Krc4safeoperation PDF

KUKA System Technology KUKA Roboter GmbH
KUKA.SafeOperation 3.1
For KUKA System Software 8.2

For VW System Software 8.2
Assembly and Operating Instructions
Issued: 31.03.2011
Version: KST SafeOperation 3.1 V1 en

© Copyright 2011
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Roboter 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, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC
Publication: Pub KST SafeOperation 3.1 en

Bookstructure: KST SafeOperation 3.1 V1.1
Label: KST SafeOperation 3.1 V1 en
2 / 143 Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

Contents
Contents
1 Introduction .................................................................................................. 7
1.1 Target group .............................................................................................................. 7
1.2 Industrial robot documentation ................................................................................... 7
1.3 Representation of warnings and notes ...................................................................... 7
1.4 Terms used ................................................................................................................ 8
2 Product description ..................................................................................... 11

2.1 Overview of SafeOperation ........................................................................................ 11
2.2 Monitoring spaces ...................................................................................................... 12
2.2.1 Coordinate systems .............................................................................................. 14
2.2.1.1 Special cases ........................................................................................................ 15
2.2.2 Cell area ............................................................................................................... 16
2.2.3 Cartesian workspaces .......................................................................................... 17
2.2.4 Cartesian protected spaces .................................................................................. 18
2.2.5 Axis-specific workspaces ...................................................................................... 19
2.2.6 Axis-specific protected spaces ............................................................................. 20
2.2.7 Space-specific velocity ......................................................................................... 22
2.2.8 Reference stop ..................................................................................................... 22
2.3 Safe tools ................................................................................................................... 23
2.4 Velocity monitoring functions ..................................................................................... 23
2.5 Safe operational stop ................................................................................................. 24
2.6 Override reduction ..................................................................................................... 24
2.7 CRR mode (safe robot retraction) .............................................................................. 25
2.8 Start-up mode ............................................................................................................ 26
2.9 Mastering test ............................................................................................................ 26
2.9.1 Reference position ................................................................................................ 27
2.9.2 Reference switch module ..................................................................................... 28
2.9.3 Connecting cables ................................................................................................ 28
3 Technical data .............................................................................................. 31

3.1 Service life ................................................................................................................. 31
3.2 Reference switch ....................................................................................................... 31
3.3 Reference switch hole pattern ................................................................................... 32
3.4 Hole pattern for actuating plate .................................................................................. 32
4 Safety ............................................................................................................ 35
4.1 General ...................................................................................................................... 35
4.1.1 Liability .................................................................................................................. 35
4.1.2 Intended use of the industrial robot ...................................................................... 35
4.1.3 EC declaration of conformity and declaration of incorporation ............................. 36
4.1.4 Terms used ........................................................................................................... 36
4.2 Personnel ................................................................................................................... 38
4.3 Workspace, safety zone and danger zone ................................................................. 39
4.4 Triggers for stop reactions ......................................................................................... 40
4.5 Safety functions ......................................................................................................... 41
4.5.1 Overview of the safety functions ........................................................................... 41
4.5.2 Safety controller .................................................................................................... 41
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en 3 / 143

4.5.3 Mode selection ..................................................................................................... 42

4.5.4 Operator safety ..................................................................................................... 42
4.5.5 EMERGENCY STOP device ................................................................................ 43
4.5.6 Logging off the higher-level safety controller ........................................................ 43
4.5.7 External EMERGENCY STOP device .................................................................. 44
4.5.8 Enabling device .................................................................................................... 44
4.5.9 External enabling device ...................................................................................... 45
4.5.10 External safe operational stop .............................................................................. 45
4.5.11 External safety stop 1 and external safety stop 2 ................................................. 45
4.5.12 Velocity monitoring in T1 ...................................................................................... 45
4.6 Additional protective equipment ................................................................................ 45
4.6.1 Jog mode .............................................................................................................. 45
4.6.2 Software limit switches ......................................................................................... 45
4.6.3 Mechanical end stops ........................................................................................... 46
4.6.4 Mechanical axis range limitation (optional) ........................................................... 46
4.6.5 Axis range monitoring (optional) ........................................................................... 46
4.6.6 Release device (optional) ..................................................................................... 46
4.6.7 Labeling on the industrial robot ............................................................................ 47
4.6.8 External safeguards ............................................................................................. 47
4.7 Overview of operating modes and safety functions ................................................... 48
4.8 Safety measures ........................................................................................................ 48
4.8.1 General safety measures ..................................................................................... 48
4.8.2 Transportation ...................................................................................................... 50
4.8.3 Start-up and recommissioning .............................................................................. 50
4.8.3.1 Start-up mode ....................................................................................................... 52
4.8.4 Manual mode ........................................................................................................ 52
4.8.5 Simulation ............................................................................................................. 53
4.8.6 Automatic mode ................................................................................................... 53
4.8.7 Maintenance and repair ........................................................................................ 54
4.8.8 Decommissioning, storage and disposal .............................................................. 55
4.8.9 Safety measures for “single point of control” ........................................................ 55
4.9 Applied norms and regulations .................................................................................. 57
5 Installation ................................................................................................... 59
5.1 System requirements ................................................................................................. 59
5.2 Installing or updating SafeOperation ......................................................................... 59
5.3 Uninstalling SafeOperation ........................................................................................ 59
6 Operation ...................................................................................................... 61
6.1 User groups ............................................................................................................... 61
6.2 Opening the safety configuration ............................................................................... 61
6.3 Overview of buttons ................................................................................................... 61
6.4 Monitor functions ....................................................................................................... 62
6.4.1 Displaying information about the safety configuration .......................................... 62
6.4.2 Displaying the change log .................................................................................... 63
6.4.3 Displaying machine data ...................................................................................... 63
7 Start-up and recommissioning ................................................................... 65

7.1 Start-up overview ....................................................................................................... 65

Contents
7.2 Safety warnings ......................................................................................................... 66

7.3 Installing the reference switch and actuating plate .................................................... 67
7.4 Connecting a reference switch ................................................................................... 67
7.5 Activating safe monitoring .......................................................................................... 68
7.6 Defining global parameters ........................................................................................ 68
7.7 Defining a cell area .................................................................................................... 70
7.8 Defining Cartesian monitoring spaces ....................................................................... 72
7.9 Defining axis-specific monitoring spaces ................................................................... 75
7.10 Defining axis-specific velocity monitoring .................................................................. 79
7.11 Defining the safe operational stop ............................................................................. 82
7.12 Defining safe tools ..................................................................................................... 84
7.13 Defining the reference position .................................................................................. 87
7.14 Checking the reference position (actuation with tool) ................................................ 89
7.15 Saving the safety configuration .................................................................................. 90
7.16 Performing a mastering test manually ....................................................................... 91
7.17 Testing safety parameters ......................................................................................... 91
7.17.1 Testing Cartesian velocity ..................................................................................... 91
7.17.2 Testing maximum axis velocity ............................................................................. 92
7.17.3 Testing Cartesian monitoring spaces ................................................................... 93
7.17.4 Testing axis-specific monitoring spaces ............................................................... 94
7.17.5 Testing safe operational stop for an axis group .................................................... 94
7.18 Safety acceptance overview ...................................................................................... 94
7.19 Activating a new safety configuration ......................................................................... 95
7.20 Deactivating safe monitoring ...................................................................................... 96
8 Programming ............................................................................................... 97
8.1 Programs for the mastering test ................................................................................. 97
8.2 Programming a mastering test ................................................................................... 97
9 System variables ......................................................................................... 99

9.1 Variables for override reduction in $CUSTOM.DAT .................................................. 99
9.2 Variables for the mastering test ................................................................................. 99
9.3 Variables for diagnosis ............................................................................................... 100
10 Interfaces to the higher-level controller .................................................... 101

10.1 SafeOperation via PROFIsafe (optional) ................................................................... 101
10.1.1 Diagnostic signals via PROFINET ........................................................................ 103
10.2 SafeOperation via interface X13 (optional) ................................................................ 107
11 Diagnosis ..................................................................................................... 109

11.1 Displaying safe I/Os ................................................................................................... 109
12 Messages ..................................................................................................... 111

12.1 Messages during operation ........................................................................................ 111
13 Appendix ...................................................................................................... 115

13.1 Checklists ................................................................................................................... 115
13.1.1 Precondition for safety acceptance based on the checklists ................................ 115
13.1.2 Checklist for robot and system ............................................................................. 115
13.1.3 Checklist for safe functions ................................................................................... 115

13.1.4 Checklist for velocity limits .................................................................................... 118

13.1.5 Checklist for configuration of the safe operational stop ........................................ 121
13.1.6 Checklist for configuration of the cell area ............................................................ 122
13.1.7 Checklist for configuration of Cartesian monitoring spaces .................................. 123
13.1.8 Checklist for configuration of axis-specific monitoring spaces ............................. 125
13.1.9 Checklist for configuration of the safe tools .......................................................... 127
13.2 Applied norms and directives .................................................................................... 130
14 KUKA Service ............................................................................................... 131

14.1 Requesting support ................................................................................................... 131
14.2 KUKA Customer Support ........................................................................................... 131
Index ............................................................................................................. 139

1 Introduction
1 Introduction
1.1 Target group
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 our products, we recommend that our customers

take part in a course of training at KUKA College. Information about
the training program can be found at www.kuka.com or can be ob-
tained directly from our subsidiaries.
1.2 Industrial robot documentation
The industrial robot documentation consists of the following parts:

 Documentation for the manipulator
 Documentation for the robot controller
 Operating and programming instructions for the KUKA System Software
 Documentation relating to options and accessories
 Parts catalog on storage medium
Each of these sets of instructions is a separate document.
1.3 Representation of warnings and notes
Safety These warnings are relevant to safety and must be observed.
These warnings mean that it is certain or highly probable

that death or severe physical injury will occur, if no pre-
cautions are taken.
These warnings mean that death or severe physical inju-

ry may occur, if no precautions are taken.
These warnings mean that minor physical injuries may

occur, if no precautions are taken.
These warnings mean that damage to property may oc-

cur, 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.
Hints These hints 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 Terms used
Term Description
Axis range Range, in degrees or millimeters, within which an
axis may move. The axis range is defined by a lower
and an upper axis limit.
Axis limit An axis has 2 axis limits which define the axis range.
There is an upper axis limit and a lower axis limit.
Stopping distance Stopping distance = reaction distance + braking dis-
tance
The stopping distance is part of the danger zone.
Workspace Monitoring space that the defined axes or the safe
tool must not leave. The axes or the safe tool must
always move within the limits of the workspace.
(>>> 2.2.5 "Axis-specific workspaces" Page 19)
(>>> 2.2.3 "Cartesian workspaces" Page 17)
Danger zone The danger zone consists of the workspace and the
stopping distances.
Mastering test The mastering test is used to check whether the cur-
rent position of the robot and the external axes cor-
responds to a reference position.
(>>> 2.9 "Mastering test" Page 26)
KL KUKA linear unit
CRR Controlled robot retraction
Operating mode for retracting the robot in the case
of a workspace violation.
Alarm space An alarm space signals a workspace violation by
setting an output. The alarm spaces are perma-
nently assigned to the configurable outputs of the
interface options PROFIsafe and X13
(SIB Extended).
Monitoring time During the monitoring time, the user is prompted to
perform a mastering test.
Polygon, convex A convex polygon is a polygon consisting of at least
3 different corners. Triangles and squares are exam-
ples of convex polygons.
(>>> 2.2.2 "Cell area" Page 16)
PROFIsafe PROFIsafe is a PROFINET-based safe interface for
connecting a safety PLC to the robot controller.
(PLC = master, robot controller = slave)
(>>> 10.1 "SafeOperation via PROFIsafe
(optional)" Page 101)
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 safe monitoring.
Reference position The reference position is a Cartesian position to
which the robot moves during the mastering test.
(>>> 2.9.1 "Reference position" Page 27)

1 Introduction
Term Description
Reference stop Safety stop that is triggered if the mastering test has
not been carried out. The reference stop can be acti-
vated for monitoring spaces.
(>>> 2.2.8 "Reference stop" Page 22)
Reference switch A reference switch is necessary for carrying out the
mastering test. The reference switch confirms the
reference position.
(>>> 3.2 "Reference switch" Page 31)
Protected space Monitoring space that the defined axes or the safe
tool must not enter. The axes or the safe tool must
always move outside the limits of the protected
space.
(>>> 2.2.6 "Axis-specific protected spaces"
Page 20)
(>>> 2.2.4 "Cartesian protected spaces" Page 18)
SIB Safety Interface Board
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 docu-
ment.
Safety STOP 1 A stop that is triggered and monitored by the safety
controller. The braking process is performed by the
non-safety-oriented part of the robot controller and
monitored by the safety controller. As soon as the
manipulator is at a standstill, the safety controller
switches off the drives and the power supply to the
brakes.
ment.
Safety STOP 2 A stop that is triggered and monitored by the safety
controller. The braking process is performed by the
non-safety-oriented part of the robot controller and
monitored by the safety controller. The drives remain
activated and the brakes released.
ment.
Safe operational In the case of a safe operational stop, the standstill
stop of the axes for which it has been configured is moni-
tored. When the axes are at a monitored standstill,
they may move within the configured axis angle or
distance tolerances.
(>>> 2.5 "Safe operational stop" Page 24)
Safe tool Tool with up to 6 spheres modeled around it. These
spheres are monitored against the limits of the Car-
tesian monitoring spaces. Each safe tool has a safe
TCP which is monitored against the configured
velocity limits.
(>>> 2.3 "Safe tools" Page 23)

Term Description
Monitoring space A monitoring space can be Cartesian or axis-specific
and can be defined as a workspace or protected
space.
(>>> 2.2 "Monitoring spaces" Page 12)
Cell area Cartesian workspace with 3 to 10 corners forming a
convex polygon and limited in the ±Z direction. The
cell area is the maximum permissible workspace of
the robot.
(>>> 2.2.2 "Cell area" Page 16)

2 Product description
2.1 Overview of SafeOperation
Functions SafeOperation is an option with software and hardware components and the
following functions:
 Safe monitoring of a maximum of 16 user-defined, axis-specific or Carte-
sian monitoring spaces
 Safe monitoring of a user-defined cell area
 Safe monitoring of axis-specific velocities
 Safe monitoring of space-specific velocities
 Safe monitoring of Cartesian velocities
 Modeling of up to 16 safe tools with safe TCP
 Safe stop via safety controller
 Safe operational stop
 Connection to a higher-level controller, e.g. to a safety PLC
 Safe inputs for activation of the monitoring functions
 Safe outputs for status messages of the monitoring functions
 Creation and editing of the safety configuration on the robot controller or
in WorkVisual.
Information about the safety configuration in WorkVisual is contained

in the WorkVisual documentation.
Components These software components are included in the SafeOperation package:

 KUKA.SafeOperation
These hardware components are included in the SafeOperation package:
 Reference switch module
Areas of appli-  Human-robot cooperation

cation  Direct loading of workpieces without an intermediate support
 Replacement of conventional axis range monitoring systems

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
Functional The components of the industrial robot move within the limits that have been
principle 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 pa-
rameters that have been set. If a component of the industrial robot violates a
monitoring limit or a safety parameter, the robot and external axes (optional)
are stopped.
Decouplable external axes are not supported by SafeOp-

eration. In the case of decouplable external axes, safe
position sensing is not possible, as the machine data change while the con-
troller is running.
Interfaces Various interfaces are available for connection to a higher-level controller. The
safe I/Os of these interfaces can be used, for example, to activate safety mon-
itoring functions or signal a violation of safety monitoring functions.
 PROFINET/PROFIsafe
 Interface X13 via SIB Extended
2.2 Monitoring spaces
A maximum of 16 monitoring spaces can be configured. A cell area must also

be configured.
Monitoring space A monitoring space can be defined as a Cartesian cuboid or by means of indi-
vidual axis ranges. Each monitoring space can be set as a workspace or pro-
tected space.
(>>> 2.2.3 "Cartesian workspaces" Page 17)

(>>> 2.2.4 "Cartesian protected spaces" Page 18)

(>>> 2.2.5 "Axis-specific workspaces" Page 19)
(>>> 2.2.6 "Axis-specific protected spaces" Page 20)
For every monitoring space, a space-specific Cartesian velocity can be de-
fined inside or outside the monitoring space.
(>>> 2.2.7 "Space-specific velocity" Page 22)
For each monitoring space, a reference stop can be set that stops the robot if
no mastering test has been carried out.
(>>> 2.2.8 "Reference stop" Page 22)
Monitoring can be activated and deactivated for each individual monitoring
space, or activated by means of safe inputs.
Safe outputs are permanently assigned to the monitoring spaces. The safe
outputs are set if a monitoring space is violated.
Whether or not a stop is triggered at the space limit is a function that can be
activated.
Cell area The cell area is a Cartesian workspace in the form of a convex polygon with 3
to 10 corners and is limited in the ±Z direction.
(>>> 2.2.2 "Cell area" Page 16)
The cell area is permanently monitored and always active. The corners can be
configured, activated and deactivated individually.
A safety stop 0 is always triggered at the space limit.
Stopping If the robot is stopped by a monitoring function, it requires a certain stopping

distance distance before coming to a standstill.
The stopping distance depends on the following factors:
 Robot type
 Velocity of the robot
 Position of the robot axes
 Payload
 Further parameters
EN ISO 10218-1, Annex B, specifies the need for information about

the stopping time and distance. These have not yet been determined
in full for all robot types in conjunction with the KR C4 robot controller.
In this respect, the industrial robot does not conform to the requirements of
EN ISO 10218-1.
Stop reactions
Stop reaction Description Example

Safety stop 0 The stop is triggered if a monitoring Robot exceeds the limit of an acti-
function is already activated and the vated workspace in Automatic mode.
robot then exceeds the monitoring Robot exceeds the limit of an acti-
limit. vated workspace in T1 mode.
Safety stop 1 The stop is triggered if a monitoring A protected space in which the robot
function is just being activated and is currently situated is activated by a
the robot has already exceeded the safety mat.
monitoring limit.

