motion to the parking position, as sagging could result in damage to property. In particular, it must be taken into consideration that certain actions trigger stops (e.g. E-STOP, opening safety gate, changing operating mode), as do certain monitoring functions (e.g. monitoring spaces). A defective brake can result in longer stopping distances. • Approach the parking position at low velocity. Description This procedure can be used to test the active axes. The axes are tested in a single cycle, from the lowest axis number to the highest. This procedure can be used to process an existing brake test request. Precondition • User rights: Function group Program selection and deselection But at least the user group “Expert” • In the start position, an adequate motion range is available for each axis to be tested. (Or, if no start position has been taught, in the actual position.) During the brake test, rotational axes move a maximum of 5° in the direction in which the software limit switch is situated further away; linear axes a maximum of 10 cm. Procedure 1. Select the program BrakeTestReq.src in the directory R1\TP\BrakeTest. The following message is displayed: Start key required 2. Press the Start key. The following message is displayed: Should the brake test be carried out manually or should the movement to the parking position be checked? 3. Select the answer BT man.. 4. The BCO run is performed. The message Programmed path reached (BCO) is displayed. 5. Press the Start key. The following message is displayed: Brake test for axes {Axis bit mask} required. The message lists the active axes. The program now tests the brakes/axes successively, starting with the lowest axis number. 6. Possible results: • If a brake is OK, this is indicated by the following message: Brake {Brake no.}{Axis no.} OK. The message Brake test for axes {Axis bit mask} required then reappears. It now only lists the axes that have not yet been tested. The program automatically tests the next axis. If all brakes are OK, this is indicated after the brake test by the following message: Brake test successful. (It is possible that one or more brakes may have reached the wear limit. This is also indicated by a message.) 164/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Now deselect the program BrakeTestReq.src. • If a brake is defective, this is indicated by the following message: Insufficient holding torque of brake {Brake no.}{Axis no.}. The test continues until all brakes have been tested. Once all brakes have been tested, the following message is displayed: CAUTION! Braking effect of the holding brakes no longer sufficient to hold the robot safely. Triggering safety functions or switching off the drives can cause the robot to sag. Following confirmation, the parking position/wait position is addressed.. Now press Park pos. to move the robot to the parking position. 7.8.5.3 Performing a brake test for further axes (e.g. couplable axes) WARNING Danger to life and limb due to entering the danger zone prematurely A defective brake may cause the robot to sag. • Do not enter the danger zone until the robot has reached its parking position. NOTICE Damage to property during motion to the parking position If a brake is defective, the robot may sag when it is stopped. • Avoid stops during the motion to the parking position, as sagging could result in damage to property. In particular, it must be taken into consideration that certain actions trigger stops (e.g. E-STOP, opening safety gate, changing operating mode), as do certain monitoring functions (e.g. monitoring spaces). A defective brake can result in longer stopping distances. • Approach the parking position at low velocity. Description With BrakeTestAxes.src, axes for which there is no brake test request can be tested. In particular, it also enables the testing of axes which cannot be activated for the brake test and thus cannot be tested via BrakeTestReq(). Couplable axes fall into this category, for example. Precondition To integrate the program: • User rights: Function group Critical KRL program changes Procedure Integrate BrakeTestAxes.src into a suitable program in such a way that it is called as a subprogram. • When calling BrakeTestAxes.src, transfer the axes to be tested as parameters. Parameters The axes to be tested can be transferred as an integer or as a bit mask. Bit 0 corresponds to A1; bit 1 to A2; …; bit 6 to A7/E1; …; bit 11 to A12/E6. Example for A7/E1, as an integer: KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 165/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 BrakeTestReq(64) Example for A7/E1, as a bit mask: BrakeTestReq('b1000000') No parameter or parameter “-1” means: all active axes. Additional info In principle, it is also possible to use BrakeTestAxes(axes) to test one or more axes for which there is a request. When calling the test, the axes must be transferred as parameters in this case too. An existing brake test request can be processed using BrakeTestAxes.src. If BrakeTestAxes.src is called for an active axis, this triggers a request for all active axes! As usual, the request must be processed within the monitoring time. It is therefore not possible to test individual active axes using BrakeTestAxes.src. 7.8.6 Automatic brake check Description The default cycle time of the brake test is 46 hours. In order to detect defective brakes as early as possible, however, even before the end of the cycle time, the robot controller performs an additional, automatic brake check. If the brake check indicates that a brake might be defective, a brake test must be performed for verification. Decoupled axes and force-controlled axes are excluded from the brake check. Sequence 1. If a brake has been applied, the robot controller automatically checks whether the axis is still moving. Motions within a narrow, internally defined tolerance range are allowed. The tolerance range corresponds to half of the standstill window. The standstill window is: $IN_POS_MA[axis] * $IN_STILL_MA. Further information about these system variables can be found in the documentation Configuration of Kinematic Systems. 2. If the tolerance range is exceeded, this indicates that the brake is defective. In this case, the robot controller switches the axis back to servo control to prevent it from sagging. The axis is now in the “BrakeDefect” state. Furthermore, the status message Brake defective, {Axis} permanently under servo control is displayed. 3. The further procedure depends on whether or not the brake test is active for the corresponding axis: • Brake test is active: The robot controller sets $BRAKETEST_REQ_INT to TRUE and generates the following message: Brake test required. A brake test must be performed within the next 2 hours, otherwise the robot will stop! • Brake test is not active: 166/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 The robot stops and the acknowledgement message Stop due to defective brake is displayed. The message can be acknowledged and the robot movement can be resumed. The axis remains permanently under servo control, i.e. its brakes are no longer applied. (Except if the safety controller resets the “Motion enable” input.) In order to enable the brakes to close again, a brake test must be performed manually! 4. Once a brake test has been performed and has indicated that the axis is working correctly, the status message Brake defective, {Axis} permanently under servo control disappears again. BrakeDefect If an axis is in the “BrakeDefect” state, the robot controller ignores brake closing requests for this axis and for the axes on the same brake channel. If an axis is in the “BrakeDefect” state, its brakes nevertheless close in the following case: the safety controller resets the “Motion enable” input, e.g. in the case of an EMERGENCY STOP or short-circuit braking. 7.8.7 System functions for the brake test 7.8.7.1 GET_AXESMASK: requesting information about the axes for the brake test Description Various queries concerning the axes involved in the brake test can be carried out. Syntax result = GET_AXESMASK(axes) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 167/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Explanation of the syntax Element result Description Variable for the return value, type: INT Bit mask, i.e. specification of which axes are involved axes Type: ENUM AXESMASK_INFO • #BRAKETEST_CONFIGURED Axes configured for the brake test Corresponds to the axes in the Active Configuration column in the Brake test configuration window. • #BRAKETEST_ACTIVATED ‒ If the brake test is active, the return value is as for #BRAKETEST_CONFIGURED. ‒ If the brake test is not active, the return value is “0”. • #BRAKETEST_REQUIRED Axes for which the brake test is currently requested • #BRAKETEST_UNTESTED Axes for which the state of the brake is BT_UNTESTED. Axes not configured for the brake test are also included. • #BRAKETEST_BRAKES_OK Axes found to be OK in the most recent brake test Example Query for which axis the brake test is currently requested: int axes_bit_mask ... axes_bit_mask = get_axesmask(#braketest_required) 7.8.7.2 GET_BRAKETEST_TIME: requesting time values for brake test Description Various time values related to the brake test can be polled. Syntax result = GET_BRAKETEST_TIME(time_type) 168/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Explanation of the syntax Element result Description Variable for the return value, type: REAL Time (unit: h) time_type Times that can be polled Type: ENUM BRAKETEST_TIME_INFO • #BT_CONFIG_CYCLE_TIME Cycle time for the brake test Corresponds to the Cycle time [h] box in the Brake test configuration window. • #BT_REMAINING_CYCLE_TIME Remaining cycle time • #BT_REMAINING_MON_TIME Remaining monitoring time Total monitoring time: following the message Brake test required, the robot can be moved for another 2 hours. 7.9 Override reduction Override reduction is not a safety function. Overview Override reduction is a function that can be activated using system variables. • Override reduction for velocity limits Override reduction prevents velocity limits that are monitored by the safety controller from being exceeded. ‒ Activation via $SR_VEL_RED (>>> 7.9.1 "$SR_VEL_RED" Page 170) ‒ Reduction factor via $SR_OV_RED (>>> 7.9.2 "$SR_OV_RED" Page 171) ‒ Example: (>>> 7.9.6 "Changing workspace: override reduction for velocity limits (example without BBRA)" Page 176) • Override reduction before space limits The override reduction ensures short stopping distances if the robot is stopped due to a space violation or a foreseeable space violation. ‒ Activation via $SR_WORKSPACE_RED (>>> 7.9.3 "$SR_WORKSPACE_RED" Page 172) ‒ Only affects monitoring spaces for which the “Stop at boundaries” function has been configured ‒ Active in T2, AUT and AUT EXT modes ‒ Generally inactive in T1 mode, i.e. it is also inactive if override reduction is activated via $SR_WORKSPACE_RED ‒ Dependent on the “Braking before restricted areas” function (>>> 7.9.4 "Override reduction before space limits without BBRA" Page 172) (>>> 7.9.5 "Override reduction before space limits with BBRA" Page 174) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 169/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Override reduction with/without spline • If the motion is carried out without spline, then override reduction only affects Cartesian velocity limits. • If motion is carried out with spline, override reduction affects Cartesian and axis-specific velocity limits. With spline Override reduction has an effect … before space limits Cartesian (in T2, AUT and AUT EXT) Axis-specific on space-specific velocity Cartesian space on velocity limits Cartesian velocity Without spline Axis-specific space • Maximum velocity (not spacedependent) • Reduced velocity • Reduced velocity in T1 Axis velocity • Maximum velocity (valid globally for every axis) • Reduced velocity • Maximum velocity in T1 Spline is a motion type that is suitable for particularly complex, curved paths. Such paths can also be generated using approximated LIN and CIRC motions, but splines have advantages, however. The advantages of spline include: • The path always remains the same, irrespective of the override setting, velocity or acceleration. • Circles and tight radii are executed with great precision. It is advisable to use spline for optimal override reduction, e.g. in the case of frequent motion along the workspace limits. Further information about motion programming with spline is contained in the “Operating and Programming Instructions for System Integrators”. 7.9.1 $SR_VEL_RED Description Activation of the override reduction function for velocity limits If override reduction is active, the velocity is automatically reduced so that the lowest velocity limit currently monitored by the safety controller is not exceeded. The extent of the override reduction can be set using the variable $SR_OV_RED. Writability The variable can be modified in $custom.dat in KRC:\STEU\Mada. 170/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 The variable can also be modified via the variable display or in the program. Modifying the variable triggers an advance run stop. Syntax $SR_VEL_RED = state Explanation of the syntax Element Description state Type: BOOL • TRUE: Override reduction is activated. • FALSE: Override reduction is deactivated. Default: TRUE 7.9.2 $SR_OV_RED Description Reduction factor for the smallest monitored velocity limit as a percentage If the override reduction for velocity limits is active ($SR_VEL_RED = TRUE), the smallest currently monitored velocity limit is reduced to the set percentage value using the variable $SR_OV_RED. Writability The variable can be modified in $custom.dat in KRC:\STEU\Mada. The variable can also be modified via the variable display or in the program. Modifying the variable triggers an advance run stop. Syntax $SR_OV_RED = reduction factor Explanation of the syntax Element Description reduction factor Type: INT; unit: % • 10 … 95 Default: 75 Example The override reduction is configured with a reduction factor of 95%: • $SR_VEL_RED = TRUE • $SR_OV_RED = 95 The lowest Cartesian velocity limit active on the safety controller is a reduced velocity of 1 000 mm/s. The override reduction function reduces the Cartesian velocity at the safety-oriented TCP of the active tool to 950 mm/ s. The override reduction function is only triggered if it is foreseeable that the limit of 950 mm/s will be exceeded without velocity reduction. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 171/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Fig. 7-30: Override reduction with $SR_VEL_RED v3 Maximum Cartesian velocity; v3 = 1 200 mm/s v2 Reduced Cartesian velocity; v2 = 1 000 mm/s v1 Velocity v2 * reduction factor; v1 = 1 000 mm/s * 95% = 950 mm/s t1 Override reduction is triggered: It is foreseeable that the limit v1 will be exceeded without the reduction in velocity. t2 Override reduction is no longer triggered. 7.9.3 $SR_WORKSPACE_RED Description Activation of the override reduction function before space limits Override reduction takes effect before limits of monitoring spaces for which the function “Stop at boundaries” has been configured. When the robot approaches the space limit with override reduction activated, the velocity is continuously reduced. If the safety controller triggers a stop at the space limit, the robot stops faster owing to the reduced velocity. Writability The variable can be modified in $custom.dat in KRC:\STEU\Mada. The variable can also be modified via the variable display or in the program. Modifying the variable triggers an advance run stop. Syntax $SR_WORKSPACE_RED = state Explanation of the syntax Element Description state Type: BOOL • TRUE: Override reduction is activated. • FALSE: Override reduction is deactivated. Default: TRUE 7.9.4 Override reduction before space limits without BBRA Description When the robot approaches the space limit with override reduction activated, the velocity is continuously reduced. When the robot moves over the 172/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 space limit and is stopped, the velocity has already been greatly reduced. The stopping distance is short and the robot quickly comes to a standstill. When the robot approaches the space limit with override reduction deactivated, the velocity is not reduced. The robot is still moving at full velocity when it is stopped at the space limit. The robot does not come to a standstill as quickly as with override reduction active, as the stopping distance is greater due to the higher velocity. Example A Cartesian protected space is configured into which the robot may not move. If the robot approaches the protected space, override reduction is triggered and reduces the velocity. If the robot attempts to enter the protected space, a safety stop 0 is triggered at the space limit. The following preconditions are met: System variables: • $SR_WORKSPACE_RED = TRUE Safety configuration: • • • • • Safe monitoring is active. The “Braking before restricted areas” function is deactivated. The “Stop at boundaries” function is active. At least one tool sphere on the active tool is monitored. The protected space is switched to active. With spline (red line), override reduction reduces the Cartesian velocity at the safety-oriented TCP of the active tool to a value that roughly corresponds to a program override of 1% while it is still in the permissible range. The robot enters the Cartesian protected space with this velocity and is stopped with a safety stop 0. Without spline (blue line), the Cartesian velocity is reduced while in the permissible range, but the override reduction function is not usually triggered early enough. The robot enters the Cartesian protected space at a higher velocity than with spline. Here, once again, the robot stops with a safety stop 0, but the braking reaction is more abrupt and the stopping distance greater. Fig. 7-31: Moving into a protected space 1 Permissible range KST SafeOperation 3.6 V3 | Issued: 10.10.2022 2 Cartesian protected space www.kuka.com | 173/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 7.9.5 Override reduction before space limits with BBRA Description When the robot approaches the space limit with override reduction activated, the velocity is continuously reduced to prevent the safety function from being triggered. If necessary, the override is reduced to 0% if, for example, the path being executed leads into a protected space. If the robot is positioned before a temporarily activated space with 0% override in T2 or AUT mode, it will resume its motion without any further intervention as soon as the space is deactivated. If the override cannot be reduced quickly enough to prevent safe space monitoring from being triggered, then a path-maintaining EMERGENCY STOP is executed. When the robot approaches the space limit with override reduction deactivated, the velocity is not reduced and the robot is stopped by the safety controller with a safety stop 1 DRS. In this case, the robot does not normally come to a stop on the path. Instead, it deviates from this path because the safety stop 1 DRS is not path-maintaining. Fig. 7-32: Overview: step-by-step prevention of space violation with BBRA 174/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Example 1 A Cartesian protected space is configured into which the robot may not move. In the example, the path leads into the protected space. The following preconditions are met: System variables: • $SR_WORKSPACE_RED = TRUE Safety configuration: • • • • • Safe monitoring is active. The “Braking before restricted areas” function is activated. The “Stop at boundaries” function is active. At least one tool sphere on the active tool is monitored. The protected space is switched to active. The override reduction function reduces the Cartesian velocity at the safety-oriented TCP of the active tool down to a standstill within the permissible range. This prevents the robot from reaching the Cartesian protected space. If it is a temporary protected space and it is deactivated, the robot resumes its motion without further intervention. Fig. 7-33: Stop before space limit using override reduction 1 The robot is braked to a standstill on the path. 2 Protected space 3 Fictitious STOP 1 - DRS end positions monitored by the safety controller do not violate the space because the velocity is sufficiently reduced. In the event that the override reduction does not reduce the velocity quickly enough, the safety controller stops the robot with a safety stop 1 DRS as soon as it detects that the end position of such a stop would violate the space. Fig. 7-34: Stop before space limit without override reduction KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 175/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 1 Robot is stopped by the safety controller using a safety stop 1 DRS if there is an impending space violation. 2 Protected space Example 2 A Cartesian protected space is configured into which the robot may not move. In the example, the path runs very closely past the protected space. The following preconditions are met: System variables: • $SR_WORKSPACE_RED = TRUE Safety configuration: • • • • • Safe monitoring is active. The “Braking before restricted areas” function is activated. The “Stop at boundaries” function is active. At least one tool sphere on the active tool is monitored. The protected space is switched to active. When the robot approaches a protected space boundary, its Cartesian velocity at the safety-oriented TCP of the active tool is reduced to such an extent that the fictitious STOP 1 - DRS end position remains outside the protected space. This makes use of the fact that the braking distance of a safety stop 1 DRS is shortened on account of the reduced velocity. In some cases, it may not be possible to reduce the velocity quickly enough to prevent the stop point from penetrating the protected space. In this case, a path-maintaining EMERGENCY STOP is triggered to prevent a safety function from being violated and the safety controller from executing a non-path-maintaining safety stop 1 DRS as a result. (>>> Fig. 7-32) 7.9.6 Changing workspace: override reduction for velocity limits (example without BBRA) A change of workspace is carried out from one Cartesian workspace to another Cartesian workspace with a lower space-specific velocity vmax. The following preconditions are met: System variables: • $SR_VEL_RED = TRUE • $SR_OV_RED = 80 Due to override reduction with $SR_OV_RED = 80, a maximum of 80 percent of the configured space-specific velocity vmax is reached in the workspaces. Safety configuration: • • • • Safe monitoring is active. The “Braking before restricted areas” function is deactivated. At least one tool sphere on the active tool is monitored. The workspace with the lower space-specific velocity vmax is switched to active (permanently for preference). • The space-specific velocity vmax is valid if the workspace is not violated. 176/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 With spline (red line), override reduction reduces the Cartesian velocity at the safety-oriented TCP of the active tool in good time in the old workspace and moves into the new workspace with the lower space-specific velocity. Without spline (blue line), the Cartesian velocity is reduced in the old workspace, but the override reduction function is not usually triggered early enough. The lower space-specific velocity of the new workspace has not yet been reached at the space limit and the robot stops with a safety stop 0. Fig. 7-35: Changing to a workspace with a lower vmax 1 Cartesian workspace with vmax = 1,000 mm/s, reduced to 800 mm/s 2 Cartesian workspace with vmax = 500 mm/s, reduced to 400 mm/s 7.10 Safety acceptance overview Description The system must not be put into operation until the safety acceptance procedure has been completed successfully. Using checklists, check and document that all safety functions are configured correctly and work correctly. Safety acceptance must be carried out in the following cases: • Following initial start-up and recommissioning of the industrial robot • After a change to the industrial robot • After a change to the safety configuration ‒ The change log must be checked after every modification of the safety configuration. (>>> 6.6 "Displaying the revision log" Page 84) ‒ It is also advisable to print out the data set containing the safety parameters using WorkVisual. • After a software update, e.g. of the System Software Safety acceptance after a software update is only necessary if the activation code of the safety configuration changes as a result of the update. Checklists The safety acceptance procedure can be carried out and documented using the checklists in the appendix or using your own checklists. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 177/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 • The items in the checklist must be completed fully and confirmed in writing. • The completed checklists, confirmed in writing, must be kept as documentary evidence. Checklists in the appendix: • Checklist for robot and system (>>> 11.1.2 "Checklist: Robot and system" Page 269) • Checklist for safety functions (>>> 11.1.3 "Checklist: Safety functions" Page 270) • Checklist for safety-oriented tools (>>> 11.1.4 "Checklist: Safety-oriented tools" Page 275) • Checklist for cell area (>>> 11.1.5 "Checklist: Cell area" Page 280) • Checklist for Cartesian monitoring spaces (>>> 11.1.6 "Checklist: Cartesian monitoring spaces" Page 282) • Checklist for axis-specific monitoring spaces (>>> 11.1.7 "Checklist: Axis-specific monitoring spaces" Page 284) • Checklist for Cartesian velocity monitoring functions (>>> 11.1.8 "Checklist: Cartesian velocity monitoring functions" Page 288) • Checklist for axis-specific velocity monitoring functions (>>> 11.1.9 "Checklist: axis-specific velocity monitoring functions" Page 290) • Checklist for safe operational stop for axis groups (>>> 11.1.10 "Checklist: Safe operational stop for axis groups" Page 293) • Checklist for “Braking before restricted areas” function (>>> 11.1.11 "Checklist: Braking before restricted areas" Page 295) 7.11 Checking the safety functions for correct operation 7.11.1 Checking a safety-oriented tool Description The configuration of every safety-oriented tool must be checked as follows: 1. The specified geometry data of the safety-oriented tool must match the geometry data entered in the safety configuration. 2. A Cartesian monitoring space must be violated once with each sphere of the safety-oriented tool: • If “Stop at boundaries” is configured, the safety controller stops the robot as soon as a sphere of the safety-oriented tool violates the boundary. • If “Stop at boundaries” is not configured, an alarm space can be used for the check. Precondition • At least 1 monitoring space is activated for the tool to be tested. • Override reduction is deactivated: 178/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 ‒ $SR_WORKSPACE_RED = FALSE ‒ $SR_VEL_RED = FALSE • T1 mode • Checklist: ‒ (>>> 11.1.4 "Checklist: Safety-oriented tools" Page 275) Procedure The following steps must be carried out for each sphere of a safety-oriented tool. SAFETY INSTRUCTION 1. Move the sphere that is to be checked up to the boundaries of a monitoring space using the jog keys or the 6D mouse. 2. If the outer shell of a sphere makes contact with the boundary, either the robot must stop or the corresponding safety-oriented output must be set via an alarm space. 3. If the robot does not stop, or if no safety-oriented output is set, check the configuration, correct if necessary, and check the sphere again. 