2.2.1 Coordinate systems
Overview The following Cartesian coordinate systems are defined in the robot controller:
 WORLD
 ROBROOT
 BASE
 TOOL
Fig. 2-2: Overview of coordinate systems
Description WORLD
The WORLD coordinate system is a permanently defined Cartesian coordi-
nate system. It is the root coordinate system for the ROBROOT and BASE co-
ordinate systems.
By default, the WORLD coordinate system is located at the robot base.
ROBROOT
The ROBROOT coordinate system is a Cartesian coordinate system, which is
always located at the robot base. It defines the position of the robot relative to
the WORLD coordinate system.
By default, the ROBROOT coordinate system is identical to the WORLD coor-
dinate system. $ROBROOT allows the definition of an offset of the robot rela-
tive to the WORLD coordinate system.
BASE
The BASE coordinate system is a Cartesian coordinate system that defines
the position of the workpiece. It is relative to the WORLD coordinate system.
By default, the BASE coordinate system is identical to the WORLD coordinate
system. It is offset to the workpiece by the user.
TOOL

The TOOL coordinate system is a Cartesian coordinate system which is locat-

ed at the tool center point.
By default, the origin of the TOOL coordinate system is located at the flange
center point. (In this case it is called the FLANGE coordinate system.) The
TOOL coordinate system is offset to the tool center point by the user.
Angles of rotation of the robot coordinate systems
Angle Rotation about axis

Angle A Rotation about the Z axis
Angle B Rotation about the Y axis
Angle C Rotation about the X axis
2.2.1.1 Special cases
Fig. 2-3: ROBROOT coordinate system Jet
In the case of Jet robots, the ROBROOT coordinate system is fixed. They do
not move with the robot.

Fig. 2-4: ROBROOT coordinate system KL
In the case of a KL, the relationship between the ROBROOT coordinate sys-
tem and the WORLD coordinate system changes. The ROBROOT coordinate
system moves with the robot on the KL.
2.2.2 Cell area
Description The cell area is a Cartesian monitoring space that is limited in the ±Z direction.
Up to 6 user-configured spheres are modeled around the safe tool on the
mounting flange of the robot; when the robot moves, these spheres move with
it. These spheres are monitored against the cell area and must only move
within this cell area. If a sphere violates the limits of the cell area, the robot
stops with a safety stop 0.
When configuring and programming, it must be remem-

bered that the Cartesian monitoring spaces are only
monitored against the modeled spheres on the mounting flange of the robot.
If robot components are situated outside the modeled spheres, they are not
monitored and a violation of the limit is not detected. Failure to observe this
precaution may result in severe physical injuries and considerable damage
to property.
The cell area is configured in the WORLD coordinate system as a convex poly-
gon with 3 to 10 corners.
A convex polygon is a polygon consisting of at least 3 different corners. The
individual line segments of the vertices must not be outside the polygon. Tri-
angles and squares are examples of convex polygons.

Fig. 2-5
1 Example of a convex polygon with 6 corners

2 Example of a non-convex polygon with 6 corners
Example The diagram shows an example of a configured cell area.
Fig. 2-6: Example of a cell area
1 Cell area
2 Spheres on safe tool
3 Robot
2.2.3 Cartesian workspaces
Description Up to 6 user-configured spheres are modeled around the safe tool on the
it. These spheres are simultaneously monitored against the activated Carte-
sian workspaces and must move within the workspaces.
If a sphere violates the limit of a workspace, the following reactions can occur:
 A safe output is set (alarm space).
If interface X13 is used, safe outputs are only available for monitoring
spaces 1 … 6.
 The robot is stopped (configurable).

 Cartesian velocity monitoring is activated (configurable).

to property.
Only KUKA linear units are supported as ROBROOT kinematic sys-

tems.
Example The diagram shows an example of a configured Cartesian workspace.
Fig. 2-7: Example of a Cartesian workspace
1 Workspace
3 Robot
2.2.4 Cartesian protected spaces
Description Up to 6 user-configured spheres are modeled around the safe tool on the
it. These spheres are simultaneously monitored against the activated Carte-
sian protected spaces and must move outside the protected spaces.
If a sphere violates the limit of a protected space, the following reactions can
occur:
spaces 1 … 6.


to property.
Only KUKA linear units are supported as ROBROOT kinematic sys-

tems.
Example The diagram shows an example of a Cartesian protected space.
Fig. 2-8: Example of a Cartesian protected space
1 Protected space
3 Robot
2.2.5 Axis-specific workspaces
Description The axis limits can be set and monitored individually for each axis via the soft-
ware. The resulting axis range is the permissible range of an axis within which
the robot may move. The individual axis ranges together make up the overall
workspace, which may consist of up to 8 axis ranges. 6 robot axes and 2 ex-
ternal axes can be defined in a workspace.
If the robot violates an axis limit, the following reactions can occur:
spaces 1 … 6.

Example The diagram shows an example of an axis-specific workspace. The work-

space of axis 1 is configured from -110° to +130° and corresponds to the per-
missible motion range of the robot.
Fig. 2-9: Example of an axis-specific workspace
1 Workspace 3 Stopping distance

2 Robot 4 Protected space
2.2.6 Axis-specific protected spaces
Description The axis limits can be set and monitored individually for each axis via the soft-
ware. The resulting axis range is the protected range of an axis within which
the robot may not move. The individual axis ranges together make up the over-
all protected space, which may consist of up to 8 axes ranges. 6 robot axes
and 2 external axes can be defined in a protected space.
If the robot violates an axis limit, the following reactions can occur:
spaces 1 … 6.
In the case of axes that can rotate more than 360°, e.g.
axis 1, the configured axis ranges refer to the position of
the axis (including sign) and not to the sector of a circle. Serious injury and
severe damage to the robot can be caused. If, for example, a protected
space of +90° to +270° is configured, the robot can move through the protect-
ed space in the other direction from -90° to -185°. In this case, it is advisable
to configure a workspace from -90° to +90°.

Fig. 2-10: Example of an axis-specific protected space through which the

robot can move
1 Workspace 3 Protected space

2 Robot 4 Protected space through
which the robot can move
Example The diagram shows an example of an axis-specific protected space. The safe-
guarded space and the stopping distances correspond to the configured pro-
tected space. The motion range of axis 1 is limited to -185° to +185° by means
of software limit switches. The protected space is configured from -110° to
-10°. This results in 2 permissible motion ranges for the robot, separated by
the configured protected space.
Fig. 2-11: Example of an axis-specific protected space
1 Permissible range 1 4 Protected space

2 Robot 5 Permissible range 2
3 Stopping distance

2.2.7 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 safe TCP
is defined for every safe tool. This safe TCP is monitored against a configured
velocity limit. If the safe TCP exceeds the velocity limit, the robot is stopped
safely.
Example The diagram shows an example of a Cartesian workspace. If the safe TCP on
the safe tool exceeds the velocity limit inside the workspace, the robot is
stopped with a safety stop 0.
Fig. 2-12: Space-specific velocity example
1 Workspace
3 Robot
2.2.8 Reference stop
Description 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 or KRR:
 Monitoring space is activated.
 Mastering test is requested internally.
If the reference stop is activated and the following preconditions are met, the
robot stops with a safety stop 2:
 Monitoring space is activated.
 Mastering test is 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.
2.3 Safe tools
Description Up to 16 safe tools can be defined. Up to 6 user-configured spheres are mod-

eled around each safe tool; these are monitored against the limits of the Car-
tesian monitoring spaces. A safe TCP is defined for each safe tool and
monitored against the configured velocity limits.
The safe tools are activated using safe inputs. Only one safe tool may be ac-
tive at any time.
The safe 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.

to property.
Example The diagram shows an example of a safe tool. 2 spheres and a safe TCP are
defined on the safe tool of the robot by means of the FLANGE coordinate sys-
tem.
Fig. 2-13: Safe tool
2.4 Velocity monitoring functions
Axis-specific and Cartesian velocities can be monitored.

Axis velocity The velocity of every axis can be monitored against a limit value.
 Axis velocity limit value
 Reduced axis velocity limit value for T1 mode
 Maximum axis velocity limit value (not axis-dependent)
Cartesian velocity The Cartesian velocity at the safe TCP of the active safe tool can be moni-
tored. The velocity monitoring is always relative to $WORLD:
 Limit value for the reduced velocity at the safe TCP
 Limit value for the reduced velocity at the safe TCP for T1 mode
 Limit value for the maximum velocity at the safe TCP and at the sphere
center points of the safe tool (not space-dependent)
 Space-specific velocity
(>>> 2.2.7 "Space-specific velocity" Page 22)
Stop reactions
Stop reaction Description Example

Safety stop 0 The stop is triggered if a monitoring In automatic operation, the robot
function is already activated and the exceeds the activated limit value for
robot then exceeds the monitoring reduced axis velocity.
limit.
Safety stop 1 The stop is triggered if a monitoring The safe reduced velocity, for which
function is just being activated and the limit value has already been
the robot has already exceeded the exceeded by the robot, is activated
monitoring limit. by a safety mat.
2.5 Safe operational stop
Description Safe operational stop can be configured for up to 6 axis groups. The axes for
which a safe operational stop is to be activated are grouped together in an axis
group. A standstill window can be configured in which an axis can still move
with the safe operational stop activated.
The axis angle or distance tolerance can be configured individually for axes 1
to 8. The axes activated for safe operational stop are not dependent on the ac-
tivated axes for axis-specific workspace monitoring.
If safe operational stop is activated, the standstill of the axes for which it has
been configured is monitored. The axes that are at a monitored standstill may
move within the configured axis angle or distance tolerances. If the safe oper-
ational stop is violated, i.e. if the tolerance is exceeded or the velocity is mini-
mally increased, a safety stop 0 is triggered. The safety stop 0 affects all axes,
not just those for which the operational stop is configured.
2.6 Override reduction
Description Override reduction is not subjected to safe monitoring.

The variables for override reduction can be modified in the $CUSTOM.DAT
file, in a KRL program or via the variable correction function. If a variable is
modified, an advance run stop is triggered.
(>>> 9.1 "Variables for override reduction in $CUSTOM.DAT" Page 99)
$SR_VEL_RED The variable $SR_VEL_RED is used to activate override reduction for the ve-
locity. The Cartesian velocity at the safe TCP of the active tool is automatically
reduced if the programmed velocity is greater than the value of the lowest ve-

locity limit that is activated and currently monitored by the safety controller.
This prevents the robot from being stopped when the Cartesian velocity limit
is exceeded.
$SR_OV_RED The variable $SR_OV_RED specifies the percentage of the lowest velocity
limit that is activated and currently monitored by the safety controller. The Car-
tesian velocity of the safe TCP of the active tool is reduced to this value.
$SR_WORKSPAC If the function Stop at boundaries is activated for a monitoring space, the ro-
E_RED bot stops before it reaches the limit of the workspace. The stopping distance
of the robot and the permissible distance between the robot and the work-
space limits depend on the velocity of the robot.
The variable $SR_WORKSPACE_RED can be used to activate override re-
duction for these monitoring spaces ($SR_WORKSPACE_RED = TRUE).
If override reduction is active and the robot approaches the limit of a work-
space, the override is continuously reduced to allow the robot to get as close
as possible to the workspace limit without being stopped by the safety control-
ler.
If override reduction is active and the robot has violated the limit of a protected
space, the robot reduces its velocity. As soon as it has reached a certain min-
imum distance from the workspace limit, the robot moves at its programmed
velocity once again.
Example The lowest velocity limit active on the safety controller is 1,000 mm/s. If
$SR_VEL_RED = TRUE and $SR_OV_RED = 95 are set, the Cartesian ve-
locity of the safe TCP of the active tool is reduced to 950 mm/s.
Fig. 2-14: Example: Override reduction with $SR_VEL_RED
v3 Maximum Cartesian velocity; v3 = 1,200 mm/s

v2 Space-specific velocity; v2 = 1,000 mm/s
v1 95% of velocity v2; v1 = 950 mm/s
t1 Override reduction is automatically activated because the pro-
grammed velocity exceeds velocity limit v1.
t2 Override reduction is automatically deactivated because the pro-
grammed velocity is lower than the velocity limit v1.
2.7 CRR mode (safe robot retraction)
Description If the robot has violated a monitoring function and been stopped by the safety
controller, it can only be moved out of the violated area in CRR mode. The mo-
tion velocity in CRR mode corresponds to that in T1 mode.
In CRR mode, the robot can be moved to any position. No stop is triggered if
it passes through other monitoring limits. The velocity monitoring functions re-
main active in CRR mode.

2.8 Start-up mode
External safeguards are disabled in Start-up mode. Ob-

serve the safety instructions relating to Start-up mode.
(>>> 4.8.3.1 "Start-up mode" Page 52)
Description Tool 1 is always active in Start-up mode. In Start-up mode, all monitoring func-
tions of the safety configuration that can be activated via safe inputs are deac-
tivated.
(>>> 10.1 "SafeOperation via PROFIsafe (optional)" Page 101)
(>>> 10.2 "SafeOperation via interface X13 (optional)" Page 107)
The following monitoring functions remain active:
 Monitoring of the cell area
 Monitoring of maximum Cartesian velocity
 Monitoring of maximum axis velocity
 Workspace monitoring functions that are configured as always active
 Monitoring of the workspace-specific velocity in workspaces that are con-
figured as always active
 Velocity monitoring in T1
2.9 Mastering test
Overview The mastering test is used to check whether the current position of the robot
and the external axes corresponds to a reference position.
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 or KRR. If the mastering test run was success-
ful, the robot can be safely monitored using the safety controller.
The position to be monitored is not verified until a mastering test has been car-
ried out. It is advisable to perform the mastering test as quickly as possible.
The safety maintenance personnel must carry out a risk assessment

and decide whether additional system-specific safety measures are
required, e.g. reference stop if the mastering test has not been carried
out.
The mastering test must be carried out in the following cases:

 After the robot controller has booted
Once the robot controller has booted, the robot can be moved for 2 hours
without a mastering test. Once the monitoring time has elapsed, the robot
stops with a safety stop 1.
 After mastering
The mastering test can be called in the following ways:
 External request via a signal and automatic call of the program
MasRef_Main.SRC
 Internal request caused by remastering or booting of the robot controller
and automatic call of the program MasRef_Main.SRC
 Manual selection of the program MasRef_Main.SRC

If, during operation, the mastering test is requested via the external signal, the
mastering test is performed next time the program MasRef_Main.SRC is au-
tomatically called.
If the reference switch is activated via PROFIsafe, the

PLC input Mastering test must only be reset if the refer-
ence switch is actuated on both channels. This prevents a single-channel
mastering test.
2.9.1 Reference position
Description The reference position must be taught in the program MasRef_USER.SRC

and in the safety configuration.
(>>> 8.2 "Programming a mastering test" Page 97)
The reference position can be approached with the actuating plate or with a
ferromagnetic part of the tool.
The reference run must be selected in accordance with the following criteria:
 The position of the reference switch and actuating plate must not interfere
with the work sequence of the robot.
 The reference position must not be a position in which the axes are in a
singularity.
 In the reference position, both proximity switch surfaces of the reference
switch must be actuated by the switching surface (actuating plate or tool).
 In the reference position, the robot axes must be at least ±5° away from
the mastering position.
Fig. 2-15: Example: position of the actuating plate on the reference

switch
1 Tool
2 Actuating plate
3 Reference switch
4 Mechanical mounting fixture for the reference switch
5 Actuated reference switch

2.9.2 Reference switch module
Description A reference switch module consists of the following components:

 Inductive reference switch XS Ref
 Actuating plate
 Reference cable X42 - XS Ref
 Reference connector X42
Fig. 2-16: Reference group hardware components
1 Inductive reference switch 2 Actuating plate
2.9.3 Connecting cables
Overview The diagram shows an example of the connecting cables of the industrial robot
with connected reference switch. The reference switch is connected via the
reference cable to the robot controller. The maximum hose length is 50 m.
Only 1 reference switch can be connected to the robot controller. If

multiple reference groups are required, the reference switches can be
connected to the safety PLC and activated via PROFIsafe. The safety
PLC must evaluate the reference switches and set the input Mastering test
accordingly.
Fig. 2-17: Overview of connecting cables

Item Description
1 Robot controller
2 Robot
3 Reference switch XS Ref
4 Reference cable X42 - XS Ref (maximum cable length 50 m)
5 Data cable X21
Cables must not be connected and disconnected during

operation. Only the reference cable X42 - XS Ref sup-
plied by KUKA Roboter GmbH may be used. Reference cable X42 - XS Ref
is suitable for use in a cable carrier. The minimum bending radii must be ob-
served when routing cables.
Type of routing Bending radius

Fixed installation Min. 5xØ of cable
Installation in cable carrier Min. 10xØ of cable


3 Technical data
3 Technical data
3.1 Service life
The maximum permissible service life of safety-relevant hardware compo-

nents is 20 years. Once this time has been reached, the safety-relevant hard-
ware components must be exchanged.
3.2 Reference switch
Designation Values
Ambient temperature -25 °C to +70 °C
Switching function Break contact
DC operating voltage or HIGH level in the case 24 V
of pulsed operating voltage of the reference
switch
Permissible range for the DC operating voltage 20 to 33 V
or HIGH level for pulsed voltage
Required pulse duty factor T(HIGH):T(LOW) for Min. 4:1
pulsed voltage
Supported pulse duration T(LOW) for pulsed 0.1 to 20 ms
voltage
Operating current (power consumption) without 5 mA
load
Permissible load current max. 250 mA
Permissible switching frequency max. 500 Hz
Permissible switching distance at the proximity 0 to 4 mm
switch surfaces
Short circuit and overload protection, pulsed Yes
Outputs  PNP
 LOW-active
 Dual-channel
LED function indicator Yes
Hysteresis when installed 0.2 to 1 mm
EMC conformity IEC 60947-5-2

3.3 Reference switch hole pattern
Description
Fig. 3-1
1 2 holes for fastening elements, Ø 6.6 mm

2 2 holes for roll pins, Ø 4 mm
3.4 Hole pattern for actuating plate
Description
Fig. 3-2