4. Check the active messages. With the space violation, the following messages must be displayed: • Monitoring space no. {Number of monitoring space} exceeded • Ackn.: Stop because workspace exceeded 5. If no message or different messages are displayed, check the configuration, correct if necessary, and check the sphere again. 7.11.2 Checking a cell area Description The cell area is a Cartesian monitoring space and, depending on the configuration, consists of 5, 6 or more space surfaces. The space surfaces can have any orientation. To check the correct configuration of the cell area, at least 2 different points on each space surface must be addressed by means of a test program: • If the check is successful, the safety controller stops the robot every time there is contact with one of the space surfaces. • Space surfaces that cannot be addressed due to circumstances in the system are excluded from the check. Fig. 7-36: Moving to space surfaces KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 179/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Precondition • Monitoring spaces that can be activated by means of safety-oriented inputs have been deactivated. • Override reduction is deactivated: ‒ $SR_WORKSPACE_RED = FALSE ‒ $SR_VEL_RED = FALSE • T1 mode • Checklist: ‒ (>>> 11.1.5 "Checklist: Cell area" Page 280) Procedure SAFETY INSTRUCTION 1. Create a test program in which all points to be addressed for checking the space surfaces are taught. 2. Execute the test program in T1 mode. 3. Every time there is contact with the space surface, the robot must stop and the following message must be displayed: • Cell area exceeded 4. If the robot does not stop, or if either no message or a different message is displayed, check the configuration and the test program and correct if necessary. Then execute the test program again. 7.11.3 Checking Cartesian monitoring spaces Description A Cartesian monitoring space consists of 6 space surfaces. The space surfaces can have any orientation. To check the correct configuration of a Cartesian monitoring space, at least 3 different points on each space surface must be addressed by means of a test program: • If “Stop at boundaries” is configured, the safety controller stops the robot every time there is contact with one of the space surfaces. • If “Stop at boundaries” is not configured, an alarm space can be used for the check. • Space surfaces that cannot be addressed due to circumstances in the system are excluded from the check. Fig. 7-37: Moving to space surfaces When checking a Cartesian monitoring space on a KL, the linear unit must also be moved. It must be ensured that the monitoring space moves with the linear unit and does not remain stationary. 180/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Checking the monitoring space also includes checking the following functionalities (insofar as they are configured/activated): • Space-specific velocity (>>> 7.11.5 "Checking the space-specific velocity" Page 182) • Stop if mastering test not yet done Precondition • The monitoring space to be checked is activated. • Monitoring spaces that can be activated by means of safety-oriented inputs have been deactivated. • Override reduction is deactivated: ‒ $SR_WORKSPACE_RED = FALSE ‒ $SR_VEL_RED = FALSE • T1 mode • Checklist: ‒ (>>> 11.1.6 "Checklist: Cartesian monitoring spaces" Page 282) Procedure SAFETY INSTRUCTION 1. Create a test program in which all points to be addressed for checking the space surfaces are taught. 2. Execute the test program in T1 mode. 3. Every time there is contact with the space surface, either the robot must stop or the corresponding safety-oriented output must be set via an alarm space. 4. If the robot does not stop, or if no safety-oriented output is set, check the configuration and the test program and correct if necessary. Then execute the test program again. 5. Check the active messages. With the space violation, the following messages must be displayed: • Monitoring space no. {Number of monitoring space} exceeded • Ackn.: Stop because workspace exceeded 6. If no message or different messages are displayed, check the configuration and the test program and correct if necessary. Then execute the test program again. 7.11.4 Checking axis-specific monitoring spaces Description In order to check the correct configuration of the monitoring space, the configured axis limits must be violated one after the other. • If “Stop at boundaries” is configured, the safety controller stops the robot at the axis limits. • If “Stop at boundaries” is not configured, an alarm space can be used for the check. Checking the monitoring space also includes checking the following functionalities (insofar as they are configured/activated): • Space-specific velocity (>>> 7.11.5 "Checking the space-specific velocity" Page 182) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 181/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 • Stop if mastering test not yet done Precondition • The monitoring space to be checked is activated. • Monitoring spaces that can be activated by means of safety-oriented inputs have been deactivated. • Override reduction is deactivated: ‒ $SR_WORKSPACE_RED = FALSE ‒ $SR_VEL_RED = FALSE • T1 mode • Checklist: ‒ (>>> 11.1.7 "Checklist: Axis-specific monitoring spaces" Page 284) Procedure SAFETY INSTRUCTION 1. Jog each of the axes of the monitoring space that is to be monitored to the upper and lower axis limit once using the jog keys or 6D mouse. 2. Every time there is contact with an axis limit, either the robot must stop or the corresponding safety-oriented output must be set via an alarm space. 3. If the robot does not stop, or if no safety-oriented output is set, check the configuration, correct if necessary, and check the axis limits again. 4. Check the active messages. With the space violation, the following messages must be displayed: • Monitoring space no. {Number of monitoring space} exceeded • Ackn.: Stop because workspace exceeded 5. If no message or different messages are displayed, check the configuration, correct if necessary, and check the axis limits again. 7.11.5 Checking the space-specific velocity Description For checking, the space-specific velocity limit configured for the monitoring space is deliberately exceeded by means of a test program. The safety controller then stops the robot. Precondition • The configured space-specific velocity limit is less than the maximum Cartesian velocity. • The monitoring space in which the space-specific velocity is monitored is activated. • Override reduction is deactivated: ‒ $SR_WORKSPACE_RED = FALSE ‒ $SR_VEL_RED = FALSE • T2 mode • Checklist: ‒ (>>> 11.1.6 "Checklist: Cartesian monitoring spaces" Page 282) 182/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 ‒ (>>> 11.1.7 "Checklist: Axis-specific monitoring spaces" Page 284) Work safety WARNING Failure to observe the safety measures for setup work in T2 can result in fatal injury. Additional safety requirements apply for setup work in operating mode T2. Non-compliance can result in death, serious injury or damage to property. • Before executing the test program, ensure that the enabling devices are operational. • Before executing the test program, ensure that there are no persons inside the safeguarded area. • To execute the program, position yourself outside the danger zone of the manipulator. Procedure SAFETY INSTRUCTION 1. Create a test program in which the space-specific velocity of the monitoring space is deliberately exceeded, e.g. configured with 180 mm/s, moved at 200 mm/s. 2. Execute the test program in T2 mode. The safety controller must stop the robot and the following message must be displayed: • Ackn.: Cartesian velocity in monitoring space no. {Number of monitoring space} exceeded 3. If the robot does not stop, or if either no message or a different message is displayed, check the configuration and the test program and correct if necessary. Then check the velocity limit again. 7.11.6 Checking Cartesian velocity limits Description The following Cartesian velocity limits must be checked: • Reduced Cartesian velocity in T1 mode • Safely reduced Cartesian velocity • Global maximum Cartesian velocity For checking, the values for the maximum Cartesian velocities are deliberately exceeded by means of a test program. The safety controller then stops the robot. When testing the Cartesian velocity on a KL, the linear unit must also be moved. Precondition • Override reduction for velocity limits is deactivated: ‒ $SR_VEL_RED = FALSE • Checklist: ‒ (>>> 11.1.8 "Checklist: Cartesian velocity monitoring functions" Page 288) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 183/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Work safety WARNING Failure to observe the safety measures for setup work in T2 can result in fatal injury. Additional safety requirements apply for setup work in operating mode T2. Non-compliance can result in death, serious injury or damage to property. • Before executing the test program, ensure that the enabling devices are operational. • Before executing the test program, ensure that there are no persons inside the safeguarded area. • To execute the program, position yourself outside the danger zone of the manipulator. Procedure SAFETY INSTRUCTION 1. Create a test program in which the velocity limits are deliberately exceeded with the safety-oriented TCP, e.g. configured with 1000 mm/s, moved at 1100 mm/s. When creating the test program, ensure that the TCP used in the program is identical to the safety-oriented TCP. 2. To check the reduced Cartesian velocity in T1, execute the test program in operating mode T1. The safety controller must stop the robot and the following message must be displayed: • Ackn.: Maximum Cartesian velocity in T1 mode exceeded 3. To check the reduced Cartesian velocity and the maximum Cartesian velocity, execute the test program in operating mode T2. The safety controller must stop the robot and the following message must be displayed: • If reduced Cartesian velocity exceeded: Ackn.: Safe reduced Cartesian velocity exceeded • If maximum Cartesian velocity exceeded: Ackn.: Maximum global Cartesian velocity exceeded 4. If the robot does not stop, or if either no message or a different message is displayed, check the configuration and the test program and correct if necessary. Then check the velocity limits again. 7.11.7 Checking axis-specific velocity limits Description The following axis-specific velocity limits must be checked: • Maximum axis velocity in T1 mode • Safely reduced axis velocity • Global maximum axis velocity ‒ It is only necessary to check the global maximum axis velocity if an axis must not exceed a defined velocity. For checking, the values for the maximum axis velocities are deliberately exceeded by means of a test program. The safety controller then stops the robot. 184/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Precondition • Override reduction for velocity limits is deactivated: ‒ $SR_VEL_RED = FALSE • Checklist: ‒ (>>> 11.1.9 "Checklist: axis-specific velocity monitoring functions" Page 290) Work safety WARNING Failure to observe the safety measures for setup work in T2 can result in fatal injury. Additional safety requirements apply for setup work in operating mode T2. Non-compliance can result in death, serious injury or damage to property. • Before executing the test program, ensure that the enabling devices are operational. • Before executing the test program, ensure that there are no persons inside the safeguarded area. • To execute the program, position yourself outside the danger zone of the manipulator. Procedure Checking limits for rotational axes: SAFETY INSTRUCTION 1. Create a test program in which the axis velocities are deliberately exceeded, e.g. axis A1 configured with 190°/s, moved at 200°/s. a. Calculate axis velocity $VEL_AXIS[x]. (>>> "Example calculation of $VEL_AXIS" Page 186) b. Enter the axis velocity $VEL_AXIS[x] in the test program. 2. To check the maximum axis velocity in T1, execute the test program in operating mode T1. The safety controller must stop the robot and the following message must be displayed: • Ackn.: Maximum axis-specific velocity in T1 mode exceeded 3. To check the reduced axis velocity and the global maximum axis velocity, execute the test program in operating mode T2. The safety controller must stop the robot and the following message must be displayed: • If reduced axis acceleration exceeded: Ackn.: Safe reduced axis velocity exceeded • If maximum axis acceleration exceeded: Ackn.: Maximum global axis velocity exceeded 4. If the robot does not stop, or if either no message or a different message is displayed, check the configuration and the test program and correct if necessary. Then check the velocity limits again. Checking limits for linear axes: KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 185/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 SAFETY INSTRUCTION 1. Create a test program in which the axis velocities are deliberately exceeded, e.g. linear axis configured with 1,000 mm/s, moved at 1,100 mm/s. 2. To check the maximum axis velocity in T1, execute the test program in operating mode T1. The safety controller must stop the robot and the following message must be displayed: • Ackn.: Maximum axis-specific velocity in T1 mode exceeded 3. To check the reduced axis velocity and the global maximum axis velocity, execute the test program in operating mode T2. The safety controller must stop the robot and the following message must be displayed: • If reduced axis acceleration exceeded: Ackn.: Safe reduced axis velocity exceeded • If maximum axis acceleration exceeded: Ackn.: Maximum global axis velocity exceeded 4. If the robot does not stop, or if either no message or a different message is displayed, check the configuration and the test program and correct if necessary. Then check the velocity limits again. Example calculation of $VEL_AXIS Calculate the axis velocity $VEL_AXIS[x] as follows: $VEL_AXIS[x] = (VTest / Vmax) * 100 = (200°/s / 360°/s) * 100 = 56 Element Description x Number of the axis Vtest Desired test velocity, in this example 200°/s Unit: °/s Vmax Maximum axis velocity according to the data sheet of the robot Unit: °/s Enter the calculated axis velocity $VEL_AXIS[x] in the test program: ... PTP {A1 -30} HALT $VEL_AXIS[1] = 56 PTP {A1 30} ... 7.11.8 Checking the safe operational stop for axis groups Description To check that the safe operational stop is functioning correctly, each axis of an axis group must be moved once in order to violate the safe operational stop deliberately. The safety controller then stops the robot. Precondition • T1 mode • Checklist: 186/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 ‒ (>>> 11.1.10 "Checklist: Safe operational stop for axis groups" Page 293) Procedure SAFETY INSTRUCTION 1. Activate safe operational stop for the axis group. 2. Jog the first axis in the axis group in the positive or negative direction using the jog keys or 6D mouse and with a jog override of 1%. The safety controller must stop the robot and the following messages must be displayed: • External safe operational stop violated (axis group {Number of axis group}) • Ackn.: Stop due to standstill monitoring violation 3. Deactivate safe operational stop for the axis group and reactivate it. 4. Repeat steps 2 to 3 to check further axes of the axis group. 7.11.9 Checking the values for the maximum braking ramp Description The “Braking before restricted areas” function is significantly dependent on the profile of the braking ramp of safety stop 1 DRS. The braking ramp of a drive ramp stop is linear and is defined by the maximum gradient that can be maintained when the brakes are applied at full velocity. Fig. 7-38: Braking ramp of a drive ramp stop 1 Monitoring of the braking ramp 2 Profile of the braking ramp 3 Gradient of the braking ramp v1 Velocity when drive ramp stop is triggered t1 End point of the braking ramp If the value that is stored as the maximum braking ramp is too low, i.e. the assumed braking ramp is too flat and the robot could, in theory, brake more quickly, the robot will still execute the drive ramp stop as configured. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 187/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Fig. 7-39: Braking ramp flatter than required 1 Monitoring of the braking ramp 2 Braking ramp as per configuration 3 Braking ramp that is theoretically possible If, on the other hand, the value that is stored as the maximum braking ramp is too high, i.e. the assumed braking ramp is too steep, the robot will not be able to maintain this braking ramp in reality and the stop will escalate to a safety stop 0. Fig. 7-40: Braking ramp steeper than possible in reality 1 Monitoring of the braking ramp 2 Braking ramp as per configuration 3 Braking ramp that is actually possible 4 Detection of the incorrect braking ramp, escalation to safety stop 0 Therefore, it is necessary to check that the braking ramp can be maintained in reality and that the braking ramp stored is not too steep. Precondition • “Braking before restricted areas” is activated. • At least 1 monitoring space is activated for the axis to be tested. • Override reduction for space monitoring is deactivated: ‒ $SR_WORKSPACE_RED = FALSE • T2 mode • Checklist: ‒ (>>> 11.1.11 "Checklist: Braking before restricted areas" Page 295) 188/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Work safety WARNING Failure to observe the safety measures for setup work in T2 can result in fatal injury. Additional safety requirements apply for setup work in operating mode T2. Non-compliance can result in death, serious injury or damage to property. • Before executing the test program, ensure that the enabling devices are operational. • Before executing the test program, ensure that there are no persons inside the safeguarded area. • To execute the program, position yourself outside the danger zone of the manipulator. Procedure The braking ramp must be checked for at least one axis per ramp stop group at a monitoring space. It may be necessary to check further axes (>>> 7.5.9 "Activating “Braking before restricted areas”" Page 124). For this purpose, the monitoring space is deliberately exceeded using a test program. The safety controller then stops the robot. The following monitoring spaces can be used for checking purposes: • An axis-specific monitoring space in which a limit is defined and active for each axis to be checked • A Cartesian monitoring space that is violated deliberately by the respective single-axis motion • The cell area that is violated deliberately by the respective single-axis motion KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 189/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 SAFETY INSTRUCTION 1. Create a test program in which the monitoring space of the axis to be tested is exceeded. 2. Execute the test program in T2 mode. The safety controller stops the robot. 3. Check the active messages. If a drive ramp stop is triggered by the safety controller due to an impending space violation, the following message is displayed depending on the type of space: • Ackn: Safety stop before violation of monitoring space no. {Number of monitoring space} • Ackn.: Safety stop before leaving cell area. 4. If it was not possible to maintain the braking ramp, the following message is displayed: • Ackn.: The braking ramp of the robot has been violated. This message suggests that the stored braking ramp is too steep. This may be because the machine data stored in the safety controller are not up to date. Remedy: a. Import the up-to-date machine data into the safety configuration and activate them. b. Check the braking ramp again. c. If it remains impossible to maintain the braking ramp, contact KUKA. 7.12 Checking the values for the safe axis monitoring functions Description When the safety configuration is saved, random errors can occur in the system, resulting in the safety configuration ultimately containing values that differ from those programmed by the user. This is an exceptional occurrence, but cannot be ruled out entirely. To rule out the possibility of such an error occurring for the parameters Braking time and Position tolerance, the values of these parameters must be verified in the diagnostic monitor. No other type of verification is possible for these parameters. WARNING Danger to life and limb due to failure to check “Braking time” and “Position tolerance” If this check is not carried out, the safety configuration may contain incorrect data. Death to persons, severe injuries or considerable damage to property may result. • Always check the values if the activation code on the Common tab in the Safety configuration window has changed. In other words, not only if the values themselves have been changed, but if any changes have been made that affect the safety configuration. 190/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Precondition • The values most recently saved for the parameters Braking time and Position tolerance are known. The most recently saved values can generally be found in a checklist, sign-off sheet, or similar. Procedure SAFETY INSTRUCTION The following procedure must be followed exactly! 1. In the main menu, select Diagnosis > Diagnostic monitor. The Diagnostic monitor window opens. 2. Select the Safety controller (HnfHlp) area in the Module box. Data are now displayed for this area. 3. Compare the values displayed for Braking time and Position tolerance with the most recently saved values. 4. Result: • If the values match: OK. Close the Diagnostic monitor window. No further action is necessary. • If the values do not match: Enter and save the values again. If necessary, transfer the WorkVisual project to the robot controller again. Then carry out the check again. KUKA must be contacted if the values still do not match. 7.13 Activating the safety configuration Description If the safety configuration on the robot controller has been updated (for example, via a newly deployed WorkVisual project or the restoration of an archive), the safety controller signals that the activation code of the safety configuration is incorrect. The safety maintenance technician must check the new safety configuration and is responsible for ensuring that the correct safety configuration is activated. The displayed activation code must match the expected activation code from the checklist for safety functions. (>>> 11.1.3 "Checklist: Safety functions" Page 270) The administrator is also authorized to activate the safety configuration following a prior check. They may only do so, however, if they have been specially trained for the safety configuration. The safety recovery technician requires the 8-digit activation code of the safety configuration in order to activate it. The correct activation code must be communicated by the safety maintenance technician or administrator. Precondition • User group “Safety recovery” or higher KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 191/304 Start-up and configuration KUKA.SafeOperation 3.6 Start-up and configuration KUKA.SafeOperation 3.6 Procedure 1. In the main menu, select Configuration > Safety configuration. The safety configuration checks whether there are any relevant deviations between the robot controller and the safety controller. The Troubleshooting wizard window opens. 2. A description of the problem and a list of possible causes is displayed. Select the cause from the list, e.g. restoration of an archive. 3. Press Activate to activate the updated safety configuration on the robot controller. 4. Only for the “Administrator” user group: Confirm the safety message with OK. 5. Only for user group “Safety recovery”: Enter the activation code and press Activate again. 7.14 Deactivating safe monitoring WARNING If safe monitoring is deactivated, the configured safety monitoring functions are inactive. Description The following monitoring functions are part of the standard safety configuration and always active. This means that these monitoring functions remain active when safe monitoring is deactivated: • Monitoring of the braking time • Monitoring of the maximum axis velocity in T1 • Monitoring of the axis positions during a global safe operational stop (all axes) Precondition • User group Safety Maintenance Technician or higher • T1 or T2 mode Procedure 1. 2. 3. 4. 192/304 | www.kuka.com Open the safety configuration. Press Global parameters. Remove the check mark from Safe monitoring. Click on Save and answer the request for confirmation with Yes. The robot controller is automatically reinitialized. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 8 Interfaces to the higher-level controller The robot controller can communicate with the higher-level controller via the safety-oriented I/Os of the following safety interfaces: • Ethernet safety interfaces: ‒ EtherCAT/FSoE ‒ EtherNet/IP/CIP Safety ‒ PROFINET/PROFIsafe Input and output bytes 2 … 7 are permanently assigned to the safety monitoring functions of KUKA.SafeOperation. Input and output bytes 0 … 1 are assigned to the standard safety functions. • Discrete safety interface for safety options: ‒ XG13 via IFBSafeExt The safety-oriented I/Os of the discrete safety interface only offer a reduced range of signals. If interface XG13 via IFBSafeExt is used, the relay outputs of the IFBSafe and IFBSafeExt must be checked cyclically. The checking instructions and further information about the interface can be found in the assembly instructions of the robot controller. 8.1 Safety functions via Ethernet safety interface (optional) Description The exchange of safety-relevant signals between the controller and the system is carried out via the Ethernet safety interface (e.g. PROFINET/ PROFIsafe or EtherNet/IP/CIP Safety). The assignment of the input and output states within the Ethernet safety interface protocol are listed below. In addition, non-safety-oriented information from the safety controller is sent to the non-safe section of the higher-level controller for the purpose of diagnosis and control. Reserved bits Reserved safety-oriented inputs can be pre-assigned by a PLC with the values 0 or 1. In both cases, the manipulator will move. If a safety function is assigned to a reserved input (e.g. in the case of a software update) and if this input is preset with the value 0, then the manipulator either does not move or comes unexpectedly to a standstill. KUKA recommends pre-assignment of the reserved inputs with 1. If a reserved input has a new safety function assigned to it, and the input is not used by the customer’s PLC, the safety function is not activated. This prevents the safety controller from unexpectedly stopping the manipulator. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 193/304 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 Input byte 0 Bit Signal Description 0 RES Reserved 1 The value 1 must be assigned to the input. 1 NHE Input for external Emergency Stop 0 = external E-STOP is active 1 = external E-STOP is not active 2 BS Operator safety 0 = operator safety is not active, e.g. safety gate open 1 = operator safety is active 3 QBS Acknowledgement of operator safety Precondition for acknowledgement of operator safety is the signal “Operator safety active” set in the BS bit. Note: If the “BS” signal is acknowledged by the system, this must be specified under Hardware options in the safety configuration. Information is contained in the Operating and Programming Instructions for System Integrators. 0 = operator safety has not been acknowledged Edge 0 ->1 = operator safety has been acknowledged 4 SHS1 Safety STOP 1 (all axes) • FF (motion enable) is set to 0. • Voltage US2 is switched off. • AF (drives enable) is set to 0 after configured braking time (default: 1.5 s) minus the brake closing time Cancelation of this function does not require acknowledgement. This function is not permissible for the EMERGENCY STOP function. 