3 Technical data
1 2 M6 threaded holes for fastening elements

2 2 holes for fastening elements, Ø 9 mm


4 Safety
4 Safety
4.1 General
4.1.1 Liability
The device described in this document is either an industrial robot or a com-

ponent 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 accor-
dance 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 accor-
dance with its intended use and only by safety-conscious persons who are ful-
ly 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 incorpo-
ration supplied together with the industrial robot. Any functional disorders af-
fecting the safety of the industrial robot must be rectified immediately.
Safety infor- Safety information cannot be held against KUKA Roboter GmbH. Even if all
mation 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 autho-
rization of KUKA Roboter GmbH. Additional components (tools, software,
etc.), not supplied by KUKA Roboter GmbH, may be integrated into the indus-
trial 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 instruc-
tions. These must also be observed.
4.1.2 Intended use of the industrial robot
The industrial robot is intended exclusively for the use designated in the “Pur-
pose” chapter of the operating instructions or assembly instructions.
Further information is contained in the “Purpose” chapter of the oper-

ating instructions or assembly instructions of the industrial robot.
Using the industrial robot for any other or additional purpose is considered im-
permissible misuse. The manufacturer cannot be held liable for any damage
resulting from such use. The risk lies entirely with the user.
Operating the industrial robot and its options within the limits of its intended
use also involves observance of the operating and assembly instructions for

the individual components, with particular reference to the maintenance spec-

ifications.
Misuse Any use or application deviating from the intended use is deemed to be imper-
missible misuse. This includes e.g.:
 Transportation of persons and animals
 Use as a climbing aid
 Operation outside the permissible operating parameters
 Use in potentially explosive environments
 Operation without additional safeguards
 Outdoor operation
4.1.3 EC declaration of conformity and declaration of incorporation
This 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:
 The industrial robot is integrated into a complete system.
Or: The industrial robot, together with other machinery, constitutes a com-
plete system.
Or: All safety functions and safeguards required for operation in the com-
plete 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 an assessment of conformity.
Declaration of The system integrator must issue a declaration of conformity for the complete
conformity system in accordance with the Machinery Directive. The declaration of confor-
mity forms the basis for the CE mark for the system. The industrial robot must
be operated in accordance with the applicable national laws, regulations and
standards.
The robot controller is CE certified under the EMC Directive and the Low Volt-
age Directive.
Declaration of The industrial robot as partly completed machinery is supplied with a declara-
incorporation tion of incorporation in accordance with Annex II B of the EC Machinery Direc-
tive 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 com-
pleted machinery remains impermissible 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 Ma-
chinery Directive, and the EC declaration of conformity is present in accor-
dance with Annex II A.
The declaration of incorporation, together with its annexes, remains with the
system integrator as an integral part of the technical documentation of the
complete machinery.
4.1.4 Terms used
STOP 0, STOP 1 and STOP 2 are the stop definitions according to EN 60204-
1:2006.

4 Safety
Term Description
Axis range Range of each axis, in degrees or millimeters, within which it 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 The manipulator is allowed to move within its workspace. The work-
space is derived from the individual axis ranges.
Operator The user of the industrial robot can be the management, employer or
(User) delegated person responsible for use of the industrial robot.
Danger zone The danger zone consists of the workspace and the stopping distances.
KCP The KCP (KUKA Control Panel) teach pendant has all the operator con-
trol and display functions required for operating and programming the
industrial robot.
The KCP variant for the KR C4 is called KUKA smartPAD. The general
term “KCP”, however, is generally used in this documentation.
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
stop the robot motion, but monitors whether the robot axes are station-
ary. If these are moved during the safe operational stop, a safety stop
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 sta-
tionary at the time of triggering, thereby causing a safety stop 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 brak-
ing process is performed by the non-safety-oriented part of the robot
controller and monitored by the safety controller. As soon as the manip-
ulator is at a standstill, the safety controller switches off the drives and
the power supply to the brakes.
When a safety STOP 1 is triggered, the robot controller sets an output to
the field bus.
The safety STOP 1 can also be triggered externally.
Safety STOP 2 A stop that is triggered and monitored by the safety controller. The brak-
ing process is performed by the non-safety-oriented part of the robot
controller and monitored by the safety controller. The drives remain acti-
vated and the brakes released. As soon as the manipulator is at a stand-
still, a safe operational stop is triggered.
When a safety STOP 2 is triggered, the robot controller sets an output to
the field bus.
The safety STOP 2 can also be triggered externally.

Term Description
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 path-main-
taining braking. The drives are deactivated after 1 s and the brakes are
applied.
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.
System integrator System integrators are people who safely integrate the industrial robot
(plant integrator) into a complete system and commission it.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)
T2 Test mode, Manual High Velocity (> 250 mm/s permissible)
External axis Motion axis which is not part of the manipulator but which is controlled
using the robot controller, e.g. KUKA linear unit, turn-tilt table, Posiflex.
4.2 Personnel
The following persons or groups of persons are defined for the industrial robot:
 User
 Personnel
All persons working with the industrial robot must have read and un-
derstood 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 instruction at defined intervals.
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 ex-
ist. 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
 Operating personnel
 Cleaning personnel
Installation, exchange, adjustment, operation, maintenance and re-

pair must be performed only as specified in the operating or assembly
instructions for the relevant component of the industrial robot and only
by personnel specially trained for this purpose.
System integrator The industrial robot is safely integrated into a complete system by the system
integrator.

4 Safety
The system integrator is responsible for the following tasks:

 Installing the industrial robot
 Connecting the industrial robot
 Performing risk assessment
 Implementing the required safety functions and safeguards
 Issuing the declaration of conformity
 Attaching the CE mark
 Creating the operating instructions for the complete system
Operator The operator must meet the following preconditions:

 The operator must be trained for the work to be carried out.
 Work on the industrial robot must only be carried out by qualified person-
nel. 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.
Example The tasks can be distributed as shown in the following table.
System
Tasks Operator Programmer
integrator
Switch robot controller
x x x
on/off
Start program x x x
Select program x x x
Select operating mode x x x
Calibration
x x
(tool, base)
Master the manipulator x x
Configuration x x
Programming x x
Start-up x
Maintenance x
Repair x
Decommissioning x
Transportation x
Work on the electrical and mechanical equipment of the industrial ro-

bot may only be carried out by specially trained personnel.
4.3 Workspace, safety zone and danger zone
Workspaces are to be restricted to the necessary minimum size. A workspace

must be safeguarded using appropriate safeguards.
The safeguards (e.g. safety gate) must be situated inside the safety zone. In
the case of a stop, the manipulator and external axes (optional) are braked
and come to a stop within the danger zone.

The danger zone consists of the workspace and the stopping distances of the
manipulator and external axes (optional). It must be safeguarded by means of
physical safeguards to prevent danger to persons or the risk of material dam-
age.
Fig. 4-1: Example of axis range A1
1 Workspace 3 Stopping distance

2 Manipulator 4 Safety zone
4.4 Triggers for stop reactions
Stop reactions of the industrial robot are triggered in response to operator ac-
tions or as a reaction to monitoring functions and error messages. The follow-
ing tables show 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
“Motion enable” input STOP 2
drops out
Robot controller switched STOP 0
off (power failure)
Internal error in non- STOP 0 or STOP 1
safety-oriented part of the
(dependent on the cause of the error)
robot controller
Operating mode changed Safety stop 2
during operation
Safety gate opened (oper- - Safety stop 1
ator safety)
Enabling switch released Safety stop 2 -
Enabling switch pressed Safety stop 1 -
fully down or error

4 Safety
Trigger T1, T2 AUT, AUT EXT

E-STOP pressed Safety stop 1
Error in safety controller Safety stop 0
or periphery of the safety
controller
4.5 Safety functions
4.5.1 Overview of the safety functions
The following safety functions are present in the industrial robot:

 Mode selection
 Operator safety (= connection for the guard interlock)
 EMERGENCY STOP device
 Enabling device
 External safe operational stop
 External safety stop 1
 External safety stop 2
The safety functions of the industrial robot have the following performance:
Category 3 and Performance Level d in accordance with EN ISO 13849-
1:2008. This corresponds to SIL 2 and HFT 1 in accordance with EN 62061.
This performance only applies under the following conditions, however:
 The EMERGENCY STOP button is pressed at least once every 6 months.
The following components are involved in the safety functions:
 Safety controller in the control PC
 KUKA Control Panel (KUKA smartPAD)
 Cabinet Control Unit (CCU)
 Resolver Digital Converter (RDC)
 KUKA Power Pack (KPP)
 KUKA Servo Pack (KSP)
 Safety Interface Board (SIB) (if used)
There are also interfaces to components outside the industrial robot and to
other robot controllers.
In the absence of operational safety functions and safe-

guards, the industrial robot can cause personal injury or
material damage. If safety functions or safeguards are dismantled or deacti-
vated, the industrial robot may not be operated.
During system planning, the safety functions of the overall system

must also be planned and designed. The industrial robot must be in-
tegrated into this safety system of the overall system.
4.5.2 Safety controller
The safety controller is a unit inside the control PC. It links safety-relevant sig-
nals and safety-relevant monitoring functions.

Safety controller tasks:

 Switching off the drives; applying the brakes
 Monitoring the braking ramp
 Standstill monitoring (after the stop)
 Evaluation of safety-relevant signals
 Setting of safety-oriented outputs
4.5.3 Mode selection
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.
Operatin
Use Velocities
g mode
 Program verification:
Programmed velocity, maxi-
For test operation, pro- mum 250 mm/s
T1 gramming and teach-
ing  Jog mode:
Jog velocity, maximum 250 mm/
s
 Program verification:
T2 For test operation Programmed velocity
 Jog mode: Not possible
For industrial robots  Program mode:
AUT without higher-level Programmed velocity
controllers  Jog mode: Not possible
For industrial robots  Program mode:
AUT EXT with higher-level con- Programmed velocity
trollers, e.g. PLC  Jog mode: Not possible
4.5.4 Operator safety
The operator safety signal is used for interlocking 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 the test modes T1 (Manual Reduced Velocity)
and T2 (Manual High Velocity).

4 Safety
Following a loss of signal, automatic operation must not

be resumed merely by closing the safeguard; it must first
additionally be acknowledged. It is the responsibility of the system integrator
to ensure this. This is to prevent automatic operation from being resumed in-
advertently while there are still persons in the danger zone, e.g. due to the
safety gate closing accidentally.
 The acknowledgement must be designed in such a way that an actual
check of the danger zone can be carried out first. Acknowledgement
functions that do not allow this (e.g. because they are automatically trig-
gered by closure of the safeguard) are not permissible.
 Failure to observe this may result in death to persons, severe physical in-
juries or considerable damage to property.
4.5.5 EMERGENCY STOP device
The EMERGENCY STOP device for the industrial robot is the EMERGENCY
STOP button on the KCP. The button must be pressed in the event of a haz-
ardous situation or emergency.
Reactions of the industrial robot if the EMERGENCY STOP button is pressed:
 The manipulator and any external axes (optional) are stopped with a safe-
ty stop 1.
Before operation can be resumed, the EMERGENCY STOP button must be
turned to release it.
Tools and other equipment connected to the manipulator

must be integrated into the EMERGENCY STOP circuit
on the system side if they could constitute a potential hazard.
Failure to observe this precaution may result in death, severe physical inju-
ries or considerable damage to property.
There must always be at least one external EMERGENCY STOP device in-
stalled. This ensures that an EMERGENCY STOP device is available even
when the KCP is disconnected.
(>>> 4.5.7 "External EMERGENCY STOP device" Page 44)
4.5.6 Logging off the higher-level safety controller
If the robot controller is connected to a higher-level safety controller, switching

off the robot controller inevitably terminates this connection. The KUKA safety
controller generates a signal that prevents the higher-level controller from trig-
gering an EMERGENCY STOP for the overall system.
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 sys-
tem could constitute a hazard and, if so, how this hazard can be countered.
Failure to take this into consideration may result in death to persons, severe
physical injuries or considerable damage to property.

If a robot controller is switched off, the E-STOP button on

the KCP is no longer functional. The user is responsible
for ensuring that the KCP is either covered or removed from the system. This
serves to prevent operational and non-operational EMERGENCY STOP fa-
cilities from becoming interchanged.
Failure to observe this precaution may result in death to persons, severe
physical injuries or considerable damage to property.
4.5.7 External EMERGENCY STOP device
There must be EMERGENCY STOP devices available at every operator sta-

tion that can initiate a robot motion or other potentially hazardous situation.
The system integrator is responsible for ensuring this.
There must always be at least one external EMERGENCY STOP device in-
stalled. This ensures that an EMERGENCY STOP device is available even
when the KCP is disconnected.
External EMERGENCY STOP devices are connected via the customer inter-
face. External EMERGENCY STOP devices are not included in the scope of
supply of the industrial robot.
4.5.8 Enabling device
The enabling devices of the industrial robot are the enabling switches on the
KCP.
There are 3 enabling switches installed on the KCP. The enabling switches
have 3 positions:
 Not pressed
 Center position
 Panic position
In the test modes, the manipulator can only be moved if one of the enabling
switches is held in the central position.
 Releasing the enabling switch triggers a safety stop 2.
 Pressing the enabling switch down fully (panic position) triggers a safety
stop 1.
 It is possible, for a short time, to hold 2 enabling switches in the center po-
sition simultaneously. This makes it possible to adjust grip from one en-
abling switch to another one. If 2 enabling switches are held
simultaneously in the center position for a longer period of time, this trig-
gers a safety stop after several seconds.
If an enabling switch malfunctions (jams), the industrial robot can be stopped
using the following methods:
 Press the enabling switch down fully
 Actuate the EMERGENCY STOP system
 Release the Start key
The enabling switches must not be held down by adhe-

sive tape or other means or manipulated in any other
way.
Death, serious physical injuries or major damage to property may result.

4 Safety
4.5.9 External enabling device
External enabling devices are required if it is necessary for more than one per-
son to be in the danger zone of the industrial robot. They are connected to the
robot controller via the customer interface.
External enabling devices are not included in the scope of supply of the indus-
trial robot.
4.5.10 External safe operational stop
The safe operational stop can be triggered via an input on the customer inter-
face. The state is maintained as long as the external signal is FALSE. If the
external signal is TRUE, the manipulator can be moved again. No acknowl-
edgement is required.
4.5.11 External safety stop 1 and external safety stop 2
Safety stop 1 and safety stop 2 can be triggered via an input on the customer
interface. The state is maintained as long as the external signal is FALSE. If
the external signal is TRUE, the manipulator can be moved again. No ac-
knowledgement is required.
4.5.12 Velocity monitoring in T1
The velocity at the TCP is monitored in T1 mode. If, due to an error, the veloc-
ity exceeds 250 mm/s, a safety stop 0 is triggered.
4.6 Additional protective equipment
4.6.1 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.
4.6.2 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 ro-
bot.
Further information is contained in the operating and programming in-

structions.

4.6.3 Mechanical end stops
The axis ranges of main axes A1 to A3 and wrist axis A5 of the manipulator
are limited by means of mechanical end stops with buffers.
Additional mechanical end stops can be installed on the external axes.
If the manipulator or an external axis hits an obstruction

or a buffer on the mechanical end stop or axis range lim-
itation, this can result in material damage to the industrial robot. KUKA Ro-
boter GmbH must be consulted before the industrial robot is put back into
operation. (>>> 14 "KUKA Service" Page 131)
The affected buffer must be replaced with a new one before operation of the
industrial robot is resumed. If a manipulator (or external axis) collides with a
buffer at more than 250 mm/s, the manipulator (or external axis) must be ex-
changed or recommissioning must be carried out by KUKA Roboter GmbH.
4.6.4 Mechanical axis range limitation (optional)
Some manipulators can be fitted with mechanical axis range limitation in axes
A1 to A3. The adjustable axis range 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 range 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 mechan-
ical axis range limitation.
If this is not possible, the workspace must be limited by means of photoelectric
barriers, photoelectric curtains or obstacles 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 spe-
cific robot models can be obtained from KUKA Roboter GmbH.
4.6.5 Axis range monitoring (optional)
Some manipulators can be fitted with dual-channel axis range monitoring sys-
tems in main axes A1 to A3. The positioner axes may be fitted with additional
axis range monitoring systems. The safety zone for an axis can be adjusted
and monitored using an axis range monitoring system. This increases person-
al safety and protection of the system.
This option is not available for all robot models. Information on spe-
cific robot models can be obtained from KUKA Roboter GmbH.
4.6.6 Release device (optional)
Description The release device can be used to move the manipulator manually after an ac-
cident or malfunction. The release device can be used for the main axis drive
motors and, depending on the robot variant, also for the wrist axis drive mo-
tors. It is only for use in exceptional circumstances and emergencies (e.g. for
freeing people).

4 Safety
The motors reach temperatures during operation which

can cause burns to the skin. Contact must be avoided.
Appropriate safety precautions must be taken, e.g. protective gloves must be
worn.
Procedure 1. Switch off the robot controller and secure it (e.g. with a padlock) to prevent
unauthorized persons from switching it on again.
2. Remove the protective cap from the motor.
3. Push the release device onto the corresponding motor and move the axis
in the desired direction.
The directions are indicated with arrows on the motors. It is necessary to
overcome the resistance of the mechanical motor brake and any other
loads acting on the axis.
Moving an axis with the release device can damage the

motor brake. This can result in personal injury and mate-
rial damage. After using the release device, the affected motor must be ex-
changed.
4.6.7 Labeling on the industrial robot
All plates, labels, symbols and marks constitute safety-relevant parts of the in-
dustrial robot. They must not be modified or removed.
Labeling on the industrial robot consists of:
 Identification plates
 Warning labels
 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 indus-
trial robot.
4.6.8 External safeguards
The access of persons to the danger zone of the industrial robot must be pre-
vented by means of safeguards. It is the responsibility of the system integrator
to ensure this.
Physical safeguards must meet the following requirements:
 They meet the requirements of EN 953.
 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 en-
closure.
 They do not, themselves, represent a hazard or potential hazard.
 The prescribed minimum clearance from the danger zone is maintained.
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 re-
quirements of Performance Level d and category 3 according to EN ISO
13849-1.
 Depending on the risk 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 953.
Other safety Other safety equipment must be integrated into the system in accordance with
equipment the corresponding standards and regulations.
4.7 Overview of operating modes and safety functions
The following table indicates the operating modes in which the safety functions
are active.
Safety functions T1 T2 AUT AUT EXT

Operator safety - - active active
EMERGENCY STOP
active active active active
device
Enabling device active active - -
Reduced velocity during
active - - -
program verification
Jog mode active active - -
Software limit switches active active active active
4.8 Safety measures
4.8.1 General safety measures
The industrial robot may only be used in perfect technical condition in accor-
dance 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. Incorrect in-
stallation (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 ex-
ternal axes must be secured by appropriate means.