0 = safety stop is active 1 = safety stop is not active 5 SHS2 Safety STOP 2 (all axes) • FF (motion enable) is set to 0. • Voltage US2 is switched off. Cancelation of this function does not require acknowledgement. This function is not permissible for the EMERGENCY STOP function. 0 = safety stop is active 1 = safety stop is not active 6 194/304 | www.kuka.com RES - KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Bit Signal Description 7 RES - Bit Signal Description 0 US2 Supply voltage US2 (signal for switching the second supply voltage, US2, without battery backup) Input byte 1 If this output is not used, it should be set to 0. 0 = switch off US2 1 = switch on US2 Note: Whether and how input US2 is used must be specified under Hardware options in the safety configuration. Information is contained in the Operating and Programming Instructions for System Integrators. 1 SBH Safe operational stop (all axes) Prerequisite: All axes are stationary Cancelation of this function does not require acknowledgement. This function is not permissible for the EMERGENCY STOP function. 0 = safe operational stop is active. 1 = safe operational stop is not active. 2 RES Reserved 11 The value 1 must be assigned to the input. 3 RES Reserved 12 The value 1 must be assigned to the input. 4 RES Reserved 13 The value 1 must be assigned to the input. 5 RES Reserved 14 The value 1 must be assigned to the input. 6 RES Reserved 15 The value 1 must be assigned to the input. 7 SPA System Powerdown Acknowledge The system confirms that it has received the powerdown signal. A second after the “SP” (System Powerdown) signal has been set by the controller, the requested action is executed, without the need for confirmation from the PLC, and the controller shuts down. 0 = confirmation is not active 1 = confirmation is active KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 195/304 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 Output byte 0 Bit Signal Description 0 NHL Local E-STOP (local E-STOP triggered) 0 = local E-STOP is active 1 = local E-STOP is not active 1 AF Drives enable (the internal safety controller of the robot controller has enabled the drives so that they can be switched on) 0 = drives enable is not active (the robot controller must switch the drives off) 1 = drives enable is active (the robot controller may switch the drives to servo-control) 2 FF Motion enable (the internal safety controller of the robot controller has enabled robot motions) 0 = motion enable is not active (the robot controller must stop the current motion) 1 = motion enable is active (the robot controller may trigger a motion) 3 ZS The signal ZS (enabling) is set to 1 (active) if the following conditions are met: • One of the enabling switches on the smartPAD is in the center position (enabling signal has been issued). • T1 or T2 mode • External enabling signal has been issued (signal ZSE1). • Robot can be moved (no external EMERGENCY STOP, safety stop, etc.). 4 PE The signal “Peri enabled” is set to 1 (active) if the following conditions are met: • Drives are switched on. • Safety controller motion enable signal present. • The message “Operator safety open” must not be active. 5 AUT The manipulator is in AUT or AUT EXT mode. 0 = AUT or AUT EXT mode is not active 1 = AUT or AUT EXT mode is active 6 T1 The manipulator is in Manual Reduced Velocity mode. 0 = T1 mode is not active 1 = T1 mode is active 7 T2 The manipulator is in Manual High Velocity mode. 0 = T2 mode is not active 1 = T2 mode is active 196/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Output byte 1 Bit Signal Description 0 NHE External E-STOP has been triggered. 0 = external E-STOP is active 1 = external E-STOP is not active 1 BSQ Operator safety acknowledged 0 = operator safety is not assured 1 = operator safety is assured (input BS = 1 and, if configured, input QBS acknowledged) 2 SHS1EXT External safety STOP 1 (all axes) 0 = external safety STOP 1 is not active 1 = external safety STOP 1 is active (input SHS1 = 0, safe state reached) 3 SHS2EXT External safety STOP 2 (all axes) 0 = external safety STOP 2 is not active 1 = external safety STOP 2 is active (input SHS2 = 0, safe state reached) 4 RES Reserved 13 5 RES Reserved 14 6 PSA Safety interface active Precondition: an Ethernet interface must be installed on the controller, e.g. PROFINET or EtherNet/IP. 0 = safety interface is not active 1 = safety interface is active 7 SP System Powerdown (controller will be shut down) One second after the SP signal has been set, the PSA output is reset by the robot controller, without confirmation from the PLC, and the controller is shut down. 0 = controller on safety interface is active. 1 = controller will be shut down 8.1.1 KUKA.SafeOperation via Ethernet safety interface Description The components of the industrial robot move within the limits that have been configured and activated. The actual positions are continuously calculated and monitored against the safety parameters that have been set. The safety controller monitors the industrial robot by means of the safety parameters that have been set. If a component of the industrial robot violates a monitoring limit or a safety parameter, the manipulator and external axes (optional) are stopped. The Ethernet safety interface can be used, for example, to signal a violation of safety monitoring functions. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 197/304 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 Reserved bits Reserved safety-oriented inputs can be pre-assigned by a PLC with the values 0 or 1. In both cases, the manipulator will move. If a safety function is assigned to a reserved input (e.g. in the case of a software update) and if this input is preset with the value 0, then the manipulator either does not move or comes unexpectedly to a standstill. KUKA recommends pre-assignment of the reserved inputs with 1. If a reserved input has a new safety function assigned to it, and the input is not used by the customer’s PLC, the safety function is not activated. This prevents the safety controller from unexpectedly stopping the manipulator. Input byte 2 Bit Signal Description 0 JR Mastering test (input for reference switch) 0 = reference switch is active (actuated). 1 = reference switch is not active (not actuated). EJB External mastering confirmation (input for high pulse from higher-level controller) 0 = external mastering confirmation is not active (there is no pulse). 1 = external mastering confirmation is active (there is a pulse). The pulse must be at least 350 ms long and must not exceed 5 s. If the EJB signal switches from “logic 0” to “logic 1” and switches back to “logic 0” within the time frame, the mastering test is successfully confirmed. 1 VRED Reduced axis-specific and Cartesian velocity (activation of reduced velocity monitoring) 0 = reduced velocity monitoring is active. 1 = reduced velocity monitoring is not active. 2 … 7 SBH1 ... 6 Safe operational stop for axis group 1 ... 6 Assignment: Bit 2 = axis group 1 … bit 7 = axis group 6 Signal for safe operational stop. The function does not trigger a stop, it only activates the safe standstill monitoring. Cancelation of this function does not require acknowledgement. 0 = safe operational stop is active. 1 = safe operational stop is not active. Input byte 3 Bit Signal Description 0 … 7 RES Reserved 25 … 32 The value 1 must be assigned to the inputs. 198/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Input byte 4 Bit Signal Description 0 … 7 UER1 … 8 Monitoring spaces 1 … 8 Assignment: Bit 0 = monitoring space 1 … bit 7 = monitoring space 8 0 = monitoring space is active. 1 = monitoring space is not active. Input byte 5 Bit Signal Description 0 … 7 UER9 … 16 Monitoring spaces 9 … 16 Assignment: Bit 0 = monitoring space 9 … bit 7 = monitoring space 16 0 = monitoring space is active. 1 = monitoring space is not active. Input byte 6 Bit Signal Description 0 … 7 WZ1 … 8 Tool selection 1 … 8 Assignment: Bit 0 = tool 1 … bit 7 = tool 8 0 = tool is not active. 1 = tool is active. Exactly one tool must be selected at all times. Input byte 7 Bit Signal Description 0 … 7 WZ9 … 16 Tool selection 9 … 16 Assignment: Bit 0 = tool 9 … bit 7 = tool 16 0 = tool is not active. 1 = tool is active. Exactly one tool must be selected at all times. Output byte 2 Bit Signal Description 0 SO Activation status of the safety option 0 = safety option is not active. 1 = safety option is active 1 RR Robot referenced Mastering test display 0 = mastering is not referenced. 1 = mastering test performed successfully. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 199/304 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 Bit Signal Description 2 JF Mastering error The space monitoring is deactivated if at least one axis is not mastered. 0 = mastering error. Space monitoring has been deactivated. 1 = no error. 3 VRED Reduced axis-specific and Cartesian velocity (activation status of reduced velocity monitoring) 0 = reduced velocity monitoring is not active. 1 = reduced velocity monitoring is active. 4 … 7 SBH1 ... 4 Activation status of safe operational stop for axis group 1 ... 4 Assignment: Bit 4 = axis group 1 … bit 7 = axis group 4 0 = safe operational stop is not active. 1 = safe operational stop is active. Output byte 3 Bit Signal Description 0 … 1 SBH5 ... 6 Activation status of safe operational stop for axis group 5 ... 6 Assignment: Bit 0 = axis group 5 … bit 1 = axis group 6 0 = safe operational stop is not active. 1 = safe operational stop is active. 2 SOS Safe Operation Stop 0 = a safety function has triggered a stop. The output remains in the “0” state for at least 200 ms. 1 = none of the safety functions has triggered a stop. 3 … 7 RES Reserved 28 … 32 Bit Signal Description 0 … 7 MR1 ... 8 Alarm space 1 … 8 Output byte 4 Assignment: Bit 0 = alarm space 1 (associated monitoring space 1) … bit 7 = alarm space 8 (associated monitoring space 8) 0 = monitoring space is violated. 1 = monitoring space is not violated. Note: An inactive monitoring space is considered to be violated by default, i.e. in this case the associated safety-oriented output MRx has the state “0”. 200/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Output byte 5 Bit Signal Description 0 … 7 MR9 ... 16 Alarm space 9 … 16 Assignment: Bit 0 = alarm space 9 (associated monitoring space 9) … bit 7 = alarm space 16 (associated monitoring space 16) 0 = monitoring space is violated. 1 = monitoring space is not violated. Note: An inactive monitoring space is considered to be violated by default, i.e. in this case the associated safety-oriented output MRx has the state “0”. Output byte 6 Bit Signal Description 0 … 7 RES Reserved 49 ... 56 Bit Signal Description 0 … 7 RES Reserved 57 ... 64 Output byte 7 8.1.2 Diagnostic signals via Ethernet interface Description Some signal states are extended to ensure that they can be detected reliably. In the case of extended signal states, the minimum duration of the extension is specified in square brackets. Values are specified in milliseconds, e.g. [200]. The diagnostic signals available via the Ethernet interface are not safety-oriented signals and may only be used for diagnostic purposes. Output byte 0 Bit Signal Description 0 DG Validity for non-safety-oriented signals and data on this interface 0 = data are not valid 1 = data are valid 1 IFS Internal error in safety controller 0 = no error 1 = error [200] 2 FF Motion enable 0 = motion enable not active [200] 1 = motion enable active KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 201/304 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 Bit Signal Description 3 AF Drives enable 0 = drives enable not active [200] 1 = drives enable active 4 IBN Start-up mode Start-up mode enables jogging of the manipulator without a higher-level controller. 0 = Start-up mode is not active. 1 = Start-up mode is active. 5 US2 Peripheral voltage 0 = US2 switched off 1 = US2 switched on 6 … 7 RES Reserved Bit Signal Description 0 SO Activation status of the safety option Output byte 1 0 = safety option is not active 1 = safety option is active 1 JF Mastering error (optional) 0 = no error 1 = mastering error, space monitoring deactivated. 2 VRED Reduced velocity (optional) 0 = reduced velocity monitoring is not active. 1 = reduced velocity monitoring is active. 3 VKUE At least one Cartesian velocity limit exceeded (optional) 0 = no error 1 = velocity exceeded [200] 4 VAUE At least one axis velocity limit exceeded (optional) 0 = no error 1 = velocity exceeded [200] 5 ZBUE Cell area exceeded (optional) 0 = no error 1 = cell area exceeded [200] 6 … 7 202/304 | www.kuka.com RES Reserved KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Output byte 2 Bit Signal Description 0 SHS1EXT External safety STOP 1 (all axes) 0 = safety stop is not active. 1 = safety stop is active. 1 ESV External stop request violated Safe operational stop SBH, SBH1, SBH2 or safety stop SHS1EXT, SHS2EXT violated Braking ramp was not maintained or a monitored axis has moved. 0 = no error 1 = violated 2 SHS2EXT External safety STOP 2 (all axes) 0 = safety stop is not active. 1 = safety stop is active. 3 SBH1 Safe operational stop (axis group 1) (optional) 0 = safe operational stop is not active. 1 = safe operational stop is active. 4 SBH2 Safe operational stop (axis group 2) (optional) 0 = safe operational stop is not active. 1 = safe operational stop is active. 5 WFK Tool error (no tool) (optional) 0 = no error 1 = no tool selected. 6 WFME Tool error (more than one tool) (optional) 0 = no error 1 = more than one tool selected. 7 RES Reserved Bit Signal Description 0 JR Mastering test (optional) Output byte 3 0 = mastering test is not active 1 = mastering test is active 1 RSF Reference switch error (optional) 0 = reference switch OK 1 = reference switch defective [200] 2 JRA Mastering test request (optional) 0 = mastering test not requested 1 = mastering test requested KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 203/304 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 Bit Signal Description 3 JRF Mastering test failed (optional) 0 = mastering test OK 1 = mastering test failed 4 RS Reference stop (optional) Reference run is only possible in T1 mode. 0 = no error 1 = reference stop due to impermissible operating mode 5 RIA Referencing interval (optional) 0 = no reminder 1 = reminder interval expired [200] 6 … 7 RES Reserved Bit Signal Description 0 … 7 WZNR Tool number (8-bit word) (optional) Output byte 4 0 = error (see WFK and WFME) 1 = tool 1 2 = tool 2, etc. Output byte 5 Bit Signal Description 0 … 7 UER1 … 8 Monitoring spaces 1 … 8 (optional) Assignment: Bit 0 = monitoring space 1 … bit 7 = monitoring space 8 0 = monitoring space is not active. 1 = monitoring space is active. Output byte 6 Bit Signal Description 0 … 7 UER9 … 16 Monitoring spaces 9 … 16 (optional) Assignment: Bit 0 = monitoring space 9 … bit 7 = monitoring space 16 0 = monitoring space is not active. 1 = monitoring space is active. 204/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Output byte 7 Bit Signal Description 0 … 7 UERV1 … 8 Stop in the event of a violation of monitoring spaces 1 … 8 (optional) Assignment: Bit 0 = monitoring space 1 … bit 7 = monitoring space 8 0 = monitoring space is not violated, or monitoring space is violated but “Stop at boundaries” has not been configured. 1 = monitoring space is violated and robot stops with a safety stop [200]. Precondition: “Stop at boundaries” has been configured. Output byte 8 Bit Signal Description 0 … 7 UERV9 … 16 Stop in the event of a violation of monitoring spaces 9 … 16 (optional) Assignment: Bit 0 = monitoring space 9 … bit 7 = monitoring space 16 0 = monitoring space is not violated, or monitoring space is violated but “Stop at boundaries” has not been configured. 1 = monitoring space is violated and robot stops with a safety stop [200]. Precondition: “Stop at boundaries” has been configured. 8.2 KUKA.SafeOperation via interface XG13 Description Interface XG13 on the IFBSafeExt consists of the following connectors: • XG13.1 • XG13.2 The interface provides the following safety-oriented I/Os for KUKA.SafeOperation. If interface XG13 is used, tool 1 is always active. The tool cannot be activated via a safety-oriented input. An automated, safely monitored tool change is thus not possible. Further information about interface XG13 is contained in the assembly instructions of the robot controller. Inputs Some of the inputs have a dual function when KUKA.SafeOperation is used. They can be used either for activating the safe operational stop SBH3 … SBH6 or for the “activate via input” of the monitoring spaces UER13 … UER16. • If a monitoring space UER13 … UER16 is configured with “activate via input”, the safe operational stop assigned to the input can no longer be used. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 205/304 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 • Conversely, if a safe operational stop SBH3 … SBH6 is configured, the monitoring space assigned to the input can no longer be configured with “activate via input”. • If axes are nevertheless selected in the corresponding safe operational stop, or if a space is configured with “activate via input”, an error message is displayed during compilation. Connector Pin (channel) Signal Description XG13.1 29/19 (TA_A/IN_A) VRED Reduced axis-specific and Cartesian velocity (activation of reduced velocity monitoring) 24/34 (TA_B/IN_B) 30/20 (TA_A/IN_A) 0 = reduced velocity monitoring is active. 1 = reduced velocity monitoring is not active. UER12 0 = monitoring space is active. 25/35 (TA_B/IN_B) 1 = monitoring space is not active. UER13 Monitoring space 13 0 = monitoring space is active. 31/21 (TA_A/IN_A) 26/36 (TA_B/IN_B) Monitoring space 12 1 = monitoring space is not active. SBH3 Safe operational stop (axis group 3) 0 = safe operational stop is active. 1 = safe operational stop is not active. XG13.2 UER14 0 = monitoring space is active. 25/19 (TA_A/IN_A) 22/28 (TA_B/IN_B) Monitoring space 14 1 = monitoring space is not active. SBH4 Safe operational stop (axis group 4) 0 = safe operational stop is active. 1 = safe operational stop is not active. UER15 0 = monitoring space is active. 26/20 (TA_A/IN_A) 23/29 (TA_B/IN_B) Monitoring space 15 1 = monitoring space is not active. SBH5 Safe operational stop (axis group 5) 0 = safe operational stop is active. 1 = safe operational stop is not active. UER16 0 = monitoring space is active. 27/21 (TA_A/IN_A) 24/30 (TA_B/IN_B) Monitoring space 16 1 = monitoring space is not active. SBH6 Safe operational stop (axis group 6) 0 = safe operational stop is active. 1 = safe operational stop is not active. 206/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Connector Pin (channel) Signal Description XG13.1 32/22 (TA_A/IN_A) SBH1 Safe operational stop (axis group 1) 0 = safe operational stop is active. 27/37 (TA_B/IN_B) 33/23 (TA_A/IN_A) 1 = safe operational stop is not active. SBH2 Safe operational stop (axis group 2) 0 = safe operational stop is active. 28/38 (TA_B/IN_B) 1 = safe operational stop is not active. The signal for the safe operational stop does not trigger a stop, it only activates the safe standstill monitoring. Cancelation of this function does not require acknowledgement. Outputs An inactive monitoring space is considered to be violated by default, i.e. in this case the associated safety-oriented output MRx has the state “0”. Connector Pin (channel) Signal Description XG13.1 1/9 (TA_A/IN_A) MR1 Alarm space 1 (associated monitoring space 1) 0 = space is violated. 5/13 (TA_B/IN_B) 2/10 (TA_A/IN_A) 1 = space is not violated. MR2 0 = space is violated. 6/14 (TA_B/IN_B) 3/11 (TA_A/IN_A) 1 = space is not violated. MR3 1/9 (TA_A/IN_A) 1 = space is not violated. MR4 1 = space is not violated. MR5 1 = space is not violated. MR6 Alarm space 6 (associated monitoring space 6) 0 = space is violated. 7/15 (TA_B/IN_B) 4/12 (TA_A/IN_A) Alarm space 5 (associated monitoring space 5) 0 = space is violated. 6/14 (TA_B/IN_B) 3/11 (TA_A/IN_A) Alarm space 4 (associated monitoring space 4) 0 = space is violated. 5/13 (TA_B/IN_B) 2/10 (TA_A/IN_A) Alarm space 3 (associated monitoring space 3) 0 = space is violated. 7/15 (TA_B/IN_B) XG13.2 Alarm space 2 (associated monitoring space 2) 1 = space is not violated. SO 8/16 (TA_B/IN_B) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Activation status of the safety option 0 = safety option is not active. 1 = safety option is active www.kuka.com | 207/304 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 Interfaces to the higher-level controller KUKA.SafeOperation 3.6 Connector Pin (channel) Signal Description XG13.1 4/12 (TA_A/IN_A) RR Robot Referenced 8/16 (TA_B/IN_B) Mastering test display 0 = mastering is not referenced. 1 = mastering test performed successfully. 8.3 Mastering test via interface XG42 Interface XG42 provides a dual-channel input for the mastering test. Signal Description JR Mastering test (input for reference switch) 0 = reference switch is active (actuated). 1 = reference switch is not active (not actuated). EJB External mastering confirmation (input for high pulse from higher-level controller) 0 = external mastering confirmation is not active (there is no pulse). 1 = external mastering confirmation is active (there is a pulse). The pulse must be at least 350 ms long and must not exceed 5 s. If the EJB signal switches from “logic 0” to “logic 1” and switches back to “logic 0” within the time frame, the mastering test is successfully confirmed. 208/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 9 Diagnosis 9.1 Displaying the diagnostic data with the diagnostic monitor Description The current status of the safety-oriented inputs/outputs can be displayed in the diagnostic monitor. Precondition • User rights: Function group Diagnostic functions Procedure 1. In the main menu, select Diagnosis > Diagnostic monitor. 2. Select the Bus process data image[Name of bus/interface] module in the Module box. 9.2 Displaying the diagnostic data for the safety interface Description For advanced diagnosis of the safety-oriented inputs/outputs, the diagnostic data for the safety interface can be displayed. Precondition • The KUKA.DiagnosisSafety option package is installed. Procedure 1. In the main menu, select Diagnosis > Safety interfaces. 2. Select the desired tab, e.g. PROFIsafe. The diagnostic data are displayed. Further information about advanced diagnosis can be found in the KUKA.DiagnosisSafety documentation. 9.3 System variables for diagnosis of the safety monitoring functions 9.3.1 $SR_ACTIVETOOL Description Number of the active safety-oriented tool The variable indicates the tool that is currently active on the safety controller. Only 1 safety-oriented tool may be active at any one time. Writability The system variable is write-protected. Syntax number = $SR_ACTIVETOOL KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 209/304 Diagnosis KUKA.SafeOperation 3.6 Diagnosis KUKA.SafeOperation 3.6 Explanation of the syntax Element Description Number Type: INT Number of the active safety-oriented tool • 0: no tool or multiple tools are active. • 1 … 16: tool 1 … 16 is active. 9.3.2 $SR_AXISSPEED_OK Description State of the monitoring of the reduced axis velocity If the configured limit for reduced axis velocity is exceeded, the variable is set to FALSE for 120 ms. It is then set back to TRUE. Writability The system variable is write-protected. Syntax state = $SR_AXISSPEED_OK Explanation of the syntax Element Description state Type: BOOL TRUE = axis velocity is below the configured limit. FALSE = axis velocity limit has been exceeded. 9.3.3 $SR_CARTSPEED_OK Description State of Cartesian velocity monitoring If a Cartesian velocity limit is exceeded, the variable is set to FALSE for 120 ms. It is then set back to TRUE. Writability The system variable is write-protected. Syntax state = $SR_CARTSPEED_OK Explanation of the syntax Element Description state Type: BOOL TRUE = Cartesian velocity is below the configured limit. FALSE = Cartesian velocity limit has been exceeded. 210/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 9.3.4 Diagnosis KUKA.SafeOperation 3.6 $SR_DRIVES_ENABLE Description Drive enable status from safety controller The variable indicates whether the safety controller has enabled the drives to start up. If the drive enable is not present, i.e. if the safety-oriented output AF has a LOW level, then the variable is set to FALSE. Writability The system variable is write-protected. Syntax state = $SR_DRIVES_ENABLE Explanation of the syntax Element Description state Type: BOOL • TRUE: Drives are enabled. • FALSE: Drives are not enabled. 9.3.5 $SR_MOVE_ENABLE Description Motion enable status from safety controller The variable indicates whether the safety controller has issued the motion enable. If the motion enable is not present, i.e. if the safety-oriented output FF has a LOW level, then the variable is set to FALSE. Writability The system variable is write-protected. Syntax state = $SR_MOVE_ENABLE Explanation of the syntax Element Description state Type: BOOL • TRUE: motion enable present • FALSE: no motion enable present 9.3.6 $SR_RANGE_ACTIVE Description Activation status of monitoring spaces 1 … 16 If the safety-oriented input UER1 … UER16 has a LOW level, i.e. if the associated monitoring space has been activated via the input, the variable KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 211/304 Diagnosis KUKA.SafeOperation 3.6 is set to TRUE. If the monitoring space is configured as “always active”, the variable is always TRUE. Writability The system variable is write-protected. Syntax state = $SR_RANGE_ACTIVE[number] Explanation of the syntax Element Description state Type: BOOL Activation status of the monitoring space • TRUE = monitoring space is activated. • FALSE = monitoring space is not activated. Number Type: INT Number of monitoring space • 1 … 16 9.3.7 $SR_RANGE_OK Description Violation state of monitoring spaces 1 … 16 The variable depends on whether a stop has been configured for the monitoring space in the event of a violation: • If a stop has been configured and an active monitoring space is violated, the variable is set to FALSE. • If no stop is configured, the variable is always TRUE. Writability The system variable is write-protected. Syntax state = $SR_RANGE_OK[number] Explanation of the syntax Element Description state Type: BOOL Violation state of the monitoring space • TRUE = monitoring space is not violated. • FALSE = monitoring space has been violated and the robot has been stopped. Number Type: INT Number of monitoring space • 1 … 16 212/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 9.3.8 Diagnosis KUKA.SafeOperation 3.6 $SR_SAFEMON_ACTIVE Description State of safe monitoring The variable indicates whether safe monitoring is activated. Writability The system variable is write-protected. Syntax state = $SR_SAFEMON_ACTIVE Explanation of the syntax Element Description state Type: BOOL • TRUE = safe monitoring is activated. • FALSE = safe monitoring is deactivated. 9.3.9 $SR_SAFEOPSTOP_ACTIVE Description Activation status of the safe operational stop The variable can be used to display the activation status of the following safe operational stops. • Global safe operational stop for all axes (can be activated via input SBH) • Safe operational stop for axis group 1 … 6 (can be activated via input SBH1 … SBH6) Writability The system variable is write-protected. Syntax state = $SR_SAFEOPSTOP_ACTIVE[number] Explanation of the syntax Element Description state Type: BOOL State of the safe operational stop • TRUE = safe operational stop is activated. • FALSE = safe operational stop is not activated. Number Type: INT Number of the safe operational stop • 1: Global safe operational stop for all axes • 2 … 7: Safe operational stop for axis group 1 ... 