4 Safety
In the absence of operational safety functions and safe-

guards, the industrial robot can cause personal injury or
material damage. If safety functions or safeguards are dismantled or deacti-
vated, the industrial robot may not be operated.
Standing underneath the robot arm can cause death or

serious physical injuries. For this reason, standing un-
derneath the robot arm is prohibited!
The motors reach temperatures during operation which

can cause burns to the skin. Contact must be avoided.
Appropriate safety precautions must be taken, e.g. protective gloves must be
worn.
KCP The user must ensure that the industrial robot is only operated with the KCP
by authorized persons.
If more than one KCP is used in the overall system, it must be ensured that
each KCP is unambiguously assigned to the corresponding industrial robot.
They must not be interchanged.
The operator must ensure that decoupled KCPs are im-

mediately removed from the system and stored out of
sight and reach of personnel working on the industrial robot. This serves to
prevent operational and non-operational EMERGENCY STOP facilities from
becoming interchanged.
Failure to observe this precaution may result in death, severe physical inju-
ries or considerable damage to property.
External An external keyboard and/or external mouse may only be used if the following
keyboard, conditions are met:
external mouse  Start-up or maintenance work is being carried out.
 The drives are switched off.
 There are no persons in the danger zone.
The KCP must not be used as long as an external keyboard and/or external
mouse are connected.
The external keyboard and/or external mouse must be removed as soon as
the start-up or maintenance work is completed or the KCP is connected.
Faults The following tasks must be carried out in the case of faults in the industrial
robot:
 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 (tag-
out).
 Keep a record of the faults.
 Eliminate the fault and carry out a function test.
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 circuits
must also be tested.
New or modified programs must always be tested first in Manual Reduced Ve-
locity 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 compo-
nents of the industrial robot and includes modifications to the software and
configuration settings.
4.8.2 Transportation
Manipulator The prescribed transport position of the manipulator must be observed. Trans-
portation must be carried out in accordance with the operating instructions or
assembly instructions of the manipulator.
Robot controller The robot controller must be transported and installed in an upright position.
Avoid vibrations and impacts during transportation in order to prevent damage
to the robot controller.
Transportation must be carried out in accordance with the operating instruc-
tions or assembly instructions of the robot controller.
External axis The prescribed transport position of the external axis (e.g. KUKA linear unit,
(optional) turn-tilt table, etc.) must be observed. Transportation must be carried out in ac-
cordance with the operating instructions or assembly instructions of the exter-
nal axis.
4.8.3 Start-up and recommissioning
Before starting up systems and devices for the first time, a check must be car-
ried 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 circuits must also be tested.
The passwords for logging onto the KUKA System Software as “Ex-
pert” and “Administrator” must be changed before start-up and must
only be communicated to authorized personnel.
The robot controller is preconfigured for the specific in-

dustrial robot. If cables are interchanged, the manipula-
tor and the external axes (optional) may receive incorrect data and can thus
cause personal injury or material damage. If a system consists of more than
one manipulator, always connect the connecting cables to the manipulators
and their corresponding robot controllers.
If additional components (e.g. cables), which are not part of the scope
of supply of KUKA Roboter GmbH, are integrated into the industrial
robot, the user is responsible for ensuring that these components do
not adversely affect or disable safety functions.
If the internal cabinet temperature of the robot controller

differs greatly from the ambient temperature, condensa-
tion can form, which may cause damage to the electrical components. Do not
put the robot controller into operation until the internal temperature of the
cabinet has adjusted to the ambient temperature.
Function test The following tests must be carried out before start-up and recommissioning:
General test:

4 Safety
It must be ensured that:

 The industrial robot is correctly installed and fastened in accordance with
the specifications in the documentation.
 There are no foreign bodies 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:
A function test must be carried out for the following safety functions to ensure
that they are functioning correctly:
 Local EMERGENCY STOP device (= EMERGENCY STOP button on the
KCP)
 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
Test of reduced velocity control:
This test is to be carried out as follows:
1. Program a straight path with the maximum possible velocity.
2. Calculate the length of the path.
3. Execute the path in T1 mode with the override set to 100% and time the
motion with a stopwatch.
It must be ensured that no persons are present within the

danger zone during path execution. Death or severe
physical injuries may result.
4. Calculate the velocity from the length of the path and the time measured
for execution of the motion.
Control of reduced velocity is functioning correctly if the following results are
achieved:
 The calculated velocity does not exceed 250 mm/s.
 The manipulator executes the path as programmed (i.e. in a straight line,
without deviations).
Machine data It must be ensured that the rating plate on the robot controller has the same
machine data as those entered in the declaration of incorporation. The ma-
chine data on the rating plate of the manipulator and the external axes (option-
al) must be entered during start-up.
The industrial robot must not be moved if incorrect ma-

chine data are loaded. Death, severe physical injuries or
considerable damage to property may otherwise result. The correct machine
data must be loaded.
Following modifications to the machine data, the safety configuration must be

checked.

Further information is contained in the Operating and Programming

Instructions for System Integrators.
Following modifications to the machine data, control of the reduced velocity

must be checked.
4.8.3.1 Start-up mode
Description The industrial robot can be set to Start-up mode via the smartHMI user inter-
face. In this mode, the manipulator can be moved in T1 in the absence of the
safety periphery.
If a connection to a higher-level safety system exists or is established, the ro-
bot controller prevents or terminates Start-up mode.
Hazards Possible hazards and risks involved in using Start-up mode:

 A person walks into the manipulator’s danger zone.
 An unauthorized person moves the manipulator.
 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 in-
dicating that the EMERGENCY STOP device is out of operation.
 If there is no safety fence, other measures must be taken to prevent per-
sons from entering the manipulator’s danger zone, e.g. use of warning
tape.
 Use of Start-up mode must be minimized – and avoided where possible –
by means of organizational measures.
Use Intended use of Start-up mode:

 Only service personnel who have received safety instruction may use
Start-up mode.
 Start-up in T1 mode when the external safeguards have not yet been in-
stalled 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 disables all external safeguards.

The service personnel are responsible for ensuring that
there is no-one in or near the danger zone of the manipulator.
Misuse Any use or application deviating from the designated use is deemed to be im-
permissible misuse. This includes, for example, use by any other personnel.
KUKA Roboter GmbH accepts no liability for damage or injury caused thereby.
The risk lies entirely with the user.
4.8.4 Manual mode
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

4 Safety
 Program verification
The following must be taken into consideration in manual mode:
 If the drives are not required, they must be switched off to prevent the ma-
nipulator or the external axes (optional) from being moved unintentionally.
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 re-
sult 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 safe-
guarded area.
If the setup work has to be carried out inside the safeguarded area, the follow-
ing must be taken into consideration:
In Manual Reduced Velocity mode (T1):
 If it can be avoided, there must be no other persons inside the safeguard-
ed area.
If it is necessary for there to be several persons inside the safeguarded ar-
ea, 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 area
and get out of harm’s way.
In Manual High Velocity mode (T2):
 This mode may only be used if the application requires a test at a velocity
higher than Manual Reduced Velocity.
 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 re-
sponsibility of the operator to ensure this.
4.8.5 Simulation
Simulation programs do not correspond exactly to reality. Robot programs cre-

ated in simulation programs must be tested in the system in Manual Reduced
Velocity mode (T1). It may be necessary to modify the program.
4.8.6 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.
 The defined working procedures are adhered to.
If the manipulator or an external axis (optional) comes to a standstill for no ap-
parent reason, the danger zone must not be entered until an EMERGENCY
STOP has been triggered.

4.8.7 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 circuits
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 operation-
al state. Repair work includes troubleshooting in addition to the actual repair
itself.
The following safety measures must be carried out when working on the indus-
trial 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 mea-
sures to ensure the safe protection of personnel.
 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 systems 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.
Before work is commenced on live parts of the robot sys-

tem, the main switch must be turned off and secured
against being switched on again. The system must then be checked to en-
sure that it is deenergized.
It is not sufficient, before commencing work on live parts, to execute an
EMERGENCY STOP or a safety stop, or to switch off the drives, as this does
not disconnect the robot system from the mains power supply in the case of
the drives of the new generation. Parts remain energized. Death or severe
physical injuries may result.
Faulty components must be replaced using new components with the same
article numbers or equivalent components approved by KUKA Roboter 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.
Water and dust must be prevented from entering the robot controller.
Counterbal- Some robot variants are equipped with a hydropneumatic, spring or gas cylin-
ancing system der counterbalancing system.

4 Safety
The hydropneumatic and gas cylinder counterbalancing systems are pressure

equipment and, as such, are subject to obligatory equipment monitoring. De-
pending on the robot variant, the counterbalancing systems correspond to cat-
egory 0, II or III, fluid group 2, of the Pressure Equipment Directive.
The user must comply with the applicable national laws, regulations and stan-
dards pertaining to pressure equipment.
Inspection intervals in Germany in accordance with Industrial Safety Order,
Sections 14 and 15. Inspection by the user before commissioning at the instal-
lation site.
The following safety measures must be carried out when working on the coun-
terbalancing system:
 The manipulator assemblies supported by the counterbalancing systems
must be secured.
 Work on the counterbalancing systems must only be carried out by quali-
fied personnel.
Hazardous The following safety measures must be carried out when handling hazardous
substances substances:
 Avoid prolonged and repeated intensive contact with the skin.
 Avoid breathing in oil spray or vapors.
 Clean skin and apply skin cream.
To ensure safe use of our products, we recommend that our custom-

ers regularly request up-to-date safety data sheets from the manufac-
turers of hazardous substances.
4.8.8 Decommissioning, storage and disposal
The industrial robot must be decommissioned, stored and disposed of in ac-

cordance with the applicable national laws, regulations and standards.
4.8.9 Safety measures for “single point of control”
Overview If certain components in the industrial robot are operated, safety measures
must be taken to ensure complete implementation of the principle of “single
point of control” (SPOC).
Components:
 Submit interpreter
 PLC
 OPC Server
 Remote control tools
 Tools for configuration of bus systems with online functionality
 KUKA.RobotSensorInterface
 External keyboard/mouse
The implementation of additional safety measures may be required.

This must be clarified for each specific application; this is the respon-
sibility of the system integrator, programmer or user of the system.
Since only the system integrator knows the safe states of actuators in the pe-
riphery 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.

T1, T2 In the test modes, the components referred to above (with the exception of the
external keyboard/mouse) 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 inter- If motions, (e.g. drives or grippers) are controlled with the Submit interpreter
preter, PLC 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 EMER-
GENCY 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.
Safety measures:
 In the test modes, the system variable $OV_PRO must not be written to
by the Submit interpreter or the PLC.
 Do not modify safety-relevant signals and variables (e.g. operating mode,
EMERGENCY STOP, safety gate contact) via the Submit interpreter or
PLC.
If modifications are nonetheless required, all safety-relevant signals and
variables must be linked in such a way that they cannot be set to a dan-
gerous state by the Submit interpreter or PLC.
OPC server, These components can be used with write access to modify programs, outputs
remote control or other parameters of the robot controller, without this being noticed by any
tools persons located inside the system.
Safety measures:
 KUKA stipulates that these components are to be used exclusively for di-
agnosis and visualization.
Programs, outputs or other parameters of the robot controller must not be
modified using these components.
 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 us-
ing an external enabling device, for example.
Tools for configu- If these components have an online functionality, they can be used with write
ration of bus access to modify programs, outputs or other parameters of the robot control-
systems ler, without this being noticed by any persons located inside the system.
 WorkVisual from KUKA
 Tools from other manufacturers
Safety measures:
 In the test modes, programs, outputs or other parameters of the robot con-
troller must not be modified using these components.
External These components can be used to modify programs, outputs or other param-
keyboard/mouse eters of the robot controller, without this being noticed by any persons located
inside the system.
Safety measures:
 Only use one operator console at each robot controller.
 If the KCP is being used for work inside the system, remove any keyboard
and mouse from the robot controller beforehand.

4 Safety
4.9 Applied norms and regulations
Name Definition Edition

2006/42/EC Machinery Directive: 2006
Directive 2006/42/EC of the European Parliament and of
the Council of 17 May 2006 on machinery, and amending
Directive 95/16/EC (recast)
2004/108/EC EMC Directive: 2004
Directive 2004/108/EC of the European Parliament and of
the Council of 15 December 2004 on the approximation of
the laws of the Member States relating to electromagnetic
compatibility and repealing Directive 89/336/EEC
97/23/EC Pressure Equipment Directive: 1997
Directive 97/23/EC of the European Parliament and of the
Council of 29 May 1997 on the approximation of the laws
of the Member States concerning pressure equipment
(Only applicable for robots with hydropneumatic counter-
balancing system.)
EN ISO 13850 Safety of machinery: 2008
Emergency stop - Principles for design
EN ISO 13849-1 Safety of machinery: 2008
Safety-related parts of control systems - Part 1: General
principles of design
Safety-related parts of control systems - Part 2: Validation
Basic concepts, general principles for design - Part 1:
Basic terminology, methodology
Basic concepts, general principles for design - Part 2:
Technical principles
EN ISO 10218-1 Industrial robots: 2008
Safety
EN 614-1 Safety of machinery: 2006
Ergonomic design principles - Part 1: Terms and general
principles
EN 61000-6-2 Electromagnetic compatibility (EMC): 2005
Part 6-2: Generic standards; Immunity for industrial envi-
ronments
EN 61000-6-4 Electromagnetic compatibility (EMC): 2007
Part 6-4: Generic standards; Emission standard for indus-
trial environments
EN 60204-1 Safety of machinery: 2006
Electrical equipment of machines - Part 1: General
requirements

EN ISO 10218-1, Annex B, specifies the need for information about

the stopping time and distance. These have not yet been determined
in full for all robot types in conjunction with the KR C4 robot controller.
In this respect, the industrial robot does not conform to the requirements of
EN ISO 10218-1.

5 Installation
5 Installation
5.1 System requirements
Hardware  KR C4
Software  KUKA System Software 8.2

 Or VW System Software 8.2
Compatibility  KUKA.SafeOperation must not be installed on a robot controller together

with the following technology packages:
 KUKA.SafeRangeMonitoring
5.2 Installing or updating SafeOperation
It is advisable to archive all relevant data before updating a software

package.
Precondition  Expert user group

 Software on KUKA.USB data stick
Only the KUKA.USB data stick may be used. Data may

be lost or modified if any other USB stick is used.
Procedure 1. Plug in USB stick.

2. Select Start-up > Install additional software in the main menu.
3. Press New software. If a software package that is on the USB stick is not
displayed, press Refresh.
4. Select the entry SafeOperation and press Install. Reply to the request
for confirmation with Yes. The files are copied onto the hard drive.
5. Repeat step 4 if another software package is to be installed from this stick.
6. Remove USB stick.
7. It may be necessary to reboot the controller, depending on the additional
software. In this case, a corresponding prompt is displayed. Confirm with
OK and reboot the robot controller. Installation is resumed and completed.
LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.
5.3 Uninstalling SafeOperation
It is advisable to archive all relevant data before uninstalling a soft-

ware package.
Before uninstalling the software, the safety maintenance technician

must deactivate the safe monitoring. If the safe monitoring is not de-
activated before uninstallation, the safety configuration remains ac-
tive.
Precondition  Expert user group
Procedure 1. Select Start-up > Install additional software in the main menu. All addi-
tional programs installed are displayed.

2. Select the entry SafeOperation and press Uninstall. Reply to the request
for confirmation with Yes. Uninstallation is prepared.
3. Reboot the robot controller. Uninstallation is resumed and completed.
LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.

6 Operation
6 Operation
6.1 User groups
Different functions are available in the KSS, depending on the user group. The
following user groups are relevant for the safety configuration of the robot:
 Safety recovery
This user can activate an existing safety configuration of the robot using
an activation code. If no safe option, e.g. KUKA.SafeOperation or KU-
KA.SafeRangeMonitoring, is being used, the safety recovery technician
has more extensive rights. In this case he is authorized, for example, to
configure the standard safety functions.
This user group is protected by means of a password.
 Safety maintenance
User group for the start-up technician. This user can edit the safety config-
uration and make safety-relevant changes.
This user group is protected by means of a password.
The safety maintenance technician must be specially trained in the configura-
tion of safety functions. For this, we recommend training courses at KUKA Col-
lege. Information about the training program can be found at www.kuka.com
or can be obtained directly from our subsidiaries.
The password for the “Safety Maintenance” and “Safety Recovery”

user groups must be changed before start-up and must only be com-
municated to authorized personnel.
6.2 Opening the safety configuration
Procedure 1. Select Configuration > Safety configuration in the main menu.

2. 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 window is
opened.
 If there are deviations, the Troubleshooting wizard window 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 con-

tained in the Operating and Programming Instructions for System In-
tegrators.
6.3 Overview of buttons
The following buttons are available:
Button Description
Reset all to default Resets all parameters of the safety configuration
values to the default values.
Reset changes Resets all changes since the last time the config-
uration was saved.
Change log The log of changes to the safety configuration is
displayed.
View The safety-relevant machine data are displayed.