6 KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 213/304 Diagnosis KUKA.SafeOperation 3.6 9.3.10 $SR_SAFEOPSTOP_OK Description Violation state of an externally activated safe operational stop The variable indicates whether a safe operational stop that has been activated via an input (externally) is violated. (>>> 9.3.9 "$SR_SAFEOPSTOP_ACTIVE" Page 213) Writability The system variable is write-protected. Syntax state = $SR_SAFEOPSTOP_OK Explanation of the syntax Element Description state Type: BOOL • TRUE = safe operational stop has been violated. • FALSE = no safe operational stop has been violated. 9.3.11 $SR_SAFEREDSPEED_ACTIVE Description State of the monitoring of the reduced velocity If the safety-oriented input VRED has a LOW level, i.e. if monitoring of the reduced velocity was activated via the input, then the variable is set to TRUE. Writability The system variable is write-protected. Syntax state = $SR_SAFEREDSPEED_ACTIVE Explanation of the syntax Element Description state Type: BOOL TRUE = monitoring of the reduced velocity is activated. FALSE = monitoring of the reduced velocity is not activated. 9.4 Outputs for space monitoring In the following error situations, outputs that signal a space violation likewise switch to the “violated” state (precondition: monitoring space is active): 214/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 • In the case of a Cartesian monitoring space, the Cartesian position is invalid. The Cartesian position is invalid if one of the robot axes has an invalid position. This applies in the following cases: ‒ An axis is unmastered. ‒ An encoder error has occurred. ‒ A communication error has occurred. • In the case of an axis-specific monitoring space, the position of one of the monitored axes is invalid. This applies in the following cases: ‒ An axis is unmastered. ‒ An encoder error has occurred. ‒ A communication error has occurred. • In the case of a Cartesian monitoring space, no tool is selected or several tools are selected simultaneously. Signal states in error situations: Output / variable Logic state MRx (safety-oriented outputs) 0 UERVx 1 $SR_RANGE_OK[x] 0 (FALSE) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 215/304 Diagnosis KUKA.SafeOperation 3.6 Diagnosis KUKA.SafeOperation 3.6 216/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 10 Messages 10.1 Information about the messages Messages KUKA.SafeOperation 3.6 The “Messages” chapter contains selected messages. It does not cover all the messages displayed in the message window. 10.2 System messages from module: CrossMeld (KSS) 10.2.1 KSS15016 Message code KSS15016 Message text Ackn.: Stop due to standstill monitoring violation Message type Acknowledgement message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Possible cause(s) Cause: Safe operational stop violated (>>> Page 217) Solution: Acknowledge message (>>> Page 217) Cause: Safe operational stop violated Description At least one of the axes monitored for standstill has moved outside the configured position tolerance. Solution: Acknowledge message Description The program can be resumed once the message has been acknowledged. Procedure • An acknowledgeable message can be acknowledged with OK. • All acknowledgeable messages can be acknowledged at once with All OK. 10.2.2 KSS15017 Message code KSS15017 Message text Ackn.: The braking ramp of the robot has been violated. Message type Acknowledgement message KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 217/304 Messages KUKA.SafeOperation 3.6 Effect Short-circuit braking Input of active commands (robot motions, program start) is blocked. Possible cause(s) Cause: Braking ramp for STOP 1 or safe operational stop not maintained (>>> Page 218) Solution: Acknowledge message (>>> Page 218) Cause: Braking ramp for STOP 1 or safe operational stop not maintained Description The robot controller has not triggered strong enough braking in the case of a STOP 1 or a safe operational stop. Solution: Acknowledge message Description The program can be resumed once the message has been acknowledged. Procedure • An acknowledgeable message can be acknowledged with OK. • All acknowledgeable messages can be acknowledged at once with All OK. 10.2.3 KSS15018 Message code KSS15018 Message text Ackn.: Maximum Cartesian velocity in T1 mode exceeded Message type Acknowledgement message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Possible cause(s) Cause: $SR_VEL_RED is FALSE (>>> Page 219) Solution: Change value of the variable (>>> Page 219) Cause: $SR_OV_RED set too high (>>> Page 219) Solution: Change value of the variable (>>> Page 220) Cause: Invalid drive configuration in WorkVisual (>>> Page 220) Solution: Adapt the drive configuration in WorkVisual (>>> Page 221) 218/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 KUKA.SafeOperation 3.6 Messages Cause: $SR_VEL_RED is FALSE Description The variable $SR_VEL_RED is used to activate the override reduction for monitored velocities. If override reduction is active, the velocity is automatically reduced so that the lowest currently monitored velocity limit is not exceeded. This override reduction is deactivated if the variable is FALSE. The procedure for checking the current value of the variable is as follows: Checking instructions 1. In the main menu, select Display > Variable > Single. The Variable display – Single window opens. 2. Enter the name of the variable in the Name box and confirm with the Enter key. The current value of the variable is displayed in the Current value box. Further information on override reduction is contained in the assembly and operating instructions of the safety option. Solution: Change value of the variable Description Change the value of the variable using the variable display function. Precondition User rights: • KSS: Function group General configuration • VSS: User group “User” or higher Procedure 1. In the main menu, select Display > Variable > Single. The Variable display – Single window opens. 2. Enter the variable name in the Name box and confirm with the Enter key. The current value of the variable is displayed. 3. Enter the new value in the New value box. 4. Press the Set value button. The new value is displayed in the Current value box. Cause: $SR_OV_RED set too high Description The override reduction for monitored velocities is activated ($SR_VEL_RED = TRUE), but the value of the variable $SR_OV_RED is set too high. The lower the value of $SR_OV_RED, the more a monitored velocity limit is reduced by the override reduction. The procedure for checking the current value of the variable is as follows: KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 219/304 Messages KUKA.SafeOperation 3.6 Checking instructions 1. In the main menu, select Display > Variable > Single. The Variable display – Single window opens. 2. Enter the name of the variable in the Name box and confirm with the Enter key. The current value of the variable is displayed in the Current value box. Further information on override reduction is contained in the assembly and operating instructions of the safety option. Solution: Change value of the variable Description Change the value of the variable using the variable display function. Precondition User rights: • KSS: Function group General configuration • VSS: User group “User” or higher Procedure 1. In the main menu, select Display > Variable > Single. The Variable display – Single window opens. 2. Enter the variable name in the Name box and confirm with the Enter key. The current value of the variable is displayed. 3. Enter the new value in the New value box. 4. Press the Set value button. The new value is displayed in the Current value box. Cause: Invalid drive configuration in WorkVisual Description The drive configuration in WorkVisual has been configured incorrectly. The wrong initial project has been loaded and supplied, for example. Fig. 10-1: Example for interchanged main and wrist axes 220/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 The procedure for checking whether the drive configuration is correct is as follows: Checking instructions 1. Check whether the motor connectors are correctly connected at the interface panel. 2. Check whether the plug-in connectors on the KPP, KSP, etc., are correctly connected. 3. Check whether the drive bus configuration in WorkVisual matches the hardware actually installed. Solution: Adapt the drive configuration in WorkVisual Description Configure the drive configuration correctly in WorkVisual. Procedure 1. Open and activate the current WorkVisual project. 2. Right-click on the Controller components node on the Hardware tab in the Project structure window. 3. Select Drive configuration from the context menu. The “Drive configuration” window opens. 4. Compare the configured configuration with the components actually installed. 5. Delete the incorrect connections between the modules (KPP, KSP). 6. Recreate the connections manually or select the correct solution via the WorkVisual project analysis in the bottom right-hand corner. 7. Then save the project and transfer it to the controller. 10.2.4 KSS15019 Message code KSS15019 Message text Ackn.: Maximum axis-specific velocity in T1 mode exceeded Message type Acknowledgement message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Possible cause(s) Cause: Jog override too high (>>> Page 222) Solution: Reduce the jog override (>>> Page 222) Cause: Program override too high (>>> Page 222) Solution: Reduce the program override (>>> Page 222) Cause: Maximum axis velocity in T1 incorrectly configured (>>> Page 223) Solution: Change the safety configuration (>>> Page 223) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 221/304 Messages KUKA.SafeOperation 3.6 Messages KUKA.SafeOperation 3.6 Cause: Kernel system commands excessively high velocity during force test (>>> Page 224) Solution: Adapt Maximum velocity T1 in the safety configuration (>>> Page 224) Cause: Jog override too high Description Jog override was set to an overly high value while jogging in T1 mode. For this reason, at least one axis was moving more quickly than is permitted for T1 mode. Solution: Reduce the jog override Description Reduce the jog override for jogging mode. Procedure 1. Touch the status indicator Overrides. The Overrides window opens. Fig. 10-2: Overrides status indicator 2. Set the desired jog override. It can be set using either the plus/minus keys or by means of the slider. • Plus/minus keys: The value can be set to 100%, 75%, 50%, 30%, 10%, 5%, 3%, 1%. • Slider: The override can be adjusted in 1 % steps. 3. Touch the status indicator Overrides again. (Or touch the area outside the window.) The window closes and the selected override value is applied. Alternative procedure Alternatively, the override can be set using the plus/minus key on the lower right-hand side of the smartPAD. Cause: Program override too high Description Program override was set to an overly high value during program control in T1 mode. For this reason, at least one axis was moving more quickly than is permitted for T1 mode. Solution: Reduce the program override Description Reduce the program override for program control. 222/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Procedure 1. Touch the status indicator Overrides. The Overrides window opens. Fig. 10-3: Overrides status indicator 2. Set the desired program override. It can be set using either the plus/ minus keys or by means of the slider. • Plus/minus keys: The override can be adjusted in predefined steps. • Slider: The override can be adjusted in 1% steps. 3. Touch the status indicator Overrides again. (Or touch the area outside the window.) The window closes and the selected override value is applied. Alternative procedure Alternatively, the override can be set using the plus/minus key on the lower right-hand side of the smartPAD. Cause: Maximum axis velocity in T1 incorrectly configured Description At least one axis moved more quickly than the highest permissible velocity in T1 mode. In the safety configuration, an incorrect value for the maximum axis velocity in T1 has been entered for at least one axis, for example, a value that is different to the one specified by the system integrator. The procedure for checking what values are configured is as follows: Checking instructions 1. In the main menu, select Configuration > Safety configuration. 2. Select the Axis monitoring tab. 3. For each axis, check what value is configured for the parameter Maximum velocity T1. Solution: Change the safety configuration Precondition • User group Safety Maintenance Technician or higher • T1 or T2 mode Procedure 1. In the main menu, select Configuration > Safety configuration. The safety configuration is opened. 2. Select the appropriate tab and modify the configuration as required. 3. Save safety configuration. Following a change to the safety configuration, safety acceptance must be carried out and documented by means of checklists. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 223/304 Messages KUKA.SafeOperation 3.6 Messages KUKA.SafeOperation 3.6 Further information on safety acceptance is contained in the assembly and operating instructions of the safety option. Cause: Kernel system commands excessively high velocity during force test Description The velocity of all axes is limited as standard to 250 mm/s in T1. For the force test in KUKA.ServoGun, the kernel system takes over the velocity of the weld gun after a certain point in time. Under certain circumstances (depending on the required force and transmission ratio), this may exceed 250 mm/s. For this reason, a higher value must also be configured for the parameter Maximum velocity T1 for the external axis. The procedure for checking what values are configured is as follows: Checking instructions 1. In the main menu, select Configuration > Safety configuration. 2. Select the Axis monitoring tab. 3. For each axis, check what value is configured for the parameter Maximum velocity T1. Solution: Adapt Maximum velocity T1 in the safety configuration Description Adapt the parameter Maximum velocity T1 in the safety configuration. To do so, cancel the axis coupling and restore it again after adapting the parameter. Precondition • The affected project is open. Procedure 1. Select Editors > Drive configuration in the menu bar. The Drive configuration window opens. 2. Right-click on the connecting line between the gun motor and the RDC and select Disable axis coupling. 3. Select Editors > Safety configuration (local) in the menu bar. 4. Switch to the Axis monitoring tab. 5. Adapt the value for Maximum velocity T1. 6. Return to the Safety configuration (local) window. 7. Right-click on the connecting line between the gun motor and the RDC again and select Enable axis coupling. Following a change to the safety configuration, safety acceptance must be carried out and documented by means of checklists. Further information on safety acceptance is contained in the assembly and operating instructions of the safety option. 224/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 10.2.5 Messages KUKA.SafeOperation 3.6 KSS15033 Message code KSS15033 Message text More then one tool activated in the safety controller Message type Status message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Follow-up message KSS15034 (>>> Page 225) Possible cause(s) Cause: More then one tool activated in the safety controller (>>> Page 225) Solution: Only activate the required safety-oriented tool (>>> Page 225) Cause: More then one tool activated in the safety controller Description More than one tool is activated in the safety controller. Only 1 safety-oriented tool may be active at any time Solution: Only activate the required safety-oriented tool Description Only activate the required tool via the associated safety-oriented input on the Ethernet safety interface. Procedure 1. Reset the inputs for invalid tools. 2. Specify the input for the required tool. 10.2.6 KSS15034 Message code KSS15034 Message text Ackn.: More than one tool activated in the safety controller Message type Acknowledgement message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Original message KSS15033 (>>> Page 225) Possible cause(s) Cause: Error cause of the original message has been eliminated. (>>> Page 226) Solution: Acknowledge message (>>> Page 226) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 225/304 Messages KUKA.SafeOperation 3.6 Cause: Error cause of the original message has been eliminated. Description This follow-up message is displayed if the error cause of the original message has been eliminated. Solution: Acknowledge message Description The program can be resumed once the message has been acknowledged. Procedure • An acknowledgeable message can be acknowledged with OK. • All acknowledgeable messages can be acknowledged at once with All OK. 10.2.7 KSS15035 Message code KSS15035 Message text No tool activated in safety controller Message type Status message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Follow-up message KSS15036 (>>> Page 227) Possible cause(s) Cause: No tool activated in safety controller (>>> Page 226) Solution: Activate safety-oriented tool (>>> Page 226) Cause: No tool activated in safety controller Description No tool is activated in the safety controller. Only 1 safety-oriented tool may be active at any time. If SafeRangeMonitoring is used, tool 1 must be active. Tool 1 can be activated via input WZ1 of the Ethernet safety interface. Solution: Activate safety-oriented tool Description Activate the required tool via the associated safety-oriented input on the Ethernet safety interface. Procedure • Specify the input for the required tool. 226/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 10.2.8 Messages KUKA.SafeOperation 3.6 KSS15036 Message code KSS15036 Message text Ackn.: No tool activated in safety controller Message type Acknowledgement message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Original message KSS15035 (>>> Page 226) Possible cause(s) Cause: Error cause of the original message has been eliminated. (>>> Page 227) Solution: Acknowledge message (>>> Page 227) Cause: Error cause of the original message has been eliminated. Description This follow-up message is displayed if the error cause of the original message has been eliminated. Solution: Acknowledge message Description The program can be resumed once the message has been acknowledged. Procedure • An acknowledgeable message can be acknowledged with OK. • All acknowledgeable messages can be acknowledged at once with All OK. 10.2.9 KSS15037 Message code KSS15037 Message text Cell area exceeded Message type Status message Effect No braking reaction No interlock of motions or commands Possible cause(s) Cause: Cell area exceeded (>>> Page 228) Solution: Move the robot out of the violated space: (>>> Page 228) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 227/304 Messages KUKA.SafeOperation 3.6 Cause: Cell area exceeded Description The active safety-oriented tool has left the cell area. There is a space violation. If the space is violated in T1 mode, the acknowledgement message Ackn.: Stop because workspace exceeded is additionally displayed. Solution: Move the robot out of the violated space: Description The robot must be moved out of the violated space in T1 mode. No other operating mode can be set until the robot has left the violated space. Precondition • Operating mode T1 Procedure 1. When the acknowledgement message is displayed, confirm it with OK. 2. Press and hold down the enabling switch. 3. Move the robot out of the violated space: • Using the jog keys (manual mode) • Using the Start and Start backwards keys (program mode) 10.2.10 KSS15039 Message code KSS15039 Message text Ackn.: Maximum global Cartesian velocity exceeded Message type Acknowledgement message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Possible cause(s) Cause: Global maximum Cartesian velocity incorrectly configured (>>> Page 228) Solution: Change the safety configuration (>>> Page 229) Cause: Global maximum Cartesian velocity exceeded by programming (>>> Page 229) Solution: Correct programming (>>> Page 229) Cause: Global maximum Cartesian velocity incorrectly configured Description The maximum permissible Cartesian velocity has been exceeded. 228/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 In the safety configuration, an incorrect value for the global maximum Cartesian velocity has been entered, for example, a value that is different to the one specified by the system integrator. The procedure for checking which value is configured for the parameter Cartesian maximum velocity is as follows: Checking instructions 1. In the main menu, select Configuration > Safety configuration. The safety configuration opens with the Common tab. 2. Press Global parameters. The global parameters are displayed. 3. Search for the parameter and check the value. Solution: Change the safety configuration Precondition • User group Safety Maintenance Technician or higher • T1 or T2 mode • Safe monitoring is active. Procedure 1. In the main menu, select Configuration > Safety configuration. The safety configuration is opened. 2. Select the appropriate tab and modify the configuration as required. 3. Save safety configuration. Following a change to the safety configuration, safety acceptance must be carried out and documented by means of checklists. Further information on safety acceptance is contained in the assembly and operating instructions of the safety option. Cause: Global maximum Cartesian velocity exceeded by programming Description The programmed path or programming method causes the Cartesian velocity to exceed the maximum global Cartesian velocity defined in the safety configuration. Checking instructions • Check programming. Solution: Correct programming Procedure • Correct programming Further information is contained in the documentation for the relevant software. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 229/304 Messages KUKA.SafeOperation 3.6 Messages KUKA.SafeOperation 3.6 10.2.11 KSS15040 Message code KSS15040 Message text Ackn.: Maximum global axis velocity exceeded Message type Acknowledgement message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Possible cause(s) Cause: Global maximum axis velocity incorrectly configured (>>> Page 230) Solution: Change the safety configuration (>>> Page 230) Cause: Global maximum axis velocity exceeded by programming (>>> Page 231) Solution: Correct programming (>>> Page 231) Cause: Global maximum axis velocity incorrectly configured Description At least one axis has exceeded the maximum permissible value for global axis velocity. In the safety configuration, an incorrect value for the maximum velocity for rotational axes or linear axes has been entered, for example, a value that is different to the one specified by the system integrator. The procedure for checking what values are configured is as follows: Checking instructions 1. In the main menu, select Configuration > Safety configuration. 2. Select the Axis monitoring tab. 3. Check the values of the following parameters: • Maximum velocity rotational axis • Maximum velocity translational axis Solution: Change the safety configuration Precondition • User group Safety Maintenance Technician or higher • T1 or T2 mode • Safe monitoring is active. Procedure 1. In the main menu, select Configuration > Safety configuration. The safety configuration is opened. 2. Select the appropriate tab and modify the configuration as required. 3. Save safety configuration. 230/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Following a change to the safety configuration, safety acceptance must be carried out and documented by means of checklists. Further information on safety acceptance is contained in the assembly and operating instructions of the safety option. Cause: Global maximum axis velocity exceeded by programming Description The programmed path or programming method causes at least one axis to exceed the maximum permissible global axis velocity defined in the safety configuration. Checking instructions • Check programming. Solution: Correct programming Procedure • Correct programming Further information is contained in the documentation for the relevant software. 10.2.12 KSS15041 Message code KSS15041 Message text Ackn.: Safe reduced Cartesian velocity exceeded Message type Acknowledgement message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Possible cause(s) Cause: Safe reduced Cartesian velocity incorrectly configured (>>> Page 231) Solution: Change the safety configuration (>>> Page 232) Cause: Safe reduced Cartesian velocity exceeded by programming (>>> Page 232) Solution: Correct programming (>>> Page 232) Cause: Safe reduced Cartesian velocity incorrectly configured Description The maximum permissible safe reduced Cartesian velocity has been exceeded. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 231/304 Messages KUKA.SafeOperation 3.6 KUKA.SafeOperation 3.6 Messages In the safety configuration, an incorrect value for the safe reduced Cartesian velocity has been entered, e.g. a value that is different to the one specified by the system integrator. The procedure for checking which value is configured for the parameter Reduced Cartesian velocity is as follows: Checking instructions 1. In the main menu, select Configuration > Safety configuration. The safety configuration opens with the Common tab. 2. Press Global parameters. The global parameters are displayed. 3. Search for the parameter and check the value. Solution: Change the safety configuration Precondition • User group Safety Maintenance Technician or higher • T1 or T2 mode • Safe monitoring is active. Procedure 1. In the main menu, select Configuration > Safety configuration. The safety configuration is opened. 2. Select the appropriate tab and modify the configuration as required. 3. Save safety configuration. Following a change to the safety configuration, safety acceptance must be carried out and documented by means of checklists. Further information on safety acceptance is contained in the assembly and operating instructions of the safety option. Cause: Safe reduced Cartesian velocity exceeded by programming Description The programmed path or programming method causes the Cartesian velocity to exceed the activated safe reduced Cartesian velocity defined in the safety configuration. Checking instructions • Check programming. Solution: Correct programming Procedure • Correct programming Further information is contained in the documentation for the relevant software. 232/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 10.2.13 Messages KUKA.SafeOperation 3.6 KSS15042 Message code KSS15042 Message text Ackn.: Safe reduced axis velocity exceeded Message type Acknowledgement message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Possible cause(s) Cause: Safe reduced axis velocity incorrectly configured (>>> Page 233) Solution: Change the safety configuration (>>> Page 233) Cause: Maximum value for safe reduced axis velocity exceeded by programming (>>> Page 234) Solution: Correct programming (>>> Page 234) Cause: Safe reduced axis velocity incorrectly configured Description At least one axis has exceeded the maximum permissible value for the safe reduced axis velocity. In the safety configuration, an incorrect value for the reduced axis velocity has been entered for at least one axis, for example, a value that is different to the one specified by the system integrator. The procedure for checking what values are configured is as follows: Checking instructions 1. In the main menu, select Configuration > Safety configuration. 