Button Description
Properties The properties of a monitoring space or safe tool
can be defined.
Device management 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 configura-
tion 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 Saves the current robot flange position or the
position for group position of the axes of a reference group as a
reference position.
Cell configuration The cell area can be defined.
Back Back to the tab
6.4 Monitor functions
6.4.1 Displaying information about the safety configuration
Procedure  Select Configuration > Safety configuration in the main menu.

The safety configuration opens with the General tab.
Description The General tab contains the following information:
Parameter Description
Robot Serial number of the robot
Safety controller  Version of SafeOperation
 Safety controller version (internal)
Parameter data set  Checksum of the safety configuration
 Time stamp of the safety configuration (date
and time last saved)
 Safety configuration version
 Activation code of the safety configuration

6 Operation
Machine data Time stamp of the safety-relevant machine data
(date and time last saved)
Current configuration  State of the safe monitoring (activated or de-
activated)
 Name of the active bus system
 Checksum of the brake test configuration
 Number of velocity-monitored axes
 Number of monitoring spaces
 Number of protected spaces
 Number of safe tools
6.4.2 Displaying the change log
Every modification to the safety configuration and every saving operation is

automatically logged. The log can be displayed.
Procedure  Select Configuration > Safety configuration in the main menu.

 Press Change log.
6.4.3 Displaying machine data
The safety-relevant machine data can be displayed.

2. Press View.


7 Start-up and recommissioning
7.1 Start-up overview
Step Description
1 Set up brake test.
Installing SafeOperation activates the brake test for the robot
controller. The brake test serves as a diagnostic measure for
the robot axis and external axis brakes. The brakes are acti-
vated for the stop reactions safety stop 0 and safety stop 1.
Note: Detailed information is contained in the Operating and
Programming Instructions for System Integrators.
2 Install reference switch and actuating plate.
(>>> 7.3 "Installing the reference switch and actuating plate"
Page 67)
3 Connect the reference switch.
(>>> 7.4 "Connecting a reference switch" Page 67)
4 Only if a safety PLC is being used: configure communication via
the interface.
(>>> 10 "Interfaces to the higher-level controller" Page 101)
5 Master the robot.
Note: Detailed information is contained in the operating and
programming instructions.
6 Activate safe monitoring.
(>>> 7.5 "Activating safe monitoring" Page 68)
7 Define global parameters.
 Mastering test input
 Cartesian velocity monitoring functions
(>>> 7.6 "Defining global parameters" Page 68)
8 Define monitoring spaces.
(>>> 7.7 "Defining a cell area" Page 70)
(>>> 7.8 "Defining Cartesian monitoring spaces" Page 72)
(>>> 7.9 "Defining axis-specific monitoring spaces" Page 75)
9 Define axis-specific velocity monitoring.
(>>> 7.10 "Defining axis-specific velocity monitoring" Page 79)
(>>> 7.11 "Defining the safe operational stop" Page 82)
10 Define safe tools.
(>>> 7.12 "Defining safe tools" Page 84)
11 Program mastering test.
12 Define reference position.
(>>> 7.13 "Defining the reference position" Page 87)
13 Only if the reference switch is actuated by the tool: Check refer-
ence position.
(>>> 7.14 "Checking the reference position (actuation with
tool)" Page 89)

Step Description
14 Save safety configuration.
(>>> 7.15 "Saving the safety configuration" Page 90)
15 Perform mastering test.
(>>> 7.16 "Performing a mastering test manually" Page 91)
16 Carry out safety acceptance.
(>>> 7.18 "Safety acceptance overview" Page 94)
(>>> 7.17 "Testing safety parameters" Page 91)
17 Archive safety configuration.
Note: Detailed information is contained in the operating and
programming instructions.
18 Only if a new safety configuration is being activated: compare
the displayed checksum with the expected checksum in the
checklist for safe functions.
(>>> 7.19 "Activating a new safety configuration" Page 95)
7.2 Safety warnings
During system planning, the safety functions must be planned. Re-

quired safety functions that are not implemented with SafeOperation
must be implemented using different safety measures.
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 safe-
ty-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 veloc-
ity.
 Define axis-specific and Cartesian monitoring spaces.
 Define axes that must be configured for a safe operational stop.
Serious damage and injury or death can result from in-

correct configuration. Consequently, SafeOperation may
not be operated until after safety acceptance has been carried out in accor-
dance with the checklists. The checklists must be completed fully and con-
firmed in writing.
(>>> 13.1 "Checklists" Page 115)
Safe monitoring with SafeOperation is deactivated by de-

fault. The safety monitoring functions can only be config-
ured or modified if safe monitoring is activated. If safe monitoring is
deactivated, the configured safety monitoring functions are inactive.
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.

7.3 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 position of the reference switch is within the motion range of the robot.
 The position of the reference switch and actuating plate does not interfere
with the work sequence of the robot.
Procedure 1. Prepare a mechanical mounting fixture for mounting the reference switch.
(>>> 3.3 "Reference switch hole pattern" Page 32)
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.
Example
Fig. 7-1: Example of an actuating plate on the tool
1 Robot
2 Actuating plate on tool
3 Tool
4 Reference switch on mounting fixture
7.4 Connecting a reference switch
The robot controller is preconfigured for the specific in-

dustrial robot. If cables are interchanged, the manipula-
tor and the external axes (optional) may receive incorrect data and can thus
cause personal injury or material damage. If a system consists of more than
one manipulator, always connect the connecting cables to the manipulators
and their corresponding robot controllers.

Only 1 reference switch can be connected to the robot controller. If

multiple reference groups are required, the reference switches can be
connected to the safety PLC and activated via PROFIsafe. The safety
PLC must evaluate the reference switches and set the input Mastering test
accordingly.
Precondition  The robot controller is switched off and secured to prevent unauthorized
persons from switching it on again.
 Reference switch is installed.
 Reference cable X42 - XS Ref (maximum cable length 50 m)
Procedure 1. Connect and route reference cable X42 - XS Ref.

2. Connect X42 to the robot controller and XS Ref to the reference switch.
7.5 Activating safe monitoring
Configuration of the safety monitoring functions is only possible if safe

monitoring has been activated.
Precondition  User group “Safety maintenance”

 Operating mode T1 or T2
Procedure 1. Open safety configuration.

2. Press Global parameters.
3. Activate the Safe monitoring check box (set the check mark).
4. Save the safety configuration or continue configuration.
7.6 Defining global parameters

 A safety configuration is open.
 Safe monitoring is active.
Procedure  Press Global parameters and set parameters.

Description
Fig. 7-2: Defining global parameters
Defining global parameters:
Safe monitoring Check box activated = safe monitoring is acti-
vated.
Check box deactivated = safe monitoring is
deactivated.
Default: Check box deactivated
Mastering test input at cabinet = reference switch is connected to
the robot controller.
via ProfiSafe = reference switch is connected
via PROFIsafe.
Default: at cabinet
Cartesian maximum Limit value for maximum Cartesian velocity (not
velocity space-dependent)
 0.5 … 30,000 mm/s
Default: 10,000 mm/s

Reduced Cartesian Limit value for safely reduced Cartesian velocity
velocity
 0.5 … 30,000 mm/s
Reduced Cartesian Limit value for safely reduced Cartesian velocity
velocity T1 in T1 mode
 0.5 … 250 mm/s
Default: 250 mm/s
7.7 Defining a cell area

Procedure 1. Select the Monitoring spaces tab and press Cell area configuration.
The Cell area configuration window is opened.
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. If required, activate the corner by means of the check box (set the check
mark).
Corners 1 to 4 are activated by default.
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.

Description
Fig. 7-3: Defining a cell area
Defining a cell area:
Reference system Reference coordinate system
 $WORLD
Z min Lower limit of the cell area
 -30,000 mm … +30,000 mm
Default: -30,000 mm
Z max Upper limit of the cell area
 -30,000 mm … +30,000 mm
Default: 30,000 mm

Activated Check box activated = corner of cell area is
activated.
(corner)
Check box deactivated = corner of cell area is
deactivated.
Default corner 1 to 4: Check box active
Default corner 5 to 10: Check box deactivated
X, Y X, Y coordinate of corner 1 to 10 relative to the
WORLD coordinate system
(corner)
 -30,000 mm … +30,000 mm
Default corner 1 or 4: +30,000 mm
Default corner 2 or 3: -30,000 mm
Default corner 5 to 10: 0 mm
7.8 Defining Cartesian monitoring spaces

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 [NameMonitoringSpace] window is opened.
5. Select the reference coordinate system and enter Cartesian positions.
Monitoring space
Fig. 7-4: Defining a Cartesian monitoring space
Defining a monitoring space:

Type Type of monitoring space
Working space = monitoring space is a work-
space.
Protected space = monitoring space is a pro-
tected space.
Default: Workspace
Activation Activation of monitoring space
Inactive = monitoring space is not active.
Always active = monitoring space is always
active.
by input = monitoring space is activated by a
safe input.
If interface X13 is used, safe inputs are only
available for monitoring spaces 12 … 16.
(>>> 10.2 "SafeOperation via interface X13
Default: Inactive
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 activated = robot stops if the moni-
toring space limits are exceeded.
Check box deactivated = robot does not stop if
the monitoring space limits are exceeded.
Default: Check box activated
V max Limit value of the space-specific velocity
 0.5 … 30,000 mm/s
Vmax valid if Validity of the space-specific velocity
Deactivated = 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 mon-
itored if the monitoring space is violated.
Default: Deactivated
Stop if mastering test Activation of reference stop
not yet done
Check box activated = reference stop is acti-
vated for the monitoring space.
Check box deactivated = reference stop is
deactivated for the monitoring space.

Properties
Fig. 7-5: Defining Cartesian properties
Defining properties:
Reference system Reference coordinate system
 $WORLD
 $ROBROOT
Default: $WORLD
Origin X, Y, Z Offset of the origin of the Cartesian monitoring
space in X, Y and Z relative to the selected refer-
ence coordinate system.
 -30,000 mm … +30,000 mm
Default: 0 mm

Origin A, B, C Orientation in A, B and C at the origin of the Car-
tesian monitoring space relative to the selected
reference coordinate system.
Origin A, C:
 -180° … +180°
Origin B:
 -90° … +90°
Default: 0°
Distance to origin Minimum X, Y and Z coordinates of the Carte-
sian monitoring space relative to the origin
XMin, YMin, ZMin
 -30,000 mm … +30,000 mm
Default: 0 mm
Distance to origin Maximum X, Y and Z coordinates of the Carte-
sian monitoring space relative to the origin
XMax, YMax, ZMax
 -30,000 mm … +30,000 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.
Fig. 7-6: Example of a Cartesian monitoring space
7.9 Defining axis-specific monitoring spaces


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 monitor-
ing space.
The Axis-specific properties of [NameMonitoringSpace] window is
opened.
5. Select axis from the list.
The axis-specific properties are displayed.
6. Activate monitoring by means of the check box (set the check mark).
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.
Monitoring space
Fig. 7-7: Defining an axis-specific monitoring space
Defining a monitoring space:

Type Type of monitoring space
Working space = monitoring space is a work-
space.
Protected space = monitoring space is a pro-
tected space.
Default: Workspace
Activation Activation of monitoring space
Inactive = monitoring space is not active.
Always active = monitoring space is always
active.
by input = monitoring space is activated by a
safe input.
available for monitoring spaces 12 … 16.
Default: Inactive
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 activated = robot stops if the moni-
toring space limits are exceeded.
Check box deactivated = robot does not stop if
the monitoring space limits are exceeded.
Default: Check box activated
V max Limit value of the space-specific velocity
 0.5 … 30,000 mm/s
Vmax valid if Validity of the space-specific velocity
Deactivated = 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 mon-
itored if the monitoring space is violated.
Default: Deactivated
Stop if mastering test Activation of reference stop
not yet done
Check box activated = reference stop is acti-
Check box deactivated = reference stop is
deactivated for the monitoring space.

Properties
Fig. 7-8: Defining axis-specific properties
Icon Description
Icon for rotational and infinitely rotating axes
Icon for linear axes

Monitoring Check box activated = axis limits are activated
for the monitoring space.
Check box deactivated = axis limits are deacti-
Lower limit The lower limit of an axis-specific workspace
must be at least 0.5° or 1.5 mm less than the
(lower axis limit)
upper limit.
The axis-specific protected space is dependent
on the maximum axis velocity. A defined mini-
mum size for the axis-specific protected space is
derived from the maximum axis velocity; the size
must not fall below this value. If this minimum
value is violated, a message is displayed.
Rotational axes:
 -360° … +360°
Linear axes:
 -30,000 mm … +30,000 mm
Default value for rotational axes: -360°
Default value for linear axes: -30,000 mm
Current position Axis-specific actual position (display only)
 Red: axis position not allowed, as monitoring
space is violated
 Green: axis position allowed
Upper limit The upper limit of an axis-specific workspace
must be at least 0.5° or 1.5 mm greater than the
(upper axis limit)
lower limit.
Rotational axes:
 -360° … +360°
Linear axes:
 -30,000 mm … +30,000 mm
Default value for rotational axes: 360°
Default value for linear axes: 30,000 mm
7.10 Defining axis-specific velocity monitoring

Procedure 1. Select the Axis monitoring tab.

2. Select an axis from the list.

The axis-specific parameters are displayed.
3. Activate monitoring by means of the check box (set the check mark).
4. Enter reduced axis velocities.
5. Repeat steps 2 to 4 to define further monitoring functions.
6. Enter maximum axis velocities.
Description
Fig. 7-9: Defining axis velocities
Defining axis velocities:

Monitoring Check box activated = axis is monitored.
Check box deactivated = axis is not monitored.
Reduced velocity Limit value for safely reduced axis velocity
Rotational axes:
 0.5 … 5,000°/s
Linear axes:
 1.5 … 10,000 mm/s
Default value for rotational axes: 5,000°/s
Default value for linear axes: 10,000 mm/s
Reduced velocity T1 Limit value for safely reduced axis velocity in T1
mode
Rotational axes:
 0.5 … 100°/s
Linear axes:
 1.5 … 250 mm/s
Default value for rotational axes: 100°/s
Default value for linear axes: 250 mm/s
Safe operational stop Check box activated = safe operational stop is
activated.
Check box deactivated = safe operational stop
is not activated.
The safe operational stop cannot be activated
here. The check box is automatically activated if
safe operational stop has been defined for an
axis.

Maximum velocity Limit value for maximum velocity for rotational
rotational axis axes
 0.5 … 5,000°/s
Default: 1,000°/s
Maximum velocity Limit value for maximum velocity for translational
translational axis axes
 0.5 … 30,000 mm/s
Default: 5,000 mm/s
7.11 Defining the safe operational stop

Procedure 1. Select the Axis monitoring tab and press Safety stop.
The Safety stop window is opened.
2. Select axis from the list.
3. Activate one or more axis groups in which the axis is to be monitored by
activating the corresponding check box (set the check mark).
4. Enter the axis angle or distance tolerance.
5. Repeat steps 2 to 4 to define further monitoring functions.

Description
Fig. 7-10: Defining the safe operational stop
Defining the safe operational stop:

Monitoring in axis Safe operational stop for axis group 1 … 6
groups 1-6
Check box activated = safe operational stop is
activated for the axis.
Check box deactivated = safe operational stop
is not activated for the axis.
available for axis group 1 … 2.
Axis angle tolerance Limit value for the axis angle or distance toler-
ance for standstill monitoring
Rotational axes:
 0.001° … 1°
Linear axes:
 0.003 … 3 mm
Default value for rotational axes: 0.01°
Default value for linear axes: 0.01 mm
7.12 Defining safe tools

Procedure 1. Select the Tools tab and select a tool from the list.
The parameters of the safe tool are displayed.
2. Activate the safe tool via the check box (set the check mark) and enter a
name for the tool (max. 24 characters).
3. Define the safe TCP of the tool.
The Properties of [NameTool] window is opened.
5. Select a sphere from the list and activate monitoring via the check box (set
the check mark).
6. Enter the coordinates of the center of the sphere and the radius of the
sphere.
7. Repeat steps 5 to 6 to define additional spheres for the safe tool.

Tool
Fig. 7-11: Defining a safe tool
Defining a safe tool:
Activation Check box activated = safe tool is activated.
Check box deactivated = safe tool is deacti-
vated.
Default tool 1: check box activated
Default tool 2 to 16: check box deactivated
If interface X13 is used, tool 1 is always active. A
tool change is not possible.
TCP X, Y, Z X, Y and Z coordinates of the safe TCP relative
to the velocity monitoring
 -10,000 mm … +10,000 mm
Default: 0 mm

Properties
Fig. 7-12: Defining the properties of the safe tool
Monitoring Check box activated = sphere is monitored.
Check box deactivated = sphere is not moni-
tored.
Default sphere 1: Check box activated
Default spheres 2 to 6: Check box deactivated

X, Y, Z X, Y and Z coordinates of the sphere center
point at the safe tool relative to the FLANGE
coordinate system
 -10,000 mm … +10,000 mm
Default: 0 mm
Radius Radius of the sphere at the safe tool
 0 … 10,000 mm
Default: 250 mm
The radius is dependent on the maximum Carte-
sian velocity. A defined minimum value for the
radius is derived from the maximum Cartesian
velocity; the radius must not be less than this
value. If this minimum value is violated, a mes-
sage is displayed.
7.13 Defining the reference position

Procedure 1. Select the tool and base for Cartesian jogging.

2. Select the Reference position tab.
3. Move robot to the reference position.
4. Select one of the robot axes.
5. Press Touch-up reference position for group to accept the current
flange position of the robot as the reference position for the axes in refer-
ence group 1.
The coordinates of the Cartesian reference position are displayed in the
configuration window.
6. If external axes are configured, enter the number of the corresponding ref-
erence group for each external axis.
7. If present, move external axes in reference group 2 to the reference posi-
tion and save with Touch-up reference position for group.
8. If present, move external axes in reference group 3 to the reference posi-
tion and save with Touch-up reference position for group.