2. Select the Axis monitoring tab. 3. For each axis, check what value is configured for the parameter Reduced velocity. Solution: Change the safety configuration Precondition • User group Safety Maintenance Technician or higher • T1 or T2 mode • Safe monitoring is active. Procedure 1. In the main menu, select Configuration > Safety configuration. The safety configuration is opened. 2. Select the appropriate tab and modify the configuration as required. 3. Save safety configuration. Following a change to the safety configuration, safety acceptance must be carried out and documented by means of checklists. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 233/304 Messages KUKA.SafeOperation 3.6 Further information on safety acceptance is contained in the assembly and operating instructions of the safety option. Cause: Maximum value for safe reduced axis velocity exceeded by programming Description The programmed path or programming method causes the maximum value for the safe reduced axis velocity defined in the safety configuration to be exceeded by at least one axis. If an override reduction is activated by $SR_VEL_RED=TRUE, but the robot moves without spline, the axis velocities are not reduced. The override reduction then only has an effect on axis velocities if spline motions are programmed. Example Axis 5 is moved into a singularity position. Axes 4 and 6 are therefore considerably accelerated and the safe reduced axis velocity is exceeded. Fig. 10-4: Wrist axis singularity Solution: Correct programming Procedure • Correct programming Further information is contained in the documentation for the relevant software. 10.2.14 KSS15043 Message code KSS15043 Message text External safe operational stop violated (axis group {Number of axis group}) 234/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Message type Status message Effect Short-circuit braking Messages KUKA.SafeOperation 3.6 Input of active commands (robot motions, program start) is blocked. Follow-up message KSS15044 (>>> Page 236) Possible cause(s) Cause: Value configured for position tolerance too low (>>> Page 235) Solution: Change the safety configuration (>>> Page 235) Cause: Axis group incorrectly configured (>>> Page 236) Solution: Change the safety configuration (>>> Page 236) Cause: Value configured for position tolerance too low Description The value configured in the safety configuration for the position tolerance of at least one axis in the axis group is too low. The values specified by the system builder must be configured. The procedure for checking what values are configured is as follows: Checking instructions 1. In the main menu, select Configuration > Safety configuration. The safety configuration opens with the Common tab. 2. Select the Axis monitoring tab and press Safe operational stop. The Safe operational stop window opens. 3. For each axis in the axis group, check whether the value entered for Position tolerance matches the specified value. Solution: Change the safety configuration Precondition • User group Safety Maintenance Technician or higher • T1 or T2 mode Procedure 1. In the main menu, select Configuration > Safety configuration. The safety configuration is opened. 2. Select the appropriate tab and modify the configuration as required. 3. Save safety configuration. Following a change to the safety configuration, safety acceptance must be carried out and documented by means of checklists. Further information on safety acceptance is contained in the assembly and operating instructions of the safety option. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 235/304 Messages KUKA.SafeOperation 3.6 Cause: Axis group incorrectly configured Description The axis group is incorrectly configured in the safety configuration, i.e. the group contains axes which are not to be monitored here. The axes specified by the system builder must be monitored. The procedure for checking whether an axis is monitored in the correct axis group is as follows: Checking instructions 1. In the main menu, select Configuration > Safety configuration. The safety configuration opens with the Common tab. 2. Select the Axis monitoring tab and press Safe operational stop. The Safe operational stop window opens. 3. Select the axis that is to be checked from the list. The check mark must be activated in the check box with the number of the axis group in which the axis is to be monitored. Solution: Change the safety configuration Precondition • User group Safety Maintenance Technician or higher • T1 or T2 mode • Safe monitoring is active. Procedure 1. In the main menu, select Configuration > Safety configuration. The safety configuration is opened. 2. Select the appropriate tab and modify the configuration as required. 3. Save safety configuration. Following a change to the safety configuration, safety acceptance must be carried out and documented by means of checklists. Further information on safety acceptance is contained in the assembly and operating instructions of the safety option. 10.2.15 KSS15044 Message code KSS15044 Message text Ackn.: External safe operational stop violated (axis group {Number of axis group}) Message type Acknowledgement message Effect Short-circuit braking Input of active commands (robot motions, program start) is blocked. Original message 236/304 | www.kuka.com KSS15043 (>>> Page 234) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Possible cause(s) Cause: Error cause of the original message has been eliminated. (>>> Page 237) Solution: Acknowledge message (>>> Page 237) Cause: Error cause of the original message has been eliminated. Description This follow-up message is displayed if the error cause of the original message has been eliminated. Solution: Acknowledge message Description The program can be resumed once the message has been acknowledged. Procedure • An acknowledgeable message can be acknowledged with OK. • All acknowledgeable messages can be acknowledged at once with All OK. 10.2.16 KSS15045 Message code KSS15045 Message text Error at mastering reference switch Message type Status message Effect No braking reaction No interlock of motions or commands Possible cause(s) Cause: Reference cable incorrectly connected (>>> Page 237) Solution: Connect cable correctly (>>> Page 238) Cause: Reference position taught incorrectly (>>> Page 238) Solution: Reteach and check the reference position (>>> Page 238) Cause: Reference switch installed incorrectly or moved (>>> Page 239) Solution: Reinstall or realign reference switch (>>> Page 239) Cause: Reference cable defective (>>> Page 239) Solution: Exchanging the reference cable (>>> Page 240) Cause: Reference cable incorrectly connected Description The reference cable connecting the reference switch to the robot controller is not correctly connected. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 237/304 Messages KUKA.SafeOperation 3.6 KUKA.SafeOperation 3.6 Messages The cabling is carried out as follows: • XS Ref (interface to the reference switch) • X42 (KR C4) or XG42 (KR C5) (interface to the robot controller) The procedure for checking whether the cable is correctly connected is as follows: Precondition • The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. • The power cable is de-energized. • Observe the ESD guidelines. Checking instructions • Check whether the connectors are correctly connected. Particular attention must be paid to: ‒ Pins pushed in ‒ Loose plug-in connections ‒ Connector on correct slot Solution: Connect cable correctly Precondition • The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. • The power cable is de-energized. • Observe the ESD guidelines. Procedure • Connect cable correctly. Cause: Reference position taught incorrectly Description The reference position to which the robot moves in the mastering test has been taught incorrectly. This results in single-channel referencing. Checking instructions 1. Move to reference position. 2. Check whether both proximity switch surfaces of the reference switch are actuated by the switching surface (actuating plate or tool). Solution: Reteach and check the reference position Description The reference position must be taught in the subprogram that is executed during the mastering test and in the safety configuration. If the reference switch is actuated by the ferromagnetic part of a tool, the correctness of the newly taught reference position must be checked. 238/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 The reference position must be taught and checked in accordance with the procedure described in the operating and assembly instructions. Cause: Reference switch installed incorrectly or moved Description The taught reference position has been addressed correctly. Single-channel mastering occurs because the reference switch has been installed in an incorrect position or has been moved. Checking instructions 1. Move to reference position. 2. Check whether both proximity switch surfaces of the reference switch are actuated by the switching surface (actuating plate or tool). Solution: Reinstall or realign reference switch Description The reference switch must installed or aligned in such a way that both proximity switch surfaces of the reference switch are actuated simultaneously when the robot is in the reference position. Fig. 10-5: Installation position of reference switch on external axis Cause: Reference cable defective Description The reference cable connecting the reference switch to the robot controller is defective. The cabling is carried out as follows: • XS Ref (interface to the reference switch) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 239/304 Messages KUKA.SafeOperation 3.6 Messages KUKA.SafeOperation 3.6 • X42 (KR C4) or XG42 (KR C5) (interface to the robot controller) The procedure for checking whether the cable is defective is as follows: Precondition • The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. • The power cable is de-energized. • Observe the ESD guidelines. Checking instructions 1. Check whether the connectors are correctly connected. Particular attention must be paid to: • Pins pushed in • Corrosion • Scorched contacts • Connector insert pushed back • Socket pushed back • Connector on correct slot 2. Check whether the cable is mechanically damaged. Causes of squashed cables or wires can include the following: • Cable straps too tight • Clips too tight • Trapped when closing a cover • Bend radius too tight 3. Check whether the cable still conducts electricity. Particular attention must be paid to: • Cross-connection of individual wires • Short-circuit of individual wires with the ground conductor • Correct wiring in accordance with circuit diagram Solution: Exchanging the reference cable NOTICE Only the reference cable supplied by KUKA may be used. Bending radius The following bending radii must be observed when installing the reference cable: • Fixed installation: At least 5 x cable diameter • Cable carrier installation: At least 10 x cable diameter Precondition • The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. • The power cable is de-energized. • Observe the ESD guidelines. 240/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Messages KUKA.SafeOperation 3.6 Procedure 1. Disconnect the defective reference cable. 2. Connect the new reference cable correctly. 3. Connect the new reference cable. 10.2.17 KSS15046 Message code KSS15046 Message text Error was at the mastering reference switch Message type Notification message Effect No braking reaction No interlock of motions or commands Possible cause(s) Cause: Notification message following elimination of state of error (>>> Page 241) Solution: System information: no operator action required (>>> Page 241) Cause: Notification message following elimination of state of error Description This notification message is displayed once the state of error has been eliminated and the associated status message has been revoked. Solution: System information: no operator action required Description This message provides system information to the operator and requires no action. 10.2.18 KSS15047 Message code KSS15047 Message text Mastering test required (internal) Message type Status message Effect No braking reaction No interlock of motions or commands KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 241/304 Messages KUKA.SafeOperation 3.6 10.2.19 KSS15048 Message code KSS15048 Message text Ackn.: Mastering test time interval expired Message type Acknowledgement message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Possible cause(s) Cause: Monitoring time elapsed (>>> Page 242) Solution: Perform mastering test and acknowledge message (>>> Page 242) Cause: Monitoring time elapsed Description Following an internal mastering test request, the robot can be moved for another 2 hours. This time has elapsed. It is possible to acknowledge the message without performing a mastering test beforehand. The robot can then be moved for another 2 hours without referenced axes (not recommended). The safety integrity of the safety functions based upon safe axis positions is limited until the mastering test has been performed and confirmed. The safety functions may behave differently from how they were configured, creating additional hazards in the system. Solution: Perform mastering test and acknowledge message Description Following a successful mastering test, the message can be acknowledged. Procedure 1. Perform mastering test. 2. Acknowledge the message with OK. 10.2.20 KSS15049 Message code KSS15049 Message text Mastering test failed Message type Status message Effect No braking reaction No interlock of motions or commands 242/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Possible cause(s) Cause: Mastering test failed (>>> Page 243) Solution: Perform mastering test and acknowledge message (>>> Page 243) Cause: Mastering test failed (>>> Page 243) Solution: Eliminate cause of error and carry out mastering test (>>> Page 243) Cause: Mastering test failed Description The mastering test has failed. The cause of the error is indicated in an additional message. Solution: Perform mastering test and acknowledge message Description Following a successful mastering test, the message can be acknowledged. Procedure 1. Perform mastering test. 2. Acknowledge the message with OK. Cause: Mastering test failed Description The mastering test has failed. The cause of the error is indicated in an additional message. Solution: Eliminate cause of error and carry out mastering test Description The error cause specified in the additional message must be eliminated and the mastering test must then be performed again. 10.2.21 KSS15050 Message code KSS15050 Message text Reference stop Message type Status message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 243/304 Messages KUKA.SafeOperation 3.6 Messages KUKA.SafeOperation 3.6 Possible cause(s) Cause: Mastering test not yet performed successfully (>>> Page 244) Solution: Perform mastering test in T1 mode (>>> Page 244) Cause: Mastering test not yet performed successfully Description The mastering test has not yet been performed successfully. The reference stop is triggered by an activated monitoring space for which the option Stop if mastering test not yet done is configured. Solution: Perform mastering test in T1 mode Description The mastering test must be performed in T1 mode. 10.2.22 KSS15051 Message code KSS15051 Message text Ackn.: Mastering test position not reached Message type Acknowledgement message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Possible cause(s) Cause: Mastering test interrupted (>>> Page 244) Solution: Acknowledge message and resume program (>>> Page 244) Cause: Mastering test interrupted Description The mastering test was interrupted before the reference position was reached: • Operating mode T1 or T2: The operator released the Start key. • AUT EXT mode: The Start signal from the higher-level controller was cancelled. Solution: Acknowledge message and resume program Description The program can be resumed once the message has been acknowledged. Procedure 1. Acknowledge the message with OK. 244/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 2. Operating mode T1 or T2: Press and hold down the Start key to resume the program. AUT EXT mode: Send the Start signal from the higher-level controller to resume the program. 10.2.23 KSS15052 Message code KSS15052 Message text Ackn.: Mastering reference switch not actuated Message type Acknowledgement message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Possible cause(s) Cause: Reference switch fouled (>>> Page 245) Solution: Clean the reference switch (>>> Page 245) Cause: Reference switch moved (>>> Page 246) Solution: Realign the reference switch (>>> Page 246) Cause: Actuating plate bent (>>> Page 246) Solution: Realign the actuating plate (>>> Page 246) Cause: Referencing with incorrectly mastered robot (>>> Page 246) Solution: Restore the mastering or remaster (>>> Page 246) Cause: Reference switch defective (>>> Page 247) Solution: Exchange the reference switch (>>> Page 247) Cause: Reference switch fouled Description The reference switch was not actuated at the reference position because the proximity switch surfaces of the reference switch are fouled. Solution: Clean the reference switch Procedure • Clean the proximity switch surfaces of the reference switch. NOTICE Do not use aggressive cleaning agents. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 245/304 Messages KUKA.SafeOperation 3.6 Messages KUKA.SafeOperation 3.6 Cause: Reference switch moved Description The taught reference position has been addressed correctly, but the reference switch not actuated. The reference switch or the device on which the reference switch is installed has been moved. Checking instructions 1. Move to reference position. 2. Check whether both proximity switch surfaces of the reference switch are actuated by the switching surface (actuating plate or tool). Solution: Realign the reference switch Description The reference switch must aligned in such a way that both proximity switch surfaces of the reference switch are actuated simultaneously when the robot is in the reference position. Cause: Actuating plate bent Description The taught reference position has been addressed correctly, but the reference switch not actuated. The actuating plate fastened to the robot flange or robot tool was bent. Checking instructions 1. Move to reference position. 2. Check whether both proximity switch surfaces of the reference switch are actuated by the actuating plate. Solution: Realign the actuating plate Description The actuating plate must be aligned so that both proximity switch surfaces of the reference switch are actuated simultaneously when the robot is in the reference position. Cause: Referencing with incorrectly mastered robot Description The reference switch was not actuated in the reference position. The reference position was not reached because the current mastering deviates from the one used to teach the reference run. Solution: Restore the mastering or remaster Description Restore the mastering with which the reference run was taught or remaster the robot. 246/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 KUKA.SafeOperation 3.6 Messages Cause: Reference switch defective Description The taught reference position has been addressed correctly, but the reference switch is defective. Solution: Exchange the reference switch Description The reference switch must be exchanged. Precondition • The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. • The power cable is de-energized. • Observe the ESD guidelines. Procedure 1. 2. 3. 4. 5. 10.2.24 Unplug the reference cable. Unscrew the reference switch. Screw on the new reference switch. Plug the reference cable into the new reference switch. Perform a mastering test in order to check whether all reference groups are referenced by the new switch. KSS15053 Message code KSS15053 Message text Ackn.: Mastering reference group no. {Number of the reference group} not referenced Message type Acknowledgement message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Possible cause(s) Cause: Reference group not taught (>>> Page 247) Solution: Teach reference group (>>> Page 248) Cause: Reference group not taught Description The reference group has not been taught. The following points must be taught for the reference group: • Motion to the reference switch • Reference position KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 247/304 Messages KUKA.SafeOperation 3.6 The reference position must additionally be taught in the safety configuration. • Motion away from the reference switch The points are taught in the following file: File Directory C:\KRC\Roboter\KRC\R1\Program File masref_user.src The file contains 2 subprograms each for reference groups 1 … 3. MASREFSTARTG1() … MASREFSTARTG3() The motion to the reference switch and the reference position are taught here. MASREFBACKG1() … MASREFBACKG3() The motion away from the reference switch is taught here. Checking instructions 1. Select the file in the Navigator and press Open. The file is displayed in the editor. 2. Check whether the points required for addressing a reference group have been taught. Solution: Teach reference group Description The points required for addressing the reference group must be taught. This activity must be carried out in accordance with the procedure described in the assembly and operating instructions. 10.2.25 KSS15054 Message code KSS15054 Message text Workspace monitoring functions deactivated (mastering error) Message type Status message Effect No braking reaction No interlock of motions or commands Possible cause(s) 248/304 | www.kuka.com Cause: Axes unmastered (>>> Page 249) Solution: Master unmastered axes (>>> Page 249) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 KUKA.SafeOperation 3.6 Messages Cause: Axes unmastered Description At least one axis is unmastered. Solution: Master unmastered axes Procedure • Remaster all unmastered axes. 10.2.26 KSS15065 Message code KSS15065 Message text Level at mastering reference switch was unexpectedly Low Message type Notification message Effect No braking reaction No interlock of motions or commands Possible cause(s) Cause: Notification message following elimination of state of error (>>> Page 249) Solution: System information: no operator action required (>>> Page 249) Cause: Notification message following elimination of state of error Description This notification message is displayed once the state of error has been eliminated and the associated status message has been revoked. Solution: System information: no operator action required Description This message provides system information to the operator and requires no action. 10.2.27 KSS15066 Message code KSS15066 Message text Level at mastering reference switch is unexpectedly "low" Message type Status message KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 249/304 Messages KUKA.SafeOperation 3.6 Effect No braking reaction No interlock of motions or commands Possible cause(s) Cause: Reference switch fouled (>>> Page 250) Solution: Clean the reference switch (>>> Page 250) Cause: Mastering test input incorrectly configured (>>> Page 250) Solution: Change the safety configuration (>>> Page 251) Cause: Reference group not taught (>>> Page 251) Solution: Teach reference group (>>> Page 252) Cause: Reference switch installed incorrectly or moved (>>> Page 252) Solution: Reinstall or realign reference switch (>>> Page 252) Cause: Reference switch defective (>>> Page 253) Solution: Exchange the reference switch (>>> Page 253) Cause: Reference switch fouled Description The reference switch was actuated for at least 5 minutes outside the mastering test because the proximity switch surfaces of the reference switch are fouled, e.g. with metal dust or weld spatter. Solution: Clean the reference switch Procedure • Clean the proximity switch surfaces of the reference switch. NOTICE Do not use aggressive cleaning agents. Cause: Mastering test input incorrectly configured Description The reference switch for the mastering test can be connected either directly to the robot controller or to a higher-level safety PLC that is linked to the robot controller via an Ethernet safety interface. The mastering test input must be configured accordingly in the safety configuration. The procedure for checking how the mastering test input is configured is as follows: Checking instructions 1. Open the safety configuration: For this, select Configuration > Safety configuration in the main menu. 2. On the Common tab, press Global parameters. 3. Check the parameter Mastering test input: 250/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 • at cabinet = reference switch is connected to the robot controller. • via bus interface = reference switch is connected via Ethernet safety interface. Solution: Change the safety configuration Precondition • User group Safety Maintenance Technician or higher • T1 or T2 mode • Safe monitoring is active. Procedure 1. In the main menu, select Configuration > Safety configuration. The safety configuration is opened. 2. Select the appropriate tab and modify the configuration as required. 3. Save safety configuration. Following a change to the safety configuration, safety acceptance must be carried out and documented by means of checklists. Further information on safety acceptance is contained in the assembly and operating instructions of the safety option. Cause: Reference group not taught Description The reference group has not been taught. The following points must be taught for the reference group: • Motion to the reference switch • Reference position The reference position must additionally be taught in the safety configuration. • Motion away from the reference switch The points are taught in the following file: File Directory C:\KRC\Roboter\KRC\R1\Program File masref_user.src The file contains 2 subprograms each for reference groups 1 … 3. MASREFSTARTG1() … MASREFSTARTG3() The motion to the reference switch and the reference position are taught here. MASREFBACKG1() … MASREFBACKG3() The motion away from the reference switch is taught here. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 251/304 Messages KUKA.SafeOperation 3.6 Messages KUKA.SafeOperation 3.6 Checking instructions 1. Select the file in the Navigator and press Open. The file is displayed in the editor. 2. Check whether the points required for addressing a reference group have been taught. Solution: Teach reference group Description The points required for addressing the reference group must be taught. This activity must be carried out in accordance with the procedure described in the assembly and operating instructions. Cause: Reference switch installed incorrectly or moved Description The reference switch was actuated outside of the mastering test for at least 5 minutes. The reference switch is installed in the wrong position or has been moved. Checking instructions 1. Move to reference position. 2. Check whether both proximity switch surfaces of the reference switch are actuated by the switching surface (actuating plate or tool). Solution: Reinstall or realign reference switch Description The reference switch must installed or aligned in such a way that both proximity switch surfaces of the reference switch are actuated simultaneously when the robot is in the reference position. 252/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Messages KUKA.SafeOperation 3.6 Fig. 10-6: Installation position of reference switch on external axis Cause: Reference switch defective Description The reference switch was actuated outside of the mastering test for at least 5 minutes. The reference switch is defective. Solution: Exchange the reference switch Description The reference switch must be exchanged. Precondition • The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. • The power cable is de-energized. • Observe the ESD guidelines. Procedure 1. 2. 3. 4. 