Description
Fig. 7-13: Defining the reference position
Defining the reference position:

Reference group Each axis that is to be subjected to safe monitor-
ing must be assigned to a reference group.
Robot axes are always assigned to reference
group 1. External axes can be assigned to other
reference groups, but also to reference group 1,
e.g. in the case of a KL.
 1: robot axes
 1 … 3: external axes
Default: 1
Reference position Axis-specific coordinates of the reference posi-
tion
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 command position.
Rotational axes:
 -360° … +360°
Linear axes:
 -30,000 mm … +30,000 mm
Default value for rotational axes: 45°
Default value for linear axes: 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 X, Y and Z coordinates of the Cartesian refer-
position X, Y, Z ence position relative to the WORLD coordinate
system (display for reference group 1)
The coordinates of the Cartesian reference posi-
tion refer to the center point of the mounting
flange.
 -30,000 mm … +30,000 mm
Default: 0 mm
7.14 Checking the reference position (actuation with tool)
The robot can move beyond the configured limits if the

reference switch is actuated by a ferromagnetic part of
the tool and the accuracy at the reference position is exceeded. Severe phys-
ical injuries or damage to property may result. The accuracy of the reference
position must be checked.

If the tool is exchanged, the reference position and the

accuracy of the reference position must be checked. If
required, the reference position must be adapted to the new tool. Failure to
observe this precaution may result in severe physical injuries or considerable
damage to property.
Precondition  Reference switch is installed and connected.

 The reference position has been taught in the program
MasRef_USER.SRC and in the safety configuration.
 User group “Safety maintenance”
 T1 or T2 operating mode
Procedure 1. Open the program MasRef_USER.SRC.

2. In the subprogram MASREFSTARTGX(), insert a HALT statement imme-
diately before the END line.
3. Close the program MasRef_USER.SRC.
4. Select the program MasRef_Main.SRC.
5. Perform block selection to the subprogram RunTest_Group(X).
6. Press the Start key. The subprogram MASREFSTARTGX() of the program
MasRef_USER.SRC is called and the robot moves to the reference posi-
tion.
7. Jog each axis individually in the positive and negative directions using the
jog keys and observe when the reference switch is no longer actuated.
8. Analyze the axis-specific tolerances determined in this way for the master-
ing test relative to the application and select a different reference position
if necessary.
9. For automatic operation, delete all HALT statements from the program
MasRef_USER.SRC once again.
7.15 Saving the safety configuration
Serious injury and severe damage to the robot can be

caused by an error during saving or a failed reinitializa-
tion. If an error message is displayed after saving, the safety configuration
must be checked and saved again.

 Safety configuration is completed.
Procedure 1. Press Save and answer the request for confirmation with Yes.
The safety configuration is saved on the hard drive and the checksum of
the safety configuration is saved to the RDC.
The robot controller is automatically reinitialized.
2. The checksum and activation code of the safety configuration are dis-
played on the General tab.
Note the checksum and activation code in the checklist for safe functions.
(>>> 13.1.3 "Checklist for safe functions" Page 115)

7.16 Performing a mastering test manually

 The reference position has been taught in the program
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 and execute the program MasRef_Main.SRC to the end of the pro-
gram.
7.17 Testing safety parameters
The configured velocity limits, the limits of the monitoring spaces and the
space-specific velocities must be checked with override reduction deactivated.
For this, the following variables must be set to FALSE in $CUSTOM.DAT:
 $SR_VEL_RED
 $WORKSPACE_RED
To check the configured limits, the space and velocity limits are deliberately
exceeded by means of test programs. If the safety configuration stops the ro-
bot, the limits are correctly configured.
If the robot is stopped by the safety controller, a message with message num-
ber 15xxx is displayed. If no message is displayed, or if a message from a dif-
ferent number range is displayed, the safety controller must be checked.
7.17.1 Testing Cartesian velocity
(>>> 13.1.4 "Checklist for velocity limits" Page 118)
Precondition  Override reduction is deactivated.
Procedure 1. Configure reduced Cartesian velocity for T1, reduced Cartesian velocity
and maximum Cartesian velocity.
(>>> 7.6 "Defining global parameters" Page 68)
2. Create a test program in which the Cartesian velocity is to be exceeded
deliberately, e.g. configured with 1000 mm/s, moved at 1100 mm/s.
When testing the Cartesian velocity on a KL, the linear unit must also
be moved.
3. Execute the test program in T1 mode for “Reduced Cartesian velocity in

T1” and in T2 mode for reduced Cartesian velocity and maximum Carte-
sian velocity.
Death, serious physical injuries or major damage to

property may occur. If a program is executed in test
mode T2, the operator must be in a position outside the danger zone.

7.17.2 Testing maximum axis velocity
It is only necessary to test the maximum axis velocity if an axis must

not exceed a defined velocity. If the maximum axis velocity is only to
limit the minimum axis-specific protected space, no test is required.
Procedure Testing linear axes:

1. Configure reduced axis velocity for T1, reduced axis velocity and maxi-
mum axis velocity.
2. Create a test program in which the axis velocity is exceeded deliberately,
e.g. KL configured with 1000 mm/s, moved at 1100 mm/s.
3. Execute the test program in T1 mode for “Reduced axis velocity in T1” and
in T2 mode for reduced axis velocity and maximum axis velocity.

Testing rotational axes:

1. Configure reduced axis velocity for T1, reduced axis velocity and maxi-
mum axis velocity.
2. Look up the maximum axis velocity Vmax in the data sheet of the robot
used.
3. Create a test program in which the axis velocity is to be exceeded deliber-
ately, e.g. axis A1 configured with 190°/s, moved at 200°/s.
4. Calculate axis velocity $VEL_AXIS[x].
(>>> "Calculation of $VEL_AXIS" Page 92)
5. Enter the axis velocity $VEL_AXIS[x] in the test program.
6. Execute the test program in T1 mode for “Reduced axis velocity in T1” and
in T2 mode for reduced axis velocity and maximum axis velocity.

Calculation of The axis velocity $VEL_AXIS[x] is calculated using the following formula:
$VEL_AXIS $VEL_AXIS[x] = (VTest / Vmax) * 100 = (200 °/s / 360 °/s) * 100 = 56
Element Description
x Number of the axis
Vtest Test velocity
Unit: °/s
Vmax Maximum axis velocity
Unit: °/s
The calculated axis velocity $VEL_AXIS[x] is entered in the test program:

...
PTP {A1 -30}
HALT
$VEL_AXIS[1] = 56
PTP {A1 30}
...
7.17.3 Testing Cartesian monitoring spaces
(>>> 13.1.7 "Checklist for configuration of Cartesian monitoring spaces"

Page 123)
Description The configuration of the boundaries and the space-specific velocity must be
checked. If “Stop at boundaries” is not configured, an alarm space is used for
this.
The space surfaces can have any orientation. The robot must be moved to
each of the 6 space surfaces of a Cartesian monitoring space in three different
positions to check whether the limits have been programmed correctly. An ex-
ception is made here for space surfaces that cannot be addressed due to cir-
cumstances in the system.
The cell area is a Cartesian monitoring space and is tested in the same way.
Depending on the configuration, the cell area consists of 5, 6 or more space
surfaces. Here, once again, each accessible space surface must be ad-
dressed in 3 different positions.
Fig. 7-14: Moving to space surfaces
Procedure 1. Configure a Cartesian monitoring space.

(>>> 7.7 "Defining a cell area" Page 70)
(>>> 7.8 "Defining Cartesian monitoring spaces" Page 72)
2. Create a test program in which all positions addressed for checking the
space surfaces are taught.
3. Execute test program in T1 mode.
When testing 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 comes to a standstill.
4. Create a test program in which the space-specific velocity is deliberately

exceeded, either inside or outside the monitoring space, e.g. 180 mm/s
configured, moved at 200 mm/s.


7.17.4 Testing axis-specific monitoring spaces
(>>> 13.1.8 "Checklist for configuration of axis-specific monitoring spaces"

Page 125)
Description The configuration of the boundaries and the space-specific velocity must be
checked. If “Stop at boundaries” is not configured, an alarm space is used for
this.
Procedure 1. Configure an axis-specific monitoring space.

(>>> 7.9 "Defining axis-specific monitoring spaces" Page 75)
2. Jog each axis once to the upper and lower boundaries of the monitoring
space in T1 mode using the jog keys or Space Mouse.
3. Create a test program in which the space-specific velocity is deliberately
exceeded, either inside or outside the monitoring space, e.g. 180 mm/s
configured, moved at 200 mm/s.

7.17.5 Testing safe operational stop for an axis group
(>>> 13.1.5 "Checklist for configuration of the safe operational stop"

Page 121)
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 axis angle or distance tolerance for
the affected axis must be increased.
Precondition  Operating mode T1
Procedure 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 and with a jog override of 1%.
A robot stop must be triggered (safety stop 0).
3. Deactivate safe operational stop for the axis group and reactivate it.
4. Repeat steps 2 to 3 to test additional axes of the axis group.
7.18 Safety acceptance overview
SafeOperation must not be put into operation until the safety acceptance pro-
cedure has been completed successfully. For successful safety acceptance,
the points in the checklists must be completed fully and confirmed in writing.
The completed checklists, confirmed in writing, must be kept as doc-

umentary evidence.
Safety acceptance must be carried out in the following cases:

 Following initial start-up or recommissioning of the industrial robot
 After a change to the industrial robot
 After a change to the safety configuration

 After a software update, e.g. of the system software

Safety acceptance after a software update is only necessary if the check-
sum of the safety configuration changes as a result of the update.
The safety configuration must be archived and the change log

checked after every modification. It is also advisable to print out the
data set containing the safety parameters using WorkVisual.
The following checklists can be found in the Appendix:

 Checklist for robot and system
(>>> 13.1.2 "Checklist for robot and system" Page 115)
 Checklist for safe functions
(>>> 13.1.3 "Checklist for safe functions" Page 115)
 Checklist for velocity limits
 Checklist for configuration of the safe operational stop
(>>> 13.1.5 "Checklist for configuration of the safe operational stop"
Page 121)
 Checklist for configuration of the cell area
(>>> 13.1.6 "Checklist for configuration of the cell area" Page 122)
 Checklist for configuration of Cartesian monitoring spaces
(>>> 13.1.7 "Checklist for configuration of Cartesian monitoring spaces"
Page 123)
 Checklist for configuration of axis-specific monitoring spaces
(>>> 13.1.8 "Checklist for configuration of axis-specific monitoring spac-
es" Page 125)
 Checklist for configuration of the safe tools
(>>> 13.1.9 "Checklist for configuration of the safe tools" Page 127)
7.19 Activating a new safety configuration
Description If the safety configuration is updated by transferring a project from WorkVisual

to the robot controller or by restoring an archive, the safety controller signals
that the checksum of the safety configuration is incorrect.
The safety maintenance technician must check the new safety configuration
on the robot controller and is responsible for ensuring that the correct safety
configuration is activated. The displayed checksum must match the expected
checksum from the checklist for safe functions.
A new safety configuration can also be activated by the safety recovery tech-
nician. The safety recovery technician requires the 8-digit activation code of
the safety configuration for this. The correct activation code must be commu-
nicated by the safety maintenance technician.
Precondition  User group “Safety recovery” or “Safety maintenance”

The safety configuration checks whether there are any relevant deviations
between the robot controller and the safety controller. The Troubleshoot-
ing wizard window is opened.
2. A description of the problem and a list of possible causes is displayed. Se-
lect 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 in the user group “Safety Recovery”: enter the activation code and
press Activate again.
7.20 Deactivating safe monitoring
If safe monitoring is deactivated, the configured safety

monitoring functions are inactive. An exception is made
here for the configured velocity limits for T1 mode. These remain active.

Procedure 1. Open safety configuration.

2. Press Global parameters.
3. Deactivate the Safe monitoring check box.
4. Press Save and answer the request for confirmation with Yes.
The robot controller is automatically reinitialized.

8 Programming
8 Programming
8.1 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 possi-
ble 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 sta-
tionary after the mastering test. The robot control-
ler generates an error message.
8.2 Programming a mastering test
During a 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.

 User group “Safety maintenance”
Procedure 1. Open the program MasRef_USER.SRC.

2. Insert a HALT statement in the subprograms MASREFSTARTGX() and
MASREFBACKGX().
3. Close the program MasRef_USER.SRC.
4. Select the program MasRef_Main.SRC.
5. Perform block selection to the subprogram RunTest_Group(X).
6. Press the Start key. The subprogram MASREFSTARTGX() of the program
MasRef_USER.SRC is called.
7. In the subprogram MASREFSTARTGX(), program a motion to a point ap-
prox. 10 cm before the reference switch and teach the required points.
8. Program a LIN motion to the reference switch so that it is actuated. This
position is the reference position.
The distance from the supplied reference switch must not exceed
2 mm. If the distance is greater, the reference switch will not be actu-
ated.

9. Teach the reference position.

10. Do not move the robot.
11. Teach the reference position in the safety configuration.
12. Return to the subprogram MASREFSTARTGX() and perform a block se-
lection to the END line.
13. Press the Start key. The subprogram MASREFBACKGX() of the program
MasRef_USER.SRC is called.
14. In the subprogram MASREFBACKGX(), program the motion away from
the reference position and teach the required points.
15. Deselect the program and save the changes.
16. For automatic operation, delete all HALT statements from the program
MasRef_USER.SRC once again.
17. Cyclically call the program MasRef_Main.SRC at a suitable point and en-
able execution of the mastering test after an internal request.
Program 1 DEF MasRef_USER()

2 END
3
4 GLOBAL DEF MASREFSTARTG1()
5 Teach path and reference position for group 1
6
7 END
8
11
12 END
13
16
17 END
18
19 GLOBAL DEF MASREFBACKG1()
20 Teach path back for group 1
21
22 END
23
26
27 END
28
31
32 END
Line Description
5 Program the motion to the reference position of reference
group 1 and teach the reference position.
20 Teach the motion away from the reference position of refer-
ence group 1.
ence group 2.
ence group 3.

9 System variables
9 System variables
9.1 Variables for override reduction in $CUSTOM.DAT
Description The variables for override reduction can be modified in the $CUSTOM.DAT
file, in a KRL program or via the variable correction function. If a variable is
modified, an advance run stop is triggered.
Variable Description
$SR_OV_RED Maximum velocity limit with override reduction activated for
the velocity.
The percentage value refers to the lowest activated velocity
limit.
 10 … 95 %
Default: 95 %
$SR_VEL_RED Override reduction for the velocity
TRUE = override reduction is activated.
FALSE = override reduction is not activated.
Default: TRUE
$SR_WORKSPACE_RED Override reduction for monitoring spaces
TRUE = override reduction is activated.
FALSE = override reduction is not activated.
Default: FALSE
9.2 Variables for the mastering test
$MASTERINGTEST_REQ_INT Internal request of the mastering test from the safety control-
ler
TRUE = mastering test is requested.
FALSE = mastering test is not requested.
Default: FALSE
$MASTERINGTEST_REQ_EXT External request for mastering test, e.g. from the safety PLC
TRUE = mastering test is requested.
FALSE = mastering test is not requested.
Default: FALSE
Note: This signal is declared in the file KRC:\ROBOTER\
KRC\STEU\MADA\$MACHINE.DAT and must be assigned
to a suitable input.
$MASTERINGTESTSWITCH_O Check of the function of the reference switch
K
TRUE = reference switch is OK.
FALSE = reference switch is defective.
Default: TRUE

9.3 Variables for diagnosis
$SR_ACTIVETOOL Number of the active safe tool
 0: no safe tool or multiple safe tools are selected.
 1 … 16: safe tool 1 … 16 is active.
$SR_AXISSPEED_OK Reduced axis acceleration exceeded
TRUE = axis velocity has not been exceeded.
FALSE = axis velocity has been exceeded.
The variable is set to FALSE when the excessive value is
detected and then set immediately back to TRUE.
$SR_CARTSPEED_OK Cartesian velocity exceeded
TRUE = Cartesian velocity has not been exceeded.
FALSE = Cartesian velocity has been exceeded.
The variable is set to FALSE when the excessive value is
detected and then set immediately back to TRUE.
$SR_DRIVES_ENABLE Enabling of the drives by the safety controller
TRUE = drives are enabled.
FALSE = drives are not enabled.
$SR_MOVE_ENABLE Enabling by the safety controller
TRUE = motion enable
FALSE = no motion enable
$SR_SAFEMON_ACTIVE Status of the safe monitoring
TRUE = monitoring is activated.
FALSE = monitoring is not activated.
$SR_SAFEOPSTOP_ACTIVE[In Status of the safe operational stop
dex]
TRUE = safe operational stop is activated.
FALSE = safe operational stop is not activated.
Index:
 1: status of the global safe operational stop (all axes)
The global operational stop is a standard safety function
of PROFIsafe. (Input byte 1, bit 1, safe operational stop)
 2 … 7: status of the safe operational stop in relation to
axis group 1 … 6 (safe operational stop 1 …safe opera-
tional stop 6)
$SR_SAFEOPSTOP_OK Violation of an externally activated operational stop
TRUE = no violation
FALSE = safe operational stop has been violated.
$SR_SAFEREDSPEED_ACTIVE Status of the monitoring of the reduced velocity
TRUE = monitoring is activated.
FALSE = monitoring is not activated.

10 Interfaces to the higher-level controller

The robot controller can communicate via the PROFIsafe protocol or interface
X13 (SIB Extended) with the higher-level controller, e.g. a PLC.
The safe I/Os of PROFIsafe are permanently assigned to the safety monitoring
functions of SafeOperation: input and output bytes 2 to 7. (Input and output
bytes 0 to 1 are assigned to the standard safety functions.) The safe I/Os of
interface X13 only offer a reduced range of signals.
Further information about SIB Extended and interface X13 can be

found in the operating or assembly instructions for the robot controller
and in the assembly and operating instructions for the optional inter-
faces of the robot controller.
10.1 SafeOperation via PROFIsafe (optional)
Reserved bits Reserved safe inputs can be pre-assigned by a PLC with the values 0 or 1. In
both cases, the robot 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 robot would either not move or would unexpectedly come 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 in-
put is not used by the customer’s PLC, the safety function is not acti-
vated. This prevents the safety controller from unexpectedly stopping the
robot.
Input byte 2
Bit Signal Description
0 JR Mastering test (input for mastering test refer-
ence switch)
0 = reference switch is active (actuated).
1 = reference switch is not active (not actu-
ated).
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 func-
tion does not require acknowledgement.
0 = safe operational stop is active.
1 = safe operational stop is not active.
Input byte 3
0…7 RES Reserved 25 ... 32
The value 1 must be assigned to the inputs.

Input byte 4
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

0…7 WZ1 … 8 Tool selection 1 … 8
Assignment: Bit 0 = tool 1 … bit 7 = tool 8
0 = tool is not active.
1 = tool 1 is active.
Exactly one tool must be selected at all times.

0…7 WZ9 … 16 Tool selection 9 … 16
Assignment: Bit 0 = tool 9 … bit 7 = tool 16
0 = tool is not active.
1 = tool 1 is active.
Exactly one tool must be selected at all times.
Output byte 2 Bit Signal Description

0 SO SafeOperation active
SafeOperation activation status
0 = SafeOperation is not active.
1 = SafeOperation is active.
1 RR Robot referenced
Mastering test display
0 = mastering test required.
1 = mastering test performed successfully.
2 JF Mastering error
Space monitoring is deactivated because 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 monitor-
ing)
4…5 SBH1 … 2 Activation status of safe operational stop for
axis group 1 ... 2
Assignment: Bit 4 = axis group 1 … bit 5 = axis
group 2
Output byte 3

0…7 MR1 … 8 Alarm space 1 … 8
Assignment: Bit 0 = alarm space 1 (associated
monitoring space 1) … bit 7 = alarm space 8
(associated monitoring space 8)
0 = space is violated.
1 = space is not violated.

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)


10.1.1 Diagnostic signals via PROFINET
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].


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
3 AF Drive enable
0 = drives enable not active [200]
1 = drives enable active
4 IBN Start-up mode
Start-up mode enables jogging of the manipula-
tor 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

0 SO SafeOperation (optional)
1 JF Mastering error (optional)
0 = no error
1 = mastering error, space monitoring deacti-
vated.
2 VRED Reduced velocity (optional)
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 RES Reserved

0 SHS1 Safety stop (all axes) STOP 0 or STOP 1
0 = safety stop is not active.
1 = safety stop is active.
1 ESV External stop request violated
Safe operational stop SBH1, SBH2 or safety
stop SHS1, SHS2 violated
Braking ramp was not maintained or a moni-
tored axis has moved.
0 = no error
1 = violated
2 SHS2 Safety stop 2
0 = safety stop is not active.
1 = safety stop is active.
3 SBH1 Safe operational stop (axis group 1) (optional)
4 SBH2 Safe operational stop (axis group 2) (optional)
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

0 JR Mastering test (optional)
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.


3 JRF Mastering test failed (optional)
0 = mastering test OK.
1 = mastering test failed.
4 RS Reference stop (optional)
Reference run only possible in operating
modes T1 and KRR.
0 = no error
1 = reference stop due to impermissible operat-
ing mode
5 RIA Referencing interval (optional)
0 = no reminder
1 = reminder interval expired [200]
6…7 RES Reserved

0…7 WZNR Tool number (8-bit word) (optional)
0 = error (see WFK and WFME)
1 = tool 1
2 = tool 2, etc.

0…7 UER1 … 8 Monitoring spaces 1 … 8 (optional)
Output byte 6
0…7 UER9 … 16 Monitoring spaces 9 … 16 (optional)
Output byte 7
0…7 UERV1 … 8 Violation of monitoring spaces 1 … 8 (optional)
0 = monitoring space not violated
1 = monitoring space violated [200]

Output byte 8
0…7 UERV9 … 16 Violation of monitoring spaces 9 … 16
(optional)
0 = monitoring space not violated
1 = monitoring space violated [200]
10.2 SafeOperation via interface X13 (optional)
Further information about connection to interface X13 and the re-

quired safety measures can be found in the assembly and operating
instructions for the optional interfaces of the robot controller.
Inputs
Signal Description
VRED Reduced axis-specific and Cartesian velocity (activation of
reduced velocity monitoring)
SBH1 … 2 Safe operational stop for axis group 1 ... 2
Signal for safe operational stop. The function does not trig-
ger a stop, it only activates the safe standstill monitoring.
Cancelation of this function does not require acknowledge-
ment.
UER12 … Monitoring spaces 12 … 16
16
Outputs
Signal Description
SO SafeOperation active
SafeOperation activation status
RR Robot referenced
Mastering test display
0 = mastering test required.
1 = mastering test performed successfully.
MR1 … 6 Alarm space 1 … 6
Alarm space 1 (associated monitoring space 1) … alarm
space 6 (associated monitoring space 8)


11 Diagnosis
11 Diagnosis
11.1 Displaying safe I/Os
Procedure 1. Select Diagnosis > Diagnostic monitor in the main menu.

2. Select the Bus process data image[Name of bus/interface] module in the
Module box.


12 Messages
12 Messages
12.1 Messages during operation
Configuration or operator errors may result in error messages in an applica-

tion.
No. Message Cause Remedy
15016 Ackn.: Stop due to stand- At least one of the axes Acknowledge the mes-
still monitoring violation monitored for standstill has sage.
moved outside the config-
ured axis angle or distance
tolerances.
15017 Ackn.: The braking ramp The robot controller has Acknowledge the mes-
of the robot has been not triggered sufficient sage.
violated. braking in the case of a
STOP 1 or a safe opera-
tional stop.
15018 Ackn.: Maximum Carte- The maximum permissible Check override reduction
sian speed limit in T1 Cartesian velocity in oper- and modify as required.
mode exceeded ating mode T1 has been
(>>> 9.1 "Variables for
exceeded.
override reduction in
$CUSTOM.DAT" Page 99)
15019 Ackn.: Maximum axis- At least one axis has Reduce jog override.
specific speed limit in T1 exceeded the configured
mode exceeded limit value for reduced axis
velocity in operating mode
T1.
15020 Start-up mode active, Start-up mode of the safety Deactivate Start-up mode.
EMERGENCY STOP has controller is activated.
LOCAL effect ONLY
15021 Safety stop 2 violated The brake ramp has not Deactivate safe opera-
(SHS2) been maintained. tional stop.
15022
Ackn.: Safety stop 2 vio- The configured axis angles
lated (SHS2) or distance tolerances
have been violated during
a monitored standstill.
15031 Ackn.: Cartesian veloc- The space-specific velocity Check the programmed
ity in Cartesian monitor- for the Cartesian monitor- motion and modify as
ing space no. Number of ing space has been required.
monitoring space exceeded. Check the active tool in the
exceeded safety controller and
$TOOL in the system soft-
ware and modify as
required.
Check the safety configu-
ration and modify as
required.
15032 Ackn.: Cartesian veloc- The space-specific velocity Check the programmed
ity in axis-specific moni- for the axis-specific moni- motion and modify as
toring space no. Number toring space has been required.
of monitoring space exceeded. Check the safety configu-
exceeded ration and modify as
required.


15033 More then one tool acti- More than one tool is Deactivate invalid tools
vated in the safety con- active in the safety control- and activate the correct
15034
troller ler. Only one tool may be tool.
active.
Ackn.: More then one
tool activated in the
safety controller
15035 No tool activated in No tool is active in the Activate the correct tool.
safety controller safety controller. One tool
15036
must be active.
Ackn.: No tool activated
in safety controller
15037 Cell area exceeded The active tool has Move robot out of the vio-
exceeded the cell area. lated area in CRR mode.
15038 Ackn.: Cell area
exceeded
15039 Ackn.: Maximum global The limit value for maxi- Acknowledge the mes-
Cartesian speed limit mum Cartesian velocity sage.
exceeded (not space-dependent) has
been exceeded.
15040 Ackn.: Maximum global The limit value for maxi- Check the programmed
axis speed exceeded mum axis velocity has motion and modify as
been exceeded. required.
required.
15041 Ackn.: Maximum safe The limit value for safely Check the programmed
reduced Cartesian speed reduced Cartesian velocity motion and modify as
exceeded has been exceeded. required.
required.
15042 Ackn.: Safe reduced axis The limit value for safely Check the programmed
speed exceeded reduced axis velocity has motion and modify as
been exceeded. required.
required.
Check whether the velocity
monitoring is activated and
activate if required.
15043 Safe operational stop Following activation of the Deactivate operational
violated (axis group safe operational stop, at stop.
15044
Number of axis group) least one axis from the axis Stop the axes in the axis
group was not braked or group before activating the
Ackn.: Safe operational
exceeded the configured operational stop.
stop violated (axis group
axis angles or distance tol-
Number of axis group) Check the configuration of
erances during a moni-
the axis group and modify
tored standstill.
as required.
15045 Error at mastering refer- The CIB signals an error at Check the reference switch
ence switch the reference switch input. connection and CIB.
15046
Ackn.: Error at mastering
reference switch

12 Messages

15047 Mastering test required The mastering test is Perform mastering test.
(internal) requested internally after
the robot controller has
booted or after mastering.
15048 Ackn.: Mastering test The monitoring time has Perform mastering test.
time interval expired elapsed.
15049 Mastering test failed The mastering test has Eliminate error and carry
failed. The cause of the out mastering test.
error is indicated in a sepa-
rate message. See mes-
sages no. 15051 to 15066.
15050 Reference stop Reference stop is acti- Perform mastering test.
vated. (= function Stop if
mastering test not yet
done)
15051 Ackn.: Mastering test It was not possible to move Check the reference posi-
position not reached to the reference position. tion in the program
MasRef_USER.SRC and
in the safety configuration
and teach again if
required.
Check mastering.
15052 Ackn.: Mastering refer- Robot is in mastering posi- Exchange the reference
ence switch not actuated tion and the reference switch.
switch is not actuated: Check the reference posi-
 Reference switch is de- tion in the program
fective. MasRef_USER.SRC and
in the safety configuration
 The distance between
and teach again if
the reference switch
required.
and the reference posi-
tion is too great. Check mastering.
15053 Ackn.: Not all mastering The mastering test for one Teach the missing refer-
reference groups refer- or more reference groups ence positions or missing
enced could not be carried out motion away from the ref-
because of a missing refer- erence position in the pro-
ence position or because gram MasRef_USER.SRC.
of a missing motion away
from the reference posi-
tion.
15054 Workspace monitoring Loss of mastering of one or Master unmastered axes.
functions deactivated more axes: the workspace
(mastering error) monitoring functions are
deactivated.
15065 Ackn.: Level at master- The reference switch is Check the reference switch
ing reference switch is actuated although no mas- and exchange if defective.
15066
unexpectedly "low" tering test is currently
being carried out.
Level at mastering refer-
ence switch is unexpect-
edly "low"
15079 Monitoring space no. One or more axes are situ- Move robot out of the vio-
Number of monitoring ated outside the monitoring lated area in CRR mode.
15080
space violated space. The monitoring was Deactivate the monitoring
only activated after the space using the safe input.
Ackn.: Monitoring space
space limit was violated.
no. Number of monitor-
ing space violated


15081 Monitoring space no. One or more axes have left Move robot out of the vio-
Number of monitoring the monitoring space. The lated area in CRR mode.
15082
space exceeded monitoring was already Deactivate the monitoring
active when the space limit space using the safe input.
Ackn.: Monitoring space
was violated.
no. Number of monitor-
ing space exceeded

13 Appendix
13 Appendix
13.1 Checklists
13.1.1 Precondition for safety acceptance based on the checklists
 Mechanical and electrical installation of the industrial robot have been

completed.
 Safety configuration is completed.
13.1.2 Checklist for robot and system
The checklist must be completed and confirmed in writing by the system build-
er.
Checklist  Serial number of the robot: ____________________
No. Activity Yes

1 The industrial robot is in flawless mechanical condition and correctly installed
and fastened in accordance with the specifications in the documentation.
2 The permissible rated payload of the robot has not been exceeded.
3 There are no foreign bodies or loose parts on the industrial robot.
4 All required safety equipment is correctly installed and operational.
5 The power supply ratings of the industrial robot correspond to the local supply
voltage and mains type.
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.
Place, date
Signature
By signing, the signatory confirms the correct and complete performance of

the safety acceptance test.
Remarks:
13.1.3 Checklist for safe functions

 Time stamp of the safety configuration: ____________________
 Checksum of the safety configuration: ____________________

 Activation code of the safety configuration: ____________________
No. Activity Yes Not relevant

1 Safe monitoring has been activated.
2 Robot is mastered.
3 The machine data are consistent with the machine data in the
safety configuration.
Inconsistent machine data are indicated when the safety con-
figuration is activated.
4 The machine data have been checked and are appropriate for
the robot used.
The machine data loaded must match the machine data on
the identification plate of the robot.
5 The machine data of the external axes have been correctly
entered and checked.
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.
6 Control of the reduced velocity has been checked and is func-
tioning correctly.
(>>> 4.8.3 "Start-up and recommissioning" Page 50)
7 The local and external safety functions have been checked
and are functioning correctly.
(>>> 4.8.3 "Start-up and recommissioning" Page 50)
8 The reference position has been taught in the program
9 Was the mastering test successful?
10 Was the brake test successful?
11 Operator safety acknowledgement has been checked and is
functioning correctly.
(>>> 4.5.4 "Operator safety" Page 42)
12 Peripheral contactor (US2) has been checked and switches at
the right time.
Note: Further information is contained in the Operating and
Programming Instructions for System Integrators.
13 The Cartesian and axis-specific velocities have been config-
ured correctly.
The checklist must be completed and confirmed in writing for
the Cartesian and axis-specific velocities.

13 Appendix

14 The correct configuration of the safe operational stop has
been checked by moving all axes.
Each axis in an axis group must be tested individually.
every axis group.
(>>> 13.1.5 "Checklist for configuration of the safe opera-
tional stop" Page 121)
15 The correct configuration of the cell area has been checked by
moving to all reachable limits.
the cell area.
(>>> 13.1.6 "Checklist for configuration of the cell area"
Page 122)
16 The correct configuration of the monitoring spaces used has
been checked by moving to all reachable limits.
Each space surface of a Cartesian monitoring space must be
addressed in 3 different positions.
The axis of an axis-specific monitoring space must be moved
to the upper and lower limits of the space.
each monitoring space used.
(>>> 13.1.7 "Checklist for configuration of Cartesian monitor-
ing spaces" Page 123)
(>>> 13.1.8 "Checklist for configuration of axis-specific moni-
toring spaces" Page 125)
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


17 The safe tools used have been configured correctly.
At least one monitoring space and one velocity must be
checked with each safe tool.
each safe tool used.
(>>> 13.1.9 "Checklist for configuration of the safe tools"
Page 127)
18 The safety configuration has been archived and the change
log has been checked.
Place, date
Signature

13.1.4 Checklist for velocity limits

 Safe tool used (in test): ____________________
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 The maximum Cartesian velocity has been correctly config-
ured and checked.
Specified value: __________ mm/s
Configured value: __________ mm/s
Test value: __________ mm/s
2 The safe reduced Cartesian velocity has been correctly con-
figured and checked.
3 The safe reduced Cartesian velocity for T1 has been cor-
rectly configured and checked.

13 Appendix

4 The maximum axis velocity has been correctly configured
and checked.
Specified value for axis 1: __________ °/s or mm/s
Configured value for axis 1: __________ °/s or mm/s
Test value for axis 1: __________ °/s or mm/s
Specified value for axis 2: __________ °/s
Configured value for axis 2: __________ °/s
Test value for axis 2: __________ °/s


5 The reduced axis velocity has been correctly configured and
checked.

13 Appendix

6 The reduced axis velocity for T1 has been correctly config-
ured and checked.
Place, date
Signature

13.1.5 Checklist for configuration of the safe operational stop
A separate checklist must be completed for each axis group.
Precondition  Operating mode T1

 Axis group number: ____________________


1 Axis 1 has been correctly configured and checked.
Specified axis angle tolerance: ______ ° or mm
Configured axis angle tolerance: ______ ° or mm
Specified axis angle tolerance: __________ °
Configured axis angle tolerance: __________ °
Specified axis angle tolerance: _______ ° or mm
Specified axis angle tolerance: ______ ° or mm
Place, date
Signature

13.1.6 Checklist for configuration of the cell area
Precondition  The monitoring spaces that can be activated by means of safe inputs have
been deactivated.
Checklist  Serial number of the robot: ________________

 Time stamp of the safety configuration: ________________
 Safe tool used in test: ________________
The surfaces arising from the configuration must be violated one after the oth-
er to demonstrate the correct configuration of the cell area.
1 Has the limit in the Z direction been configured correctly?
Z min: ____________mm
Z max: ____________mm

13 Appendix

2 Corner 1 has been correctly configured?
X coordinate: __________ mm
Y coordinate: __________ mm
Place, date
Signature

13.1.7 Checklist for configuration of Cartesian monitoring spaces
A separate checklist must be completed for each monitoring space.
Precondition  The monitoring space to be checked is activated.

 The monitoring spaces that can be activated by means of safe inputs have
been deactivated.


 Monitoring space checked (name, number): __________
 Type of space (protected space or workspace): ____________________
 Stop at boundaries (TRUE|FALSE): __________
 Reference stop (TRUE|FALSE): __________
 Space-specific velocity __________mm/s
 Space-specific velocity valid in: __________
 Safe tool used in test of velocity
or space limit: _________________
 Always active (TRUE|FALSE): __________
 Reference coordinate system: _____________
The configured limit values must successively be violated to demonstrate the

correct functioning of the monitoring space.
1 The coordinates of the monitoring space have been correctly
configured and checked?
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 function-

ing of the reference stop:
 Reference stop is active.
 Mastering test is requested.
 Monitored monitoring space is activated.

2 The correct functioning of the reference stop has been
checked?

ing 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.

13 Appendix

 Robot exceeds the configured space-specific velocity.

3 The space-specific velocity has been correctly configured
and checked?
Place, date
Signature

13.1.8 Checklist for configuration of axis-specific monitoring spaces
A separate checklist must be completed for each monitoring space.
Precondition  The monitoring space to be checked is activated.