5. Unplug the reference cable. Unscrew the reference switch. Screw on the new reference switch. Plug the reference cable into the new reference switch. Perform a mastering test in order to check whether all reference groups are referenced by the new switch. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 253/304 Messages KUKA.SafeOperation 3.6 10.2.28 KSS15079 Message code KSS15079 Message text Monitoring space no. {Number of monitoring space} violated Message type Status message Effect No braking reaction No interlock of motions or commands Possible cause(s) Cause: Monitoring space violated in T1 or T2 (>>> Page 254) Solution: Move the robot out of the violated space: (>>> Page 254) Cause: Monitoring space violated in T1 or T2 Description The monitoring space has been violated in T1 or T2 mode. The active safety-oriented tool, or at least one of the robot axes, is no longer situated in the permissible range of the monitoring space. If the space is violated in T1 mode, the acknowledgement message Ackn.: Stop because workspace exceeded is additionally displayed. The monitoring space is considered to have been violated if the monitoring was only activated after the robot had moved over the space limit. The permissible range depends on the type of monitoring space: Space type Workspace Protected space Cartesian space The active safety-oriented tool must move within the limits of the monitoring space. The active safety-oriented tool must move outside the limits of the monitoring space. The space is violated if the safetyoriented tool leaves the monitoring space. The space is violated if the safetyoriented tool enters the monitoring space. The axes must move within the limits of the monitoring space. The axes must move outside the limits of the monitoring space. The space is violated if the axes leave the monitoring space. The space is violated if the axes enter the monitoring space. Axis space Solution: Move the robot out of the violated space: Description The robot must be moved out of the violated space in T1 mode. No other operating mode can be set until the robot has left the violated space. Precondition • Operating mode T1 Procedure 1. When the acknowledgement message is displayed, confirm it with OK. 2. Press and hold down the enabling switch. 254/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 3. Move the robot out of the violated space: • Using the jog keys (manual mode) • Using the Start and Start backwards keys (program mode) 10.2.29 KSS15081 Message code KSS15081 Message text Monitoring space no. {Number of monitoring space} exceeded Message type Status message Effect No braking reaction No interlock of motions or commands Possible cause(s) Cause: Monitoring space exceeded in T1 or T2 (>>> Page 255) Solution: Move the robot out of the violated space: (>>> Page 255) Cause: Monitoring space exceeded in T1 or T2 Description The monitoring space has been exceeded in T1 or T2 mode. The active safe tool, or at least one of the robot axes, is no longer situated in the permissible range of the monitoring space. If the space is exceeded in T1 mode, the acknowledgment message Ackn.: Stop because workspace exceeded is also displayed. The monitoring space is considered to have been exceeded if the monitoring was already activated when the robot moved over the space limit. The permissible range depends on the type of monitoring space: Space type Workspace Protected space Cartesian space The active safe tool must move within the limits of the monitoring space. The active safe tool must move outside the limits of the monitoring space. The space is exceeded if the safe tool leaves the monitoring space. The space is exceeded if the safe tool enters the monitoring space. The axes must move within the limits of the monitoring space. The axes must move outside the limits of the monitoring space. The space is exceeded if the axes leave the monitoring space. The space is exceeded if the axes enter the monitoring space. Axis space Solution: Move the robot out of the violated space: Description The robot must be moved out of the violated space in T1 mode. No other operating mode can be set until the robot has left the violated space. Precondition • Operating mode T1 KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 255/304 Messages KUKA.SafeOperation 3.6 Messages KUKA.SafeOperation 3.6 Procedure 1. When the acknowledgement message is displayed, confirm it with OK. 2. Press and hold down the enabling switch. 3. Move the robot out of the violated space: • Using the jog keys (manual mode) • Using the Start and Start backwards keys (program mode) 10.2.30 KSS15083 Message code KSS15083 Message text Ackn.: Cartesian velocity in monitoring space no. {Number of monitoring space} exceeded Message type Acknowledgement message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. 10.2.31 KSS15107 Message code KSS15107 Message text Error at the mastering confirmation input Message type Status message Effect No braking reaction No interlock of motions or commands Possible cause(s) Cause: Reference cable incorrectly connected (>>> Page 256) Solution: Connect cable correctly (>>> Page 257) Cause: Reference cable defective (>>> Page 257) Solution: Exchanging the reference cable (>>> Page 258) Cause: Reference cable incorrectly connected Description The referencing system is connected to interface X42 (KR C4) or XG42 (KR C5) on the robot controller via the reference cable. The procedure for checking whether the cable is correctly connected is as follows: Precondition • The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. 256/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 • The higher-level controller and the connected referencing system are switched off and secured against being switched on again. • The power cable is de-energized. • Observe the ESD guidelines. Checking instructions • Check whether the connectors are correctly connected. Particular attention must be paid to: ‒ Pins pushed in ‒ Loose plug-in connections ‒ Connector on correct slot Solution: Connect cable correctly Precondition • The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. • The power cable is de-energized. • Observe the ESD guidelines. Procedure • Connect cable correctly. Cause: Reference cable defective Description The referencing system is connected to interface X42 (KR C4) or XG42 (KR C5) on the robot controller via the reference cable. The procedure for checking whether the cable is defective is as follows: Precondition • The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. • The higher-level controller and the connected referencing system are switched off and secured against being switched on again. • The power cable is de-energized. • Observe the ESD guidelines. Checking instructions 1. Check whether the connectors are correctly connected. Particular attention must be paid to: • • • • • • Pins pushed in Corrosion Scorched contacts Connector insert pushed back Socket pushed back Connector on correct slot KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 257/304 Messages KUKA.SafeOperation 3.6 Messages KUKA.SafeOperation 3.6 2. Check whether the cable is mechanically damaged. Causes of squashed cables or wires can include the following: • Cable straps too tight • Clips too tight • Trapped when closing a cover • Bend radius too tight 3. Check whether the cable still conducts electricity. Particular attention must be paid to: • Cross-connection of individual wires • Short-circuit of individual wires with the ground conductor • Correct wiring in accordance with circuit diagram Solution: Exchanging the reference cable NOTICE Only the reference cable supplied by KUKA may be used. Bending radius The following bending radii must be observed when installing the reference cable: • Fixed installation: At least 5 x cable diameter • Cable carrier installation: At least 10 x cable diameter Precondition • The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. • The higher-level controller and the connected referencing system are switched off and secured against being switched on again. • The power cable is de-energized. • Observe the ESD guidelines. Procedure 1. Disconnect the defective reference cable. 2. Connect the new reference cable correctly. 3. Connect the new reference cable. 10.2.32 KSS15108 Message code KSS15108 Message text Error was at the mastering confirmation input Message type Notification message Effect No braking reaction No interlock of motions or commands 258/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Possible cause(s) Cause: Notification message following elimination of state of error (>>> Page 259) Solution: System information: no operator action required (>>> Page 259) Cause: Notification message following elimination of state of error Description This notification message is displayed once the state of error has been eliminated and the associated status message has been revoked. Solution: System information: no operator action required Description This message provides system information to the operator and requires no action. 10.2.33 KSS15109 Message code KSS15109 Message text Level at mastering confirmation input is unexpectedly high Message type Status message Effect No braking reaction No interlock of motions or commands Possible cause(s) Cause: Input EJB is set to the wrong state (>>> Page 259) Solution: Eliminate the error in the program of the higher-level controller (>>> Page 260) Cause: Reference cable wired incorrectly (>>> Page 260) Solution: Wire the reference cable correctly (>>> Page 261) Cause: Input EJB is set to the wrong state Description If a mastering test is requested, for example after rebooting the robot controller, and input EJB goes into the state “logic 1”, no external mastering confirmation is possible. Input EJB is set to the wrong state. The error lies in the higher-level controller program that is used to address input EJB. Input EJB must be in the state “logic 0” in order to confirm mastering via a positive pulse signal. The procedure for checking the level at input EJB is as follows: Checking instructions 1. In the main menu, select Diagnosis > Diagnostic monitor. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 259/304 Messages KUKA.SafeOperation 3.6 Messages KUKA.SafeOperation 3.6 2. In the Module box, select the device, i.e. the interface via which the pulse signal for external mastering confirmation is provided. To do so, select the entry Device (Device name). The diagnostic data for the device are displayed. The device name displayed in the entry depends on the configuration in WorkVisual. The default name of the device can be changed in WorkVisual. 3. Search for the entry E: Mastering confirmation (EJB) in the diagnostic data: • confirmed: Input EJB is in the state “logic 1” • not confirmed: Input EJB is in the state “logic 0” Solution: Eliminate the error in the program of the higher-level controller Description The error must be eliminated in the higher-level controller program that is used to address input EJB. Information on the external mastering confirmation and the signals relevant to the connection of the higher-level controller can be found in the assembly and operating instructions of the safety option. Procedure • Eliminate the error in the program. Cause: Reference cable wired incorrectly Description If a mastering test is requested, e.g. after rebooting the robot controller, and input EJB goes into the state “logic 1”, no external mastering confirmation is possible. Interface X42 (KR C4) or XG42 (KR C5), via which the pulse signal is provided, is incorrectly wired. Input EJB must be in the state “logic 0” in order to confirm mastering via a positive pulse signal. The procedure for checking the level at input EJB is as follows: Checking instructions 1. In the main menu, select Diagnosis > Diagnostic monitor. 2. In the Module box, select the device, i.e. the interface via which the pulse signal for external mastering confirmation is provided. To do so, select the entry Device (Device name). The diagnostic data for the device are displayed. The device name displayed in the entry depends on the configuration in WorkVisual. The default name of the device can be changed in WorkVisual. 3. Search for the entry E: Mastering confirmation (EJB) in the diagnostic data: • confirmed: Input EJB is in the state “logic 1” • not confirmed: Input EJB is in the state “logic 0” 260/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 KUKA.SafeOperation 3.6 Messages Solution: Wire the reference cable correctly Procedure • Wire the reference cable to X42 (KR C4) or XG42 (KR C5) in accordance with the circuit diagram. 10.2.34 KSS15110 Message code KSS15110 Message text Level at mastering confirmation input was unexpectedly High Message type Notification message Effect No braking reaction No interlock of motions or commands Possible cause(s) Cause: Notification message following elimination of state of error (>>> Page 261) Solution: System information: no operator action required (>>> Page 261) Cause: Notification message following elimination of state of error Description This notification message is displayed once the state of error has been eliminated and the associated status message has been revoked. Solution: System information: no operator action required Description This message provides system information to the operator and requires no action. 10.2.35 KSS15111 Message code KSS15111 Message text Pulse time monitoring of mastering confirmation violated Message type Status message Effect No braking reaction No interlock of motions or commands Possible cause(s) Cause: Pulse signal at input EJB too long (>>> Page 262) Solution: Eliminate the error in the program of the higher-level controller (>>> Page 262) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 261/304 Messages KUKA.SafeOperation 3.6 Cause: Pulse signal at input EJB too long Description The higher-level controller confirmed a successful mastering test with a positive pulse signal at input EJB. Because the pulse signal lasted longer than 5 s at input EJB, the external mastering confirmation failed. The pulse duration is incorrectly programmed in the higher-level controller program that is used to address input EJB. The pulse must be at least 350 ms long and must not exceed 5 s. If the EJB signal switches from “logic 0” to “logic 1” and switches back to “logic 0” within the time frame, the mastering test is successfully confirmed. Solution: Eliminate the error in the program of the higher-level controller Description The error must be eliminated in the higher-level controller program that is used to address input EJB. Information on the external mastering confirmation and the signals relevant to the connection of the higher-level controller can be found in the assembly and operating instructions of the safety option. Procedure • Eliminate the error in the program. 10.2.36 KSS15112 Message code KSS15112 Message text Pulse time monitoring of mastering confirmation violated Message type Notification message Effect No braking reaction No interlock of motions or commands Possible cause(s) Cause: Notification message following elimination of state of error (>>> Page 262) Solution: System information: no operator action required (>>> Page 263) Cause: Notification message following elimination of state of error Description This notification message is displayed once the state of error has been eliminated and the associated status message has been revoked. 262/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 KUKA.SafeOperation 3.6 Messages Solution: System information: no operator action required Description This message provides system information to the operator and requires no action. 10.2.37 KSS15113 Message code KSS15113 Message text Mastering without reference request confirmed Message type Status message Effect No braking reaction No interlock of motions or commands Possible cause(s) Cause: Pulse signal at input EJB toggles continuously (>>> Page 263) Solution: Eliminate the error in the program of the higher-level controller (>>> Page 264) Cause: Reference cable incorrectly connected (>>> Page 264) Solution: Connect cable correctly (>>> Page 264) Cause: Pulse signal at input EJB toggles continuously Description The higher-level controller confirmed a successful mastering test with a positive pulse signal at input EJB, even though no mastering test was requested. The error lies in the higher-level controller program that is used to address input EJB. The pulse signal may be toggling continuously. The procedure for checking the level at input EJB is as follows: Checking instructions 1. In the main menu, select Diagnosis > Diagnostic monitor. 2. In the Module box, select the device, i.e. the interface via which the pulse signal for external mastering confirmation is provided. To do so, select the entry Device (Device name). The diagnostic data for the device are displayed. The device name displayed in the entry depends on the configuration in WorkVisual. The default name of the device can be changed in WorkVisual. 3. Search for the entry E: Mastering confirmation (EJB) in the diagnostic data: • confirmed: Input EJB is in the state “logic 1” • not confirmed: Input EJB is in the state “logic 0” KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 263/304 Messages KUKA.SafeOperation 3.6 Solution: Eliminate the error in the program of the higher-level controller Description The error must be eliminated in the higher-level controller program that is used to address input EJB. Information on the external mastering confirmation and the signals relevant to the connection of the higher-level controller can be found in the assembly and operating instructions of the safety option. Procedure • Eliminate the error in the program. Cause: Reference cable incorrectly connected Description The higher-level controller confirmed a successful mastering test with a positive pulse signal at input EJB, even though no mastering test was requested. The reference cable is not correctly connected to interface X42 (KR C4) or XG42 (KR C5) of the robot controller, via which the pulse signal is provided. There may be a loose connection. The procedure for checking whether the cable is correctly connected is as follows: Precondition • The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. • The higher-level controller and the connected referencing system are switched off and secured against being switched on again. • The power cable is de-energized. • Observe the ESD guidelines. Checking instructions • Check whether the connectors are correctly connected. Particular attention must be paid to: ‒ Pins pushed in ‒ Loose plug-in connections ‒ Connector on correct slot Solution: Connect cable correctly Precondition • The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. • The power cable is de-energized. • Observe the ESD guidelines. Procedure • Connect cable correctly. 264/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 10.2.38 Messages KUKA.SafeOperation 3.6 KSS15114 Message code KSS15114 Message text Mastering confirmed without reference request Message type Notification message Effect No braking reaction No interlock of motions or commands Possible cause(s) Cause: Notification message following elimination of state of error (>>> Page 265) Solution: System information: no operator action required (>>> Page 265) Cause: Notification message following elimination of state of error Description This notification message is displayed once the state of error has been eliminated and the associated status message has been revoked. Solution: System information: no operator action required Description This message provides system information to the operator and requires no action. 10.2.39 KSS15127 Message code KSS15127 Message text Ackn.: Stop because workspace exceeded Message type Acknowledgement message Effect Ramp stop Input of active commands (robot motions, program start) is blocked. Possible cause(s) Cause: Monitoring space violated or exceeded in T1 (>>> Page 266) Solution: Acknowledge the message and move the robot out of the violated space (>>> Page 266) Cause: Impending violation or exceeding of monitoring space in T1 mode (>>> Page 266) Solution: Acknowledge message and move robot away from workspace limit (>>> Page 266) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 265/304 Messages KUKA.SafeOperation 3.6 Cause: Monitoring space violated or exceeded in T1 Description The active safety-oriented tool or an axis position has violated or exceeded a monitoring space in T1 mode. A status message additionally indicates the affected space. Solution: Acknowledge the message and move the robot out of the violated space Description The robot must be moved out of the violated space in T1 mode. This is only possible once the message has been acknowledged. Precondition • Operating mode T1 Procedure 1. Acknowledge the message with OK. 2. Press and hold down the enabling switch. 3. Move the robot in the desired direction: • Using the jog keys (manual mode) • Using the Start and Start backwards keys (program mode) Cause: Impending violation or exceeding of monitoring space in T1 mode Description The active safety-oriented tool or an axis position threatened to violate or exceed a monitoring space in T1 mode. It was possible to stop the robot before it reached the space limit because the “Braking before restricted areas” function is active. Solution: Acknowledge message and move robot away from workspace limit Description The robot must be moved away from the workspace limit in T1 mode. This is only possible once the message has been acknowledged. Precondition • Operating mode T1 Procedure 1. Acknowledge the message with OK. 2. Press and hold down the enabling switch. 3. Move the robot in the desired direction: • Using the jog keys (manual mode) • Using the Start and Start backwards keys (program mode) 266/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 10.2.40 Messages KUKA.SafeOperation 3.6 KSS15134 Message code KSS15134 Message text Ackn: Safety stop before violation of monitoring space no. {Number of monitoring space} Message type Acknowledgement message Effect Maximum braking; the drives are switched off at standstill. Input of active commands (robot motions, program start) is blocked. Possible cause(s) Cause: Impending violation or exceeding of monitoring space in T2, AUT or AUT EXT mode (>>> Page 267) Solution: Acknowledge message and move robot away from workspace limit (>>> Page 267) Cause: Impending violation or exceeding of monitoring space in T2, AUT or AUT EXT mode Description The active safety-oriented tool or an axis position threatened to violate or exceed a monitoring space in T2, AUT or AUT EXT mode. The robot was stopped for this reason. Solution: Acknowledge message and move robot away from workspace limit Description The robot must be moved away from the workspace limit in T1 mode. This is only possible once the message has been acknowledged. Precondition • Operating mode T1 Procedure 1. Acknowledge the message with OK. 2. Press and hold down the enabling switch. 3. Move the robot in the desired direction: • Using the jog keys (manual mode) • Using the Start and Start backwards keys (program mode) 10.2.41 KSS15135 Message code KSS15135 Message text Ackn.: Safety stop before leaving cell area. Message type Acknowledgement message KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 267/304 Messages KUKA.SafeOperation 3.6 Effect Maximum braking; the drives are switched off at standstill. Input of active commands (robot motions, program start) is blocked. Possible cause(s) Cause: Impending violation of cell area limits (>>> Page 268) Solution: Acknowledge message and move robot away from area limit (>>> Page 268) Cause: Impending violation of cell area limits Description The active safety-oriented tool threatened to exceed the cell area limits. The robot was stopped for this reason. Solution: Acknowledge message and move robot away from area limit Description The robot must be moved away from the area limit in T1 mode. This is only possible once the message has been acknowledged. Precondition • Operating mode T1 Procedure 1. Acknowledge the message with OK. 2. Press and hold down the enabling switch. 3. Move the robot in the desired direction: • Using the jog keys (manual mode) • Using the Start and Start backwards keys (program mode) 268/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 11 Appendix 11.1 Checklists for safety acceptance Appendix KUKA.SafeOperation 3.6 The checklists here serve merely as examples of checklists for safety acceptance. It is permissible to carry out and document safety acceptance using user-specific checklists. 11.1.1 Precondition for safety acceptance based on the checklists • Mechanical and electrical installation of the industrial robot have been completed. • Safety configuration is completed. • The safety maintenance technician is trained. (Training course at KUKA College) The system integrator is responsible for the design of the cell. The safety maintenance technician uses the values and configurations supplied by the system integrator to configure the robot and tests whether the safety functions work as specified. The safety maintenance technician does not perform a safety assessment of the system. 11.1.2 Checklist: Robot and system The inspection items of this checklist must be completed and confirmed in writing by the system integrator. Checklist • Serial number of the robot: ____________________ • Serial number of the robot controller: ____________________ • Name of system integrator: ____________________ No. Inspection item 1 The industrial robot is in flawless mechanical condition and correctly installed and fastened in accordance with the assembly or operating instructions of the robot. 2 The permissible rated payload of the robot has not been exceeded. 3 There are no foreign bodies or defective or loose parts on the industrial robot. 4 All safety equipment required for the system and robot is correctly installed and operational. 5 The power supply ratings of the industrial robot correspond to the local supply voltage and mains type, and the machine data correspond to these. 6 The connecting cables are correctly connected and the connectors are locked. 7 The ground conductor and the equipotential bonding cable are sufficiently rated and correctly connected. 8 The system meets all the relevant laws, regulations and norms valid for the installation site. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 OK www.kuka.com | 269/304 Appendix KUKA.SafeOperation 3.6 Remarks / deviations By signing, the signatory confirms the correct and complete performance of the safety acceptance test. ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature 11.1.3 Checklist: Safety functions The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician. Checklist • Serial number of the robot: ____________________ • Serial number of the robot controller: ____________________ • Safety configuration: ‒ Activation code: ____________________ ‒ Last changed (date, time): ____________________ ‒ Version: ____________________ • Mastering test type (reference switch / external confirmation): ____________________ • Name of safety maintenance technician: ____________________ No. Inspection item 1 Safe monitoring is activated. 2 Robot is mastered. 3 If simulated axes are used: OK Not relevant The safe Cartesian monitoring has been activated or deactivated according to the requirements and, if applicable, in accordance with a hazard assessment. (>>> 7.5.2.1 "Switching safe Cartesian monitoring on/off" Page 99) 4 Is the “Braking before restricted areas” function activated? 5 The machine data have been checked and are appropriate for the robot used. (>>> 3.12.4.1 "Checking machine data and safety configuration" Page 59) The machine data loaded must match the machine data on the identification plate of the robot. 270/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 No. Inspection item 6 The machine data of the external axes have been correctly entered and checked. OK Not relevant Checking instructions: • Move each external axis a defined distance by means of a PTP_REL motion, e.g. 90°. Carry out a visual inspection and check whether this distance is covered. • In the case of a KL, move the external axis a defined distance by means of a PTP_REL motion, e.g. 500 mm. Carry out a visual inspection and additionally monitor the display of the Cartesian actual position to check whether this distance is covered. 7 The local and external safety functions have been checked and are functioning correctly. (>>> 3.6.1 "Overview of the safety functions" Page 42) (>>> 3.12.4 "Start-up and recommissioning: KSS/VSS" Page 57) 8 The reference switch is firmly and stably mounted on the mounting fixture. (>>> 7.7.1.3 "Installing the reference switch and actuating plate" Page 137) 9 The actuating plate is firmly and stably mounted on the robot flange or tool. (>>> 7.7.1.3 "Installing the reference switch and actuating plate" Page 137) 10 The reference position has been taught in both the mastering test program and in the safety configuration. 11 The correctness of the reference position has been checked. (>>> 7.7.1.7 "Checking the reference position (actuation with tool)" Page 142) 12 Was the mastering test successful? 13 Was the brake test successful? Note: These checks only need to be made if the brake test is active. The checks only need to be made for the axes that need to be tested by means of a brake test in accordance with a hazard assessment. Axis A1 Axis A2 Axis A3 Axis A4 Axis A5 Axis A6 External axes 14 Operator safety acknowledgement has been checked and is functioning correctly. (>>> 3.6.3 "“Operator safety” signal: KSS" Page 43) (>>> 3.6.4 "“Operator safety” signal: VSS" Page 44) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 271/304 Appendix KUKA.SafeOperation 3.6 Appendix KUKA.SafeOperation 3.6 No. Inspection item OK 15 Peripheral contactor (US2) has been checked and switches at the right time. Not relevant Note: Further information about checking the peripheral contactor is contained in the assembly instructions of the robot controller. 16 Have the Cartesian and axis-specific velocities been configured correctly and checked? The corresponding checklists must be completed and confirmed in writing for the Cartesian and axis-specific velocity monitoring functions. (>>> 11.1.8 "Checklist: Cartesian velocity monitoring functions" Page 288) (>>> 11.1.9 "Checklist: axis-specific velocity monitoring functions" Page 290) 17 Has the correct configuration of the safe operational stop been checked by moving all axes? Each axis in an axis group must be tested individually. The corresponding checklist must be completed and confirmed in writing for every axis group. (>>> 11.1.10 "Checklist: Safe operational stop for axis groups" Page 293) 18 The values for the parameters Braking time and Position tolerance have been checked in the diagnostic monitor and correctly saved. (>>> 7.12 "Checking the values for the safe axis monitoring functions" Page 190) 19 Has the correct configuration of the cell area been checked by moving to all reachable limits? The corresponding checklist must be completed and confirmed in writing for the cell area. (>>> 11.1.5 "Checklist: Cell area" Page 280) 272/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 No. Inspection item 20 Has the correct configuration of the monitoring spaces used been checked by moving to all reachable limits with a safety-oriented tool? OK Not relevant Each space surface of a Cartesian monitoring space must be addressed at 3 different points. The axis of an axis-specific monitoring space must be moved to the upper and lower limits of the space. The corresponding checklist must be completed and confirmed in writing for each monitoring space used. (>>> 11.1.6 "Checklist: Cartesian monitoring spaces" Page 282) (>>> 11.1.7 "Checklist: Axis-specific monitoring spaces" Page 284) Monitoring space 1 Monitoring space 2 Monitoring space 3 Monitoring space 4 Monitoring space 5 Monitoring space 6 Monitoring space 7 Monitoring space 8 Monitoring space 9 Monitoring space 10 Monitoring space 11 Monitoring space 12 Monitoring space 13 Monitoring space 14 Monitoring space 15 Monitoring space 16 21 Have the values stored for the maximum braking ramp for the “Braking before restricted areas” function been checked? (>>> 11.1.11 "Checklist: Braking before restricted areas" Page 295) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 273/304 Appendix KUKA.SafeOperation 3.6 Appendix KUKA.SafeOperation 3.6 No. Inspection item OK 22 Have the safety-oriented tools used been configured correctly and checked? Not relevant At least one monitoring space and one velocity must be checked with each safety-oriented tool. The corresponding checklist must be completed and confirmed in writing for each safety-oriented tool used. (>>> 11.1.4 "Checklist: Safety-oriented tools" Page 275) Tool 1 Tool 2 Tool 3 Tool 4 Tool 5 Tool 6 Tool 7 Tool 8 Tool 9 Tool 10 Tool 11 Tool 12 Tool 13 Tool 14 Tool 15 Tool 16 23 If an existing safety configuration has been changed: A change log has been created and checked. (>>> 6.6 "Displaying the revision log" Page 84) Remarks / deviations : Must be checked by system integrator By signing, the signatory confirms the correct and complete performance of the safety acceptance test. ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature 274/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 11.1.4 Checklist: Safety-oriented tools The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician. A separate checklist must be completed for each safety-oriented tool. Description A monitoring space must be violated by each configured sphere to demonstrate the correct functioning of the safety-oriented tool. Precondition • Override reduction is deactivated: ‒ $SR_WORKSPACE_RED = FALSE ‒ $SR_VEL_RED = FALSE Checklist • Serial number of the robot: _________________ • Serial number of the robot controller: ____________________ • Safety configuration: ‒ Activation code: ____________________ ‒ Last changed (date, time): ____________________ ‒ Version: ____________________ • Safety-oriented tool checked (name, number): _______________ • Monitoring space used in sphere test (name, number): ________________ • Name of safety maintenance technician: ____________________ Specified value: • Value specified by cell planner, design engineer Configured value: • Value entered in the safety configuration No. Inspection item 1 Safety-oriented TCP of the tool OK Not relevant The X, Y and Z coordinates of the safety-oriented TCP are correctly configured and checked. TCP X (specified value): __________ mm TCP X (configured value): __________ mm TCP Y (specified value): __________ mm TCP Y (configured value): __________ mm TCP Z (specified value): __________ mm TCP Z (configured value): __________ mm KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 275/304 Appendix KUKA.SafeOperation 3.6 Appendix KUKA.SafeOperation 3.6 No. Inspection item 2 1. sphere on tool OK Not relevant The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm Radius (configured value): __________ mm 3 2. sphere on tool The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm Radius (configured value): __________ mm 4 3. sphere on tool The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm Radius (configured value): __________ mm 276/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 No. Inspection item 5 4. sphere on tool OK Not relevant The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm Radius (configured value): __________ mm 6 5. sphere on tool The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm Radius (configured value): __________ mm 7 6. sphere on tool The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm Radius (configured value): __________ mm KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 277/304 Appendix KUKA.SafeOperation 3.6 Appendix KUKA.SafeOperation 3.6 No. Inspection item 8 7. sphere on tool OK Not relevant The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm Radius (configured value): __________ mm 9 8. sphere on tool The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm Radius (configured value): __________ mm 10 9. sphere on tool The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm Radius (configured value): __________ mm 278/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 No. Inspection item 11 10. sphere on tool OK Not relevant The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm Radius (configured value): __________ mm 12 11. sphere on tool The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm Radius (configured value): __________ mm 13 12. sphere on tool The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm Radius (configured value): __________ mm Remarks / deviations : Must be checked by system integrator KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 279/304 Appendix KUKA.SafeOperation 3.6 Appendix KUKA.SafeOperation 3.6 By signing, the signatory confirms the correct and complete performance of the safety acceptance test. ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature 11.1.5 Checklist: Cell area The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician. Description The accessible surfaces resulting from the configuration must be violated one after the other, each at 2 different points, to demonstrate the correct configuration of the cell area. Precondition • The monitoring spaces that can be activated by means of safety-oriented inputs have been deactivated. • Override reduction is deactivated: ‒ $SR_WORKSPACE_RED = FALSE ‒ $SR_VEL_RED = FALSE Checklist • Serial number of the robot: ________________ • Serial number of the robot controller: ____________________ • Safety configuration: ‒ Activation code: ____________________ ‒ Last changed (date, time): ____________________ ‒ Version: ____________________ • Safety-oriented tool used in test: ________________ • Name of safety maintenance technician: ____________________ No. Inspection item 1 The limit in the Z direction has been configured correctly and checked. OK Not relevant Z min: ____________mm Z max: ____________mm 2 Corner 1 has been correctly configured and checked. X coordinate: __________ mm Y coordinate: __________ mm 280/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 No. Inspection item 3 Corner 2 has been correctly configured and checked. OK Not relevant X coordinate: __________ mm Y coordinate: __________ mm 4 Corner 3 has been correctly configured and checked. X coordinate: __________ mm Y coordinate: __________ mm 5 Corner 4 has been correctly configured and checked. X coordinate: __________ mm Y coordinate: __________ mm 6 Corner 5 has been correctly configured. X coordinate: __________ mm Y coordinate: __________ mm 7 Corner 6 has been correctly configured and checked. X coordinate: __________ mm Y coordinate: __________ mm 8 Corner 7 has been correctly configured and checked. X coordinate: __________ mm Y coordinate: __________ mm 9 Corner 8 has been correctly configured and checked. X coordinate: __________ mm Y coordinate: __________ mm 10 Corner 9 has been correctly configured and checked. X coordinate: __________ mm Y coordinate: __________ mm 11 Corner 10 has been correctly configured and checked. X coordinate: __________ mm Y coordinate: __________ mm Remarks / deviations : Must be checked by system integrator By signing, the signatory confirms the correct and complete performance of the safety acceptance test. ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 281/304 Appendix KUKA.SafeOperation 3.6 Appendix KUKA.SafeOperation 3.6 Place, date 11.1.6 Signature Checklist: Cartesian monitoring spaces The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician. A separate checklist must be completed for each monitoring space. Description The accessible surfaces resulting from the configuration must be violated one after the other, each at 3 different points, to demonstrate the correct configuration of the monitoring space. Precondition • The monitoring space to be checked is activated. • The monitoring spaces that can be activated by means of safety-oriented inputs have been deactivated. • Override reduction is deactivated: ‒ $SR_WORKSPACE_RED = FALSE ‒ $SR_VEL_RED = FALSE Checklist • Serial number of the robot: ____________________ • Serial number of the robot controller: ____________________ • Safety configuration: • • • • • • • • • • 282/304 | www.kuka.com ‒ Activation code: ____________________ ‒ Last changed (date, time): ____________________ ‒ Version: ____________________ Monitoring space checked (name, number): __________ Type of space (protected space|workspace): ____________________ Stop at boundaries (TRUE|FALSE): __________ Reference stop (TRUE|FALSE): __________ Space-specific velocity __________mm/s Space-specific velocity valid if: __________ Safety-oriented tool used in test: _________________ Always active (TRUE|FALSE): __________ Reference coordinate system: _____________ Name of safety maintenance technician: ____________________ KST SafeOperation 3.6 V3 | Issued: 10.10.2022 No. Inspection item 1 The coordinates of the monitoring space have been correctly configured and checked. OK Not relevant Origin X: __________ mm Origin Y: __________ mm Origin Z: __________ mm Origin A: __________ ° Origin B: __________ ° Origin C: __________ ° Distance to origin XMin: __________ mm Distance to origin YMin: __________ mm Distance to origin ZMin: __________ mm Distance to origin XMax: __________ mm Distance to origin YMax: __________ mm Distance to origin ZMax: __________ mm The following preconditions must be met to demonstrate the correct functioning of the reference stop: • Reference stop is active. • Mastering test requested. • Checked monitoring space is activated. No. Inspection item 2 The correct functioning of the reference stop has been checked. OK Not relevant The following preconditions must be met to demonstrate the correct functioning of the space-specific velocity: • Space-specific velocity is active. • The configured limit value of the space-specific velocity is less than the limit value of the maximum Cartesian velocity. • Checked monitoring space is activated. • Robot exceeds the configured space-specific velocity. • Override reduction for the velocity is deactivated: $SR_VEL_RED = FALSE Specified value: • Value specified by cell planner, design engineer Configured value: • Value entered in the safety configuration No. Inspection item 3 The space-specific velocity has been correctly configured and checked. OK Not relevant Specified value: __________ mm/s Configured value: __________ mm/s KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 283/304 Appendix KUKA.SafeOperation 3.6 Appendix KUKA.SafeOperation 3.6 Remarks / deviations : Must be checked by system integrator By signing, the signatory confirms the correct and complete performance of the safety acceptance test. ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature 11.1.7 Checklist: Axis-specific monitoring spaces The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician. A separate checklist must be completed for each monitoring space. Description The configured limit values must successively be violated to demonstrate the correct functioning of the monitoring space. Precondition • The monitoring space to be checked is activated. • The monitoring spaces that can be activated by means of safety-oriented inputs have been deactivated. • Override reduction is deactivated: ‒ $SR_WORKSPACE_RED = FALSE ‒ $SR_VEL_RED = FALSE Checklist • Serial number of the robot: ____________________ • Serial number of the robot controller: ____________________ • Safety configuration: • • • • • 284/304 | www.kuka.com ‒ Activation code: ____________________ ‒ Last changed (date, time): ____________________ ‒ Version: ____________________ Monitoring space checked (name, number): _________________ Type of space (protected space|workspace): ____________________ Stop at boundaries (TRUE|FALSE):_________________ Reference stop (TRUE|FALSE): _________________ Space-specific velocity _________________ mm/s KST SafeOperation 3.6 V3 | Issued: 10.10.2022 • • • • Space-specific velocity valid in: _________________ Safe tool used in test: _________________ Always active (TRUE|FALSE): _________________ Name of safety maintenance technician: ____________________ Specified value: • Value specified by cell planner, design engineer Configured value: • Value entered in the safety configuration Determined value: • Value determined during the test No. 1 Axis name Inspection item OK Not relevant 1st axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm Upper limit (determined value): __________ ° or mm 2 2nd axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm Upper limit (determined value): __________ ° or mm KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 285/304 Appendix KUKA.SafeOperation 3.6 Appendix KUKA.SafeOperation 3.6 No. Axis name 3 Inspection item OK Not relevant 3rd axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm Upper limit (determined value): __________ ° or mm 4 4th axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm Upper limit (determined value): __________ ° or mm 5 5th axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm Upper limit (determined value): __________ ° or mm 286/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 No. 6 Axis name Inspection item OK Not relevant 6th axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm Upper limit (determined value): __________ ° or mm 7 7th axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm Upper limit (determined value): __________ ° or mm 8 8th axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm Upper limit (determined value): __________ ° or mm The following preconditions must be met to demonstrate the correct functioning of the reference stop: • Reference stop is active. • Mastering test requested. • Checked monitoring space is activated. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 287/304 Appendix KUKA.SafeOperation 3.6 Appendix KUKA.SafeOperation 3.6 No. Inspection item 9 The correct functioning of the reference stop has been checked. OK Not relevant The following preconditions must be met to demonstrate the correct functioning of the space-specific velocity: • Space-specific velocity is active. • The configured limit value of the space-specific velocity is less than the limit value of the maximum Cartesian velocity. • Checked monitoring space is activated. • Robot exceeds the configured space-specific velocity. • Override reduction for the velocity is deactivated: $SR_VEL_RED = FALSE No. Inspection item 10 The space-specific velocity has been correctly configured and checked. OK Not relevant Specified value: __________ mm/s Configured value: __________ mm/s Remarks / deviations : Must be checked by system integrator By signing, the signatory confirms the correct and complete performance of the safety acceptance test. ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature 11.1.8 Checklist: Cartesian velocity monitoring functions The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician. Description The Cartesian velocity monitoring functions cannot be tested against a discrete value. It is possible to carry out a test using an exaggerated value in order to check whether velocity monitoring is triggered. Precondition • Override reduction for velocity limits is deactivated: 288/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Appendix KUKA.SafeOperation 3.6 ‒ $SR_VEL_RED = FALSE Checklist • Serial number of the robot: ____________________ • Serial number of the robot controller: ____________________ • Safety configuration: ‒ Activation code: ____________________ ‒ Last changed (date, time): ____________________ ‒ Version: ____________________ • Safety-oriented tool used in test: ____________________ • Name of safety maintenance technician: ____________________ Specified value: • Value specified by cell planner, design engineer Configured value: • Value entered in the safety configuration No. Inspection item 1 The global maximum Cartesian velocity has been correctly configured and checked. OK Not relevant Specified value: __________ mm/s Configured value: __________ mm/s 2 The safely reduced Cartesian velocity has been correctly configured and checked. Specified value: __________ mm/s Configured value: __________ mm/s 3 The reduced Cartesian velocity for T1 has been correctly configured and checked. Specified value: __________ mm/s Configured value: __________ mm/s Remarks / deviations : Must be checked by system integrator By signing, the signatory confirms the correct and complete performance of the safety acceptance test. ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 289/304 Appendix KUKA.SafeOperation 3.6 11.1.9 Checklist: axis-specific velocity monitoring functions The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician. The trace function (oscilloscope) can be used to determine the axis velocities. Precondition • Override reduction for velocity limits is deactivated: ‒ $SR_VEL_RED = FALSE Checklist • Serial number of the robot: ____________________ • Serial number of the robot controller: ____________________ • Safety configuration: ‒ Activation code: ____________________ ‒ Last changed (date, time): ____________________ ‒ Version: ____________________ • Name of safety maintenance technician: ____________________ Specified value: • Value specified by cell planner, design engineer Configured value: • Value entered in the safety configuration Test value: • Value with which the test was carried out 1. Checking the global maximum axis velocity It is only necessary to check the global maximum axis velocity if an axis must not exceed a defined velocity. No. Axis name Inspection item OK Not relevant OK Not relevant The global maximum axis velocity has been correctly entered and checked using at least one axis. 1 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 2. Checking the safely reduced axis velocity No. Axis name Inspection item The safely reduced axis velocity has been correctly configured and checked for each axis. 2.1 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 290/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 No. 2.2 Axis name Inspection item OK Not relevant Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 2.3 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 2.4 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 2.5 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 2.6 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: _________ °/s or mm/s 2.7 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 2.8 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: ________ °/s or mm/s 2.9 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 2.10 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 2.11 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 2.12 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 2.13 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: ________ °/s or mm/s 2.14 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 291/304 Appendix KUKA.SafeOperation 3.6 Appendix KUKA.SafeOperation 3.6 No. Axis name 2.15 Inspection item OK Not relevant OK Not relevant Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 2.16 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 3. Checking the maximum axis velocity for T1 No. Axis name Inspection item The maximum axis velocity for T1 has been correctly configured and checked for each axis. 3.1 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 3.2 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 3.3 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 3.4 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 3.5 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 3.6 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: _________ °/s or mm/s 3.7 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 3.8 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: ________ °/s or mm/s 3.9 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 3.10 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 292/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 No. Axis name Inspection item 3.11 OK Not relevant Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 3.12 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 3.13 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: ________ °/s or mm/s 3.14 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 3.15 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 3.16 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s Remarks / deviations : Must be checked by system integrator By signing, the signatory confirms the correct and complete performance of the safety acceptance test. ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature 11.1.10 Checklist: Safe operational stop for axis groups The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician. A separate checklist must be completed for each axis group. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 293/304 Appendix KUKA.SafeOperation 3.6 Appendix KUKA.SafeOperation 3.6 Precondition • Operating mode T1 Checklist • Serial number of the robot: ____________________ • Serial number of the robot controller: ____________________ • Safety configuration: ‒ Activation code: ____________________ ‒ Last changed (date, time): ____________________ ‒ Version: ____________________ • Axis group number: ____________________ • Name of safety maintenance technician: ____________________ Specified value: • Value specified by cell planner, design engineer Configured value: • Value entered in the safety configuration No. Axis name 1 Inspection item OK Not relevant 1st axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm 2 2nd axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm 3 3rd axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm 4 4th axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm 5 5th axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm 294/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 No. Axis name Inspection item 6 OK Not relevant 6th axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm 7 7th axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm 8 8th axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm Remarks / deviations : Must be checked by system integrator By signing, the signatory confirms the correct and complete performance of the safety acceptance test. ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature 11.1.11 Checklist: Braking before restricted areas The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician. Precondition • “Braking before restricted areas” is activated. • At least 1 monitoring space is activated for the axis to be tested: ‒ Axis-specific monitoring space ‒ Or Cartesian monitoring space ‒ Or cell area (always activated) KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 295/304 Appendix KUKA.SafeOperation 3.6 Appendix KUKA.SafeOperation 3.6 • Override reduction for space monitoring is deactivated: ‒ $SR_WORKSPACE_RED = FALSE Checklist • Serial number of the robot: ____________________ • Serial number of the robot controller: ____________________ • Safety configuration: • • • • ‒ Activation code: ____________________ ‒ Last changed (date, time): ____________________ ‒ Version: ____________________ Safety-oriented tool used in test: ____________________ Monitoring space used in test: ____________________ Name of safety maintenance technician: ____________________ Values for axis group and braking ramp: Axis Ramp stop group Braking ramp of drive The braking ramp must be checked for at least one axis per ramp stop group at a monitoring space. It may be necessary to check further axes (>>> 7.5.9 "Activating “Braking before restricted areas”" Page 124). No. Inspection item OK 1 The correct configuration of the monitoring space used for testing has been checked. Not relevant (>>> 11.1.7 "Checklist: Axis-specific monitoring spaces" Page 284) (>>> 11.1.6 "Checklist: Cartesian monitoring spaces" Page 282) (>>> 11.1.5 "Checklist: Cell area" Page 280) 2 When the axis approaches the monitoring space limit, the robot stops with a safety stop 1 and, depending on the type of space, one of the following messages is displayed: • Ackn: Safety stop before violation of monitoring space no. {Number of monitoring space} • Ackn.: Safety stop before leaving cell area. 3 The message Ackn.: The braking ramp of the robot has been violated. is not displayed. 