 The monitoring spaces that can be activated by means of safe inputs have
been deactivated.

 Monitoring space checked (name, number): __________
 Type of space (protected space or workspace): ____________________
 Stop at boundaries (TRUE|FALSE): __________
 Reference stop (TRUE|FALSE): __________
 Space-specific velocity __________mm/s
 Space-specific velocity valid in: __________
 Safe tool used in test of velocity
or space limit: _________________
 Always active (TRUE|FALSE): __________
The configured limit values must successively be violated to demonstrate the

correct functioning of the monitoring space.
Specified lower axis limit: __________ ° or mm
Configured lower axis limit: __________ ° or mm
Determined lower axis limit: __________ ° or mm
Specified upper axis limit: __________ ° or mm
Configured upper axis limit: __________ ° or mm
Determined upper axis limit: __________ ° or mm


Specified lower axis limit: __________ °
Configured lower axis limit: __________ °
Determined lower axis limit: __________ °
Specified upper axis limit: __________ °
Configured upper axis limit: __________ °
Determined upper axis limit: __________ °

13 Appendix


ing of the reference stop:
 Reference stop is active.
 Mastering test is requested.

9 The correct functioning of the reference stop has been
checked?

ing 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.
 Robot exceeds the configured space-specific velocity.

10 The space-specific velocity has been correctly configured
and checked?
Place, date
Signature

13.1.9 Checklist for configuration of the safe tools
A separate checklist must be completed for each safe tool.

Checklist  Serial number of the robot: _________________

 Time stamp of the safety configuration: _________________
 Safe tool checked (name, number): _______________
 Velocity limit during TCP test: ____________ mm/s
 Monitoring space used in sphere test (name, number):
________________
A monitoring space must be violated by each configured sphere to demon-

strate the correct functioning of the safe tool.
1 Safe TCP of the tool
The coordinates have been correctly configured and
checked (velocity check)?
Specified value for the X coordinate: __________ mm
Configured value for the X coordinate: __________ mm
Specified value for the Y coordinate: __________ mm
Configured value for the Y coordinate: __________ mm
Specified value for the Z coordinate: __________ mm
Configured value for the Z coordinate: __________ mm
2 1st sphere on tool
checked?
Specified radius: __________ mm
Configured radius: __________ mm
3 2nd sphere on tool
checked?

13 Appendix

4 3rd sphere on tool
checked?
5 4th sphere on tool
checked?
checked?
checked?

Place, date
Signature

13.2 Applied norms and directives
The safety functions of KUKA.SafeOperation meet the requirements of Cate-

gory 3 and Performance Level d in accordance with EN ISO 13849-1:2007.
This corresponds to SIL 2 in accordance with EN 62061.

14 KUKA Service
14 KUKA Service
14.1 Requesting support
Introduction The KUKA Roboter GmbH documentation offers information on operation and
provides assistance with troubleshooting. For further assistance, please con-
tact your local KUKA subsidiary.
Information The following information is required for processing a support request:

 Model and serial number of the robot
 Model and serial number of the controller
 Model and serial number of the linear unit (if applicable)
 Version of the KUKA System Software
 Optional software or modifications
 Archive of the software
 Application used
 Any external axes used
 Description of the problem, duration and frequency of the fault
14.2 KUKA Customer Support
Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.
Argentina Ruben Costantini S.A. (Agency)

Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com
Australia Headland Machinery Pty. Ltd.

Victoria (Head Office & Showroom)
95 Highbury Road
Burwood
Victoria 31 25
Australia
Tel. +61 3 9244-3500
Fax +61 3 9244-3501
vic@headland.com.au
www.headland.com.au

Belgium KUKA Automatisering + Robots N.V.

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

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

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

Songjiang Industrial Zone
No. 388 Minshen Road
201612 Shanghai
China
Tel. +86 21 6787-1808
Fax +86 21 6787-1805
info@kuka-sha.com.cn
www.kuka.cn
Germany KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
info@kuka-roboter.de
www.kuka-roboter.de

14 KUKA Service
France KUKA Automatisme + Robotique SAS

Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
commercial@kuka.fr
www.kuka.fr
India KUKA Robotics, Private Limited

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

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

Daiba Garden City Building 1F
2-3-5 Daiba, Minato-ku
Tokyo
135-0091
Japan
Tel. +81 3 6380-7311
Fax +81 3 6380-7312
info@kuka.co.jp
Korea KUKA Robotics Korea Co. Ltd.

RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
info@kukakorea.com

Malaysia KUKA Robot Automation Sdn Bhd

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

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

Bryggeveien 9
2821 Gjövik
Norway
Tel. +47 61 133422
Fax +47 61 186200
geir.ulsrud@kuka.no
Austria KUKA Roboter Austria GmbH

Vertriebsbüro Österreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
office@kuka-roboter.at
www.kuka-roboter.at
Poland KUKA Roboter Austria GmbH

Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
ServicePL@kuka-roboter.de

14 KUKA Service
Portugal KUKA Sistemas de Automatización S.A.

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

Webnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
kuka-robotics.ru
Sweden KUKA Svetsanläggningar + Robotar AB

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

Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
info@kuka-roboter.ch
www.kuka-roboter.ch
Spain KUKA Robots IBÉRICA, S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
Fax +34 93 8142-950
Comercial@kuka-e.com
www.kuka-e.com

South Africa Jendamark Automation LTD (Agency)

76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za
Taiwan KUKA Robot Automation Taiwan Co., Ltd.

No. 249 Pujong Road
Jungli City, Taoyuan County 320
Taiwan, R. O. C.
Tel. +886 3 4331988
Fax +886 3 4331948
info@kuka.com.tw
www.kuka.com.tw
Thailand KUKA Robot Automation (M)SdnBhd

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

Organisation Tschechien und Slowakei
Sezemická 2757/2
193 00 Praha
Horní Počernice
Czech Republic
Tel. +420 22 62 12 27 2
Fax +420 22 62 12 27 0
support@kuka.cz
Hungary KUKA Robotics Hungaria Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu

14 KUKA Service
USA KUKA Robotics Corp.

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

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


Index
Index
Symbols Brake defect 48
$MASTERINGTEST_REQ_EXT 99 Braking distance 8, 37
$MASTERINGTEST_REQ_INT 99 Buttons, overview 61
$MASTERINGTESTSWITCH_OK 99
$ROBROOT, special cases 15 C
$SR_ACTIVETOOL 100 Cartesian monitoring spaces, defining 72
$SR_AXISSPEED_OK 100 Cartesian monitoring spaces, testing 93
$SR_CARTSPEED_OK 100 Cartesian protected spaces 18
$SR_DRIVES_ENABLE 100 Cartesian velocity, maximum 69, 91
$SR_MOVE_ENABLE 100 Cartesian velocity, reduced 70, 91
$SR_OV_RED 25, 99 Cartesian velocity, reduced for T1 70, 91
$SR_SAFEMON_ACTIVE 100 Cartesian velocity, testing 91
$SR_SAFEOPSTOP_ACTIVE 100 Cartesian workspaces 17
$SR_SAFEOPSTOP_OK 100 CE mark 36
$SR_SAFEREDSPEED_ACTIVE 100 Cell area 10, 13, 16, 17
$SR_VEL_RED 24, 99 Cell area, defining 70
$SR_WORKSPACE_RED 25, 99 Change log 63
Checking the reference position 89
Numbers Checklist, Cartesian monitoring spaces 123
2004/108/EC 57 Checklist, configuration of axis-specific monito-
2006/42/EC 57 ring spaces 125
89/336/EEC 57 Checklist, configuration of safe tools 127
95/16/EC 57 Checklist, configuration of the cell area 122
97/23/EC 57 Checklist, configuration of the safe operational
stop 121
A Checklist, robot and system 115
Accessories 35 Checklist, safe functions 115
Activating a new safety configuration 95 Checklist, velocity limits 118
Activation code, safety configuration 62 Checklists 115
Activation, monitoring space 73, 77 Checksum, brake test configuration 63
Activation, reference stop 73, 77 Checksum, safety configuration 62
Actuating plate, hole pattern 32 Cleaning work 54
Actuating plate, installation 67 Components 11
Alarm space 8 Connecting cables 35
Ambient temperature, reference switch 31 Connecting cables, overview 28
Appendix 115 Connecting, reference switch 67
Applied norms and regulations 57 Coordinate systems 14
Areas of application 11 Coordinate systems, angles 15
Automatic mode 53 Coordinate systems, orientation 15
Axis angle tolerance 84 Counterbalancing system 54
Axis angle, lower limit 79 Criteria, reference position 27
Axis angle, upper limit 79 CRR 8, 25
Axis limit 8, 19, 20
Axis range 8, 19, 20, 37 D
Axis range limitation 46 Danger zone 8, 37
Axis range monitoring 46 Declaration of conformity 36
Axis velocity, maximum 82, 92 Declaration of incorporation 35, 36
Axis velocity, reduced 24, 81, 92 Decommissioning 55
Axis velocity, reduced for T1 81, 92 Diagnosis 109
Axis velocity, testing 92 Diagnosis, variables 100
Axis-specific monitoring spaces, defining 75 Diagnostic monitor (menu item) 109
Axis-specific monitoring spaces, testing 94 Diagnostic signals via PROFINET 103
Axis-specific protected spaces 20 Directives 130
Axis-specific velocity monitoring, defining 79 Displaying information, safety configuration 62
Axis-specific workspaces 19 Displaying machine data 63
Displaying, change log 63
B Disposal 55
BASE coordinate system 14 Documentation, industrial robot 7

E Knowledge, required 7
EC declaration of conformity 36 KUKA Customer Support 131
EMC conformity, reference switch 31 KUKA smartPAD 37
EMC Directive 36, 57
EMERGENCY STOP button 43, 51 L
EMERGENCY STOP device 43, 44, 48 Labeling 47
EMERGENCY STOP, external 44, 51 Liability 35
EMERGENCY STOP, local 51 Linear unit 35
EN 60204-1 57 Low Voltage Directive 36
EN 61000-6-2 57
EN 61000-6-4 57 M
EN 614-1 57 Machine data 51, 63
EN ISO 10218-1 57 Machinery Directive 36, 57
EN ISO 12100-1 57 Maintenance 54
EN ISO 12100-2 57 Manipulator 35, 37, 40
EN ISO 13849-1 57, 130 Manual mode 52
EN ISO 13849-2 57 Mastering position, reference position 89
EN ISO 13850 57 Mastering test 8
Enabling device 44, 48 Mastering test input 69
Enabling device, external 45 Mastering test, overview 26
Enabling switches 44 Mastering test, performing manually 91
Error messages 111 Mastering test, programming 97
External axes 35, 38 Mastering test, variables 99
Mechanical axis range limitation 46
F Mechanical end stops 46
Faults 49 Messages 111
FLANGE coordinate system 15 Mode selection 41, 42
Function test 50 Monitoring space 10
Functional principle 12 Monitoring space, axis-specific 75
Functions, SafeOperation 11 Monitoring space, Cartesian 72
Monitoring spaces 12
G Monitoring time 8
General safety measures 48 Monitoring, velocity 45
Global parameters, defining 68 Mouse, external 49
Guard interlock 42
N
H Norms 130
Hardware components, scope of supply 11
Hazardous substances 55 O
Hole pattern, actuating plate 32 Operating current, reference switch 31
Hole pattern, reference switch 32 Operating voltage, reference switch 31
Hysteresis, reference switch 31 Operation 61
Operator 37, 39
I Operator safety 41, 42, 48
I/Os, interface X13 107 Options 35
Industrial robot 35 Outputs, reference switch 31
Installation 59 Overload 48
Installation, SafeOperation 59 Override reduction 24
Intended use 35 Override reduction, variables 99
Interface, X13 107 Overview, buttons 61
Interface, X13 12 Overview, SafeOperation 11
Interfaces 101 Overview, safety acceptance 94
Introduction 7 Overview, start-up 65
J P
Jog mode 45, 48 Panic position 44
Performance Level 41
K Permissible load current, reference switch 31
KCP 37, 49 Permissible switching distance, reference switch
Keyboard, external 49 31
KL 8 Permissible switching frequency, reference swit-

Index
ch 31 Safety configuration, saving 90

Personnel 38 Safety controller 41
Plant integrator 38 Safety functions 48
Polygon, convex 8, 13, 16 Safety functions, overview 41
Positioner 35 Safety instructions 7
Pressure Equipment Directive 55, 57 Safety parameters, testing 91
Preventive maintenance work 54 Safety STOP 0 9, 37
Product description 11 Safety STOP 1 9, 37
PROFINET 12 Safety STOP 2 9, 37
PROFIsafe 8, 12 Safety STOP 0 37
Programming 97 Safety STOP 1 37
Programs, mastering test 97 Safety STOP 2 37
Protected space 9, 12, 18, 20 Safety stop, external 45
Protective equipment 45 Safety warnings 66
Pulse duration, reference switch 31 Safety zone 37, 39, 40
Pulse duty factor, reference switch 31 Safety, general 35
Serial number, robot 62
R Service life 31
Reaction distance 8, 37 Service, KUKA Roboter 131
Recommissioning 50, 65 SIB 9
Reference group 8, 89 SIB Extended 12
Reference position 8, 27 Simulation 53
Reference position, axis angle 89 Single point of control 55
Reference position, Cartesian 89 smartPAD 37
Reference position, defining 87 Software 35
Reference stop 9, 22 Software components, scope of supply 11
Reference switch 9 Software limit switches 45, 48
Reference switch module 28 Space type 73, 77
Reference switch, connecting 67 Space-specific velocity 22, 73, 77
Reference switch, hole pattern 32 Special cases, $ROBROOT 15
Reference switch, installation 67 SPOC 55
Reference switch, technical data 31 Standstill monitoring 24, 84
Reference system 71, 74 Start-up 50, 65
Release device 46 Start-up mode 26, 52
Repair 54 Start-up, overview 65
Robot controller 35 STOP 0 36, 38
ROBROOT coordinate system 14 STOP 1 36, 38
STOP 2 36, 38
S Stop at boundaries 73, 77
Safe I/Os, displaying 109 Stop category 0 38
Safe monitoring 69 Stop category 1 38
Safe monitoring, activating 68 Stop category 2 38
Safe monitoring, deactivating 96 Stop reactions 13, 24, 40
Safe operational stop 9, 24, 37, 45, 81 Stopping distance 8, 37, 40
Safe operational stop, axis group 1 to 6 84 Storage 55
Safe operational stop, defining 82 Support request 131
Safe operational stop, testing 94 Switching function, reference switch 31
Safe robot retraction 25 System integrator 36, 38
Safe TCP 9 System requirements 59
Safe tool 9 System variables 99
Safe tools 23
Safe tools, defining 84 T
Safeguards, external 47 T1 38
SafeOperation via PROFIsafe 101 T2 38
SafeOperation, overview 11 Target group 7
Safety 35 Teach pendant 35
Safety acceptance, overview 94 Technical data 31
Safety acceptance, precondition 115 Technical data, reference switch 31
Safety configuration, displaying information 62 Terms used 8
Safety configuration, new, activating 95 Terms used, safety 36
Safety configuration, opening 61 Time stamp, machine data 63

Time stamp, safety configuration 62

TOOL coordinate system 14
Training 7
Transport position 50
Transportation 50
Turn-tilt table 35
Type of monitoring space 73, 77
U
Uninstallation, SafeOperation 59
Update, SafeOperation 59
Use, contrary to intended use 35
Use, improper 35
User 37, 38
User groups 61
V
Velocity monitoring 45
Velocity monitoring functions 23
Velocity monitoring, axis-specific 79
Velocity, space-specific 22
Version, SafeOperation 62
Version, safety configuration 62
W
Warnings 7
Working range limitation 46
Workspace 8, 12, 17, 19, 37, 39, 40
WORLD coordinate system 14


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KUKA System Technology KUKA Roboter GmbH

For KUKA System Software 8.2

Version: KST SafeOperation 3.1 V1 en

Publication: Pub KST SafeOperation 3.1 en

2 / 143 Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

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

3 Technical data .............................................................................................. 31

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4.5.3 Mode selection ..................................................................................................... 42

7 Start-up and recommissioning ................................................................... 65

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7.2 Safety warnings ......................................................................................................... 66

9 System variables ......................................................................................... 99

10 Interfaces to the higher-level controller .................................................... 101

11 Diagnosis ..................................................................................................... 109

12 Messages ..................................................................................................... 111

13 Appendix ...................................................................................................... 115

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13.1.4 Checklist for velocity limits .................................................................................... 118

14 KUKA Service ............................................................................................... 131

Index ............................................................................................................. 139

6 / 143 Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

1.1 Target group

For optimal use of our products, we recommend that our customers

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

1.3 Representation of warnings and notes

Safety These warnings are relevant to safety and must be observed.

These warnings mean that it is certain or highly probable

These warnings mean that death or severe physical inju-

These warnings mean that minor physical injuries may

These warnings mean that damage to property may oc-

These warnings contain references to safety-relevant information or

Tip to make your work easier or reference to further information.

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1.4 Terms used

8 / 143 Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

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10 / 143 Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

2.1 Overview of SafeOperation

Information about the safety configuration in WorkVisual is contained

Components These software components are included in the SafeOperation package:

Areas of appli-  Human-robot cooperation

Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en 11 / 143

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

1 Reference switch 5 System control panel

Decouplable external axes are not supported by SafeOp-

2.2 Monitoring spaces

A maximum of 16 monitoring spaces can be configured. A cell area must also

12 / 143 Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

(>>> 2.2.4 "Cartesian protected spaces" Page 18)

Stopping If the robot is stopped by a monitoring function, it requires a certain stopping

EN ISO 10218-1, Annex B, specifies the need for information about

Stop reaction Description Example

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2.2.1 Coordinate systems

Fig. 2-2: Overview of coordinate systems

14 / 143 Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

The TOOL coordinate system is a Cartesian coordinate system which is locat-

Angles of rotation of the robot coordinate systems

Angle Rotation about axis

2.2.1.1 Special cases

Fig. 2-3: ROBROOT coordinate system Jet