296/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Appendix KUKA.SafeOperation 3.6 Remarks / deviations : Must be checked by system integrator By signing, the signatory confirms the correct and complete performance of the safety acceptance test. ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature ___________________________________________ ___________________________________________ Place, date Signature 11.2 Applied standards and regulations The safety functions of KUKA.SafeOperation meet the requirements of Category 3 and Performance Level d in accordance with EN ISO 13849-1:2015. KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 297/304 Appendix KUKA.SafeOperation 3.6 298/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 12 KUKA Service 12.1 Requesting support KUKA Service KUKA.SafeOperation 3.6 Introduction This documentation provides information on operation and operator control, and provides assistance with troubleshooting. For further assistance, please contact your local KUKA subsidiary. Information The following information is required for processing a support request: • Description of the problem, including information about the duration and frequency of the fault • The greatest possible amount of information about the hardware and software components of the overall system The following list gives an indication of the information which is relevant in many cases: ‒ Model and serial number of the kinematic system, e.g. the manipulator ‒ Model and serial number of the controller ‒ Model and serial number of the energy supply system ‒ Designation and version of the system software ‒ Designations and versions of other software components or modifications ‒ System Software diagnosis package Additionally for KUKA Sunrise: Existing projects including applications For versions of KUKA System Software older than V8: Archive of the software (Diagnosis package is not yet available here.) ‒ Application used ‒ External axes used 12.2 KUKA Customer Support The contact details of the local subsidiaries can be found at: www.kuka.com/customer-service-contacts KST SafeOperation 3.6 V3 | Issued: 10.10.2022 www.kuka.com | 299/304 KUKA Service KUKA.SafeOperation 3.6 300/304 | www.kuka.com KST SafeOperation 3.6 V3 | Issued: 10.10.2022 KUKA.SafeOperation 3.6 Index $BRAKES_OK.............................................. 157 $BRAKETEST_MONTIME............................156 $BRAKETEST_REQ_EX.............................. 156 $BRAKETEST_REQ_INT............................. 157 $BRAKETEST_WARN..................................157 $BRAKETEST_WORK................................. 157 $MASTERINGTEST_ACTIVE...................... 144 $MASTERINGTEST_GROUP...................... 144 $MASTERINGTEST_REQ_EXT...................145 $MASTERINGTEST_REQ_INT....................145 $MASTERINGTEST_SWITCH_OK.............. 146 $SR_ACTIVETOOL...................................... 209 $SR_AXISSPEED_OK................................. 210 $SR_CARTSPEED_OK................................210 $SR_DRIVES_ENABLE................................211 $SR_MOVE_ENABLE.................................. 211 $SR_OV_RED.............................................. 171 $SR_RANGE_ACTIVE................................. 211 $SR_RANGE_OK......................................... 212 $SR_SAFEMON_ACTIVE............................ 213 $SR_SAFEOPSTOP_ACTIVE......................213 $SR_SAFEOPSTOP_OK............................. 214 $SR_SAFEREDSPEED_ACTIVE.................214 $SR_VEL_RED.............................................170 $SR_WORKSPACE_RED............................ 172 “Drives ready” interface..................................52 ”Drives ready” interface..................................51 ”Drives ready” lamp........................................51 A Accessories.....................................................35 Activating, monitoring space................ 108, 112 Activating, reference stop.................... 109, 113 Activating, safety configuration.................... 191 Activation code, safety configuration............. 83 Actuating plate, hole pattern..........................73 Actuating plate, installing............................. 137 Administrator (user group)............................. 81 Alarm space....................................................11 Ambient temperature, reference switch.........69 ANSI/UL 1740.................................................51 Appendix....................................................... 269 Applied standards and regulations.............. 297 Areas of application........................................14 AUT (operating mode)....................................36 AUT EXT (operating mode)........................... 36 Automatic (operating mode) AUT............................................................36 AUT EXT................................................... 36 Automatic External (operating mode)............ 53 Automatic mode..............................................64 Axis-specific monitoring space, configuring. 111 Axis-specific monitoring spaces, checking.. 181 Axis-specific protected spaces.......................26 Axis-specific velocity limits, checking.......... 184 Axis-specific velocity monitoring functions, configuring.................................................... 115 Axis-specific workspaces................................25 KST SafeOperation 3.6 V3 | Issued: 10.10.2022 Axis angle, lower limit.................................. 114 Axis angle, upper limit..................................115 Axis limitation, mechanical............................. 49 Axis monitoring functions, checking............ 190 Axis range.......................................................36 Axis velocity, maximum..................32, 115, 118 Axis velocity, maximum global..................... 184 Axis velocity, maximum in T1....32, 115, 118, 184 Axis velocity, reduced..............32, 33, 115, 118 Axis velocity, safely reduced........................184 Axis, active................................................... 151 Axis, requested.............................................151 B BBRA.............................................................. 10 Brake check, automatic....................... 150, 166 Brake defect................................................... 54 Brake release device......................................49 Brake test............................................... 15, 149 Brake test, cycle time.................................. 150 Brake test, manual....................................... 163 Brake test, operating modes........................150 Brake test, programs....................................151 Brake test, signals............................... 155, 158 Brake test, state............................................. 83 Brake test, teaching positions......................159 Brake, defective........................... 161, 163–165 BrakeTestAxes.src........................................ 152 BrakeTestBack.src................................152, 160 BrakeTestPark.src................................ 152, 160 BrakeTestReq.src..........................................152 BrakeTestStart.src................................ 152, 159 Braking before restricted areas..................... 28 Braking before restricted areas, activating..124 Braking distance............................................. 36 Braking ramp of drive unit........................... 127 Braking ramp, checking................................187 Braking time..................................................117 Buttons, overview........................................... 82 C Cable lengths, reference switch module....... 16 Cartesian monitoring space, configuring..... 107 Cartesian monitoring spaces, checking.......180 Cartesian protected spaces........................... 23 Cartesian velocity limits, checking...............183 Cartesian velocity, maximum................. 99, 183 Cartesian velocity, reduced....................99, 183 Cartesian velocity, reduced in T1................ 183 Cartesian workspaces.................................... 22 CE mark..........................................................36 Cell area............................................ 12, 18, 20 Cell area, checking.......................................179 Cell area, configuring................................... 105 Checking the reference position.................. 142 Checklists for safety acceptance................. 269 CIP Safety................................. 10, 15, 75, 193 www.kuka.com | 301/304 KUKA.SafeOperation 3.6 Circuit diagram, reference switch.................. 72 CK.............................................................10, 15 CK, monitoring................................................47 Cleaning work.................................................65 Configuration...................................................89 Configuration, overview.................................. 91 Connecting cables....................................17, 35 Connector pin assignment, reference cable XG42 - XS RefReference cable XG42 - XS Ref, connector pin assignment...................... 71 Counterbalancing system............................... 65 Couplable external axes.................................15 D Danger zone................................................... 37 Declaration of conformity............................... 35 Declaration of incorporation.....................35, 36 Decommissioning............................................66 Diagnosis...................................................... 209 Diagnosis package....................................... 299 Diagnostic data, displaying.......................... 209 Diagnostic monitor (menu item)...................209 Diagnostic signals Ethernet interface.................................... 201 Disclaimer....................................................... 35 Discrete safety interface........................ 15, 193 Disposal.......................................................... 66 Documentation, industrial robot....................... 9 Drive ramp stop group................................. 127 DRS................................................................ 10 E EC declaration of conformity......................... 35 EMC conformity, reference switch................. 69 EMC Directive.................................................36 EMERGENCY STOP device...... 44, 46, 52, 54 EMERGENCY STOP, external................ 46, 59 EMERGENCY STOP, local............................ 59 EN ISO 13849-1...........................................297 Enabling device................................. 46, 52, 54 Enabling device, external............................... 47 Enabling switches...........................................46 EtherCAT..........................................10, 15, 193 Ethernet interface..................................... 10, 11 Diagnostic signals................................... 201 Ethernet safety interfaces......................15, 193 EtherNet/IP................................ 11, 15, 75, 193 EXT (operating mode)....................................53 External axes..................................................35 External axis................................................... 39 F Faults.............................................................. 56 Fictitious STOP 1 - DRS end position.......... 11 FSoE................................................ 11, 15, 193 Function test................................................... 58 Functional description.....................................13 302/304 | www.kuka.com Functions........................................................ 13 G General safety measures............................... 54 GET_AXESMASK.........................................167 GET_BRAKETEST_TIME.............................168 Global parameters, configuring...................... 97 H Hardware components................................... 16 Hazardous substances................................... 66 Hole pattern, actuating plate..........................73 Hole pattern, reference switch.......................70 Hysteresis, reference switch.......................... 69 I IFBSafeExt...................................................... 11 Industrial robot................................................35 Installation.......................................................75 Installing via smartHMI............................................. 77 via WorkVisual...........................................75 Interface, XG13............................. 15, 193, 205 Interface, XG42............................................ 208 Interfaces...................................................... 193 Introduction....................................................... 9 IT security....................................................... 56 J Jog mode...........................................48, 52, 54 K KL....................................................................11 Knowledge, required.........................................9 KR C............................................................... 11 KSS.................................................................37 KUKA Customer Support............................. 299 KUKA Service...............................................299 KUKA smartPAD.............................................37 KUKA smartPAD-2......................................... 37 L Labeling.......................................................... 50 Licenses..........................................................12 Limit value for safely reduced Cartesian velocity in T1 mode........................................99 Linear unit.......................................................35 Low Voltage Directive.....................................36 M Machine data............................................59, 83 KST SafeOperation 3.6 V3 | Issued: 10.10.2022 KUKA.SafeOperation 3.6 Machine data, displaying................................84 Machinery Directive........................................ 36 Maintenance................................................... 64 Manipulator...............................................35, 37 Manual mode..................................................63 Mastering confirmation, external.................. 147 Mastering position, reference position.........130 Mastering test.........................................11, 132 Mastering test input........................................99 Mastering test via reference switch.............133 Mastering test, performing manually........... 143 Mastering test, programs............................. 135 Mastering test, teaching positions............... 140 Mastering type................................................ 99 Mechanical end stops.................................... 48 Messages......................................................217 Monitoring space............................................ 12 Monitoring spaces.......................................... 18 Monitoring time.............................. 11, 132, 150 Monitoring, physical safeguards.............. 43, 44 Monitoring, velocity.........................................47 O Open source................................................... 12 Operating current, reference switch.............. 69 Operating mode selection........................51, 52 Operating voltage, reference switch.............. 69 Operation........................................................ 81 Operator safety............................42–44, 52, 54 Operators........................................................ 40 Options............................................................35 Outputs, reference switch.............................. 69 Overload......................................................... 54 Override reduction........................................ 169 Overview, buttons........................................... 82 Overview, configuration.................................. 91 Overview, safety acceptance....................... 177 Overview, start-up...........................................91 P Panic position................................................. 46 Performance Level......................................... 43 Peripheral contactor....................................... 62 Permissible load current, reference switch... 69 Permissible switching distance, reference switch..............................................................69 Permissible switching frequency, reference switch..............................................................69 Personal protective equipment...................... 39 Personnel........................................................39 Plant integrator............................................... 39 Polygon, convex.................................11, 18, 21 Position tolerance......................................... 123 Positioner........................................................ 35 PPE.................................................................39 Pressure Equipment Directive........................65 Preventive maintenance work........................ 65 Product description.........................................13 KST SafeOperation 3.6 V3 | Issued: 10.10.2022 PROFINET.................................11, 15, 75, 193 PROFIsafe................................. 11, 15, 75, 193 Protected space................................. 11, 18, 23 Protection rating............................................. 69 Protective equipment......................................48 Pulse duration, reference switch................... 69 Pulse duty factor, reference switch......... 69, 70 R Radius, tool sphere........................................ 93 Reaction distance........................................... 36 Recommissioning............................................57 Reference group............................ 11, 130, 133 Reference group, configuring.......................128 Reference groups, configuration.................. 139 Reference position................................. 11, 133 Reference position, axis angle.................... 130 Reference position, Cartesian......................130 Reference position, configuring................... 128 Reference position, selecting....................... 135 Reference stop......................................... 11, 30 Reference switch............................................ 11 Reference switch module...............................16 Reference switch XS Ref, circuit diagram.... 72 Reference switch, connecting...................... 138 Reference switch, installing..........................137 Reference switch, technical data...................69 Reference system................................ 106, 110 Release device............................................... 49 Repair............................................................. 64 Revision log, displaying..................................84 Robot controller.............................................. 35 S Safe monitoring.............................................. 99 Safe monitoring, activating.............................97 Safe monitoring, deactivating.......................192 Safe operational stop...............................33, 37 Safe operational stop, axis group 1 to 6.... 123 Safe operational stop, checking.................. 186 Safe operational stop, configuring............... 122 Safe robot retraction.......................................87 Safeguards, external...................................... 50 SafeOperation via Ethernet safety interface........................................................ 197 Safety..............................................................35 Safety-oriented TCP....................................... 31 Safety-oriented tool........................................ 12 Safety-oriented tool, checking......................178 Safety-oriented tool, configuring.................. 101 Safety-oriented tools.......................................31 Safety acceptance, overview....................... 177 Safety acceptance, precondition.................. 269 Safety configuration, activating.................... 191 Safety configuration, displaying information.. 83 Safety configuration, exporting...................... 87 Safety configuration, importing.......................84 Safety configuration, opening........................ 82 www.kuka.com | 303/304 KUKA.SafeOperation 3.6 Safety configuration, saving......................... 131 Safety controller..............................................43 Safety functions........................................42, 52 Safety functions, checking........................... 178 Safety functions, Ethernet safety interface..193 Safety functions, overview............................. 42 Safety instructions......................................9, 89 Safety interfaces.............................................15 Safety maintenance (user group).................. 81 Safety measures.............................................54 Safety of machinery..................................... 297 Safety options.................................................38 Safety recovery (user group)......................... 81 Safety STOP 0............................................... 37 Safety STOP 1............................................... 37 Safety STOP 2............................................... 38 Safety stop 0.................................................. 37 Safety stop 1.................................................. 37 Safety STOP 1 – Drive Ramp Stop.............. 38 Safety STOP 1 DRS...................................... 38 Safety stop 2.................................................. 38 Safety zone.............................................. 37, 40 Safety, general................................................35 Serial number, robot.......................................83 Service life................................................37, 69 Signals, brake test............................... 155, 158 Simulation....................................................... 64 Single (menu item).............................. 219, 220 Single point of control.................................... 66 smartPAD................................................. 38, 55 smartPAD-2.....................................................38 Software..........................................................35 Software limit switches......................48, 52, 54 Space-specific velocity.......... 30, 108, 109, 113 Space-specific velocity, checking.................182 Space dimensions........................................ 110 Space type........................................... 108, 112 Sphere, radius................................................ 93 SPOC..............................................................66 Standstill monitoring...............................33, 123 Start-up.....................................................57, 89 Start-up mode.......................................... 62, 90 Start-up, overview...........................................91 STOP 0.................................................... 36, 38 STOP 1.................................................... 36, 38 STOP 2.................................................... 36, 39 Stop at boundaries...............................108, 113 Stop category 0.............................................. 38 Stop category 1.............................................. 38 Stop category 2.............................................. 39 Stop category 1, Drive Ramp Stop............... 38 Stop reactions....................................19, 33, 41 STOP 1 - DRS............................................... 38 STOP 1, DRS end position............................11 Stopping distance.............................. 19, 36, 40 Storage........................................................... 66 Support request............................................ 299 Switching function, reference switch............. 69 System integrator.............................. 36, 39, 40 System requirements 304/304 | www.kuka.com Compatibility.............................................. 75 Hardware................................................... 75 Software.....................................................75 System variables, mastering test.................144 System variables, safety monitoring functions....................................................... 209 T T1 (operating mode)................................ 39, 53 T2 (operating mode)................................ 39, 53 Target group..................................................... 9 Teach pendant................................................ 35 Technical data.................................................69 Technical data, reference switch................... 69 Terms used..................................................... 10 Terms, safety.................................................. 36 Time stamp, machine data............................ 83 Time stamp, safety configuration...................83 Tool sphere, radius.........................................93 Trademarks..................................................... 10 Training.......................................................9, 81 Transportation................................................. 56 Turn-tilt table...................................................35 Type of monitoring space.................... 108, 112 U Uninstalling via smartHMI.............................. 78 Uninstalling via WorkVisual............................76 Updating via smartHMI...................................77 Updating via WorkVisual................................ 75 US2................................................................. 62 User.......................................................... 37, 39 User groups.................................................... 81 User rights, displaying....................................82 V Velocity monitoring......................................... 47 Velocity monitoring functions..........................32 Velocity, space-specific...................................30 Version, safety configuration.......................... 83 Version, safety option.....................................83 VSS.................................................................39 W Warnings........................................................... 9 Workspace............................ 10, 18, 22, 36, 40 WorkVisual...................................................... 15 X XG13, interface..............................15, 193, 205 XG42, interface.............................................208 XML export..................................................... 87 XML import..................................................... 84 KST SafeOperation 3.6 V3 | Issued: 10.10.2022

KUKA SafeOperation 3.6: Assembly & Operating Instructions

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