KUKA SafeRobot 11 en

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V6.2 03.08.200
Issued: 03.08.2007 Version: 6.2
KUKA Robot Group
KUKA System Technology (KST)
KUKA.SafeRobot 1.1
For KUKA System Software (KSS) 5.4
© Copyright 2007
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without 
the express permission of the KUKA ROBOT GROUP.
Other functions not described in this documentation may be operable in the controller. The user has no 
claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software de-
scribed. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guaran-
tee total conformity. The information in this documentation is checked on a regular basis, however, and 
necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS4-DOC
V0.4 22.03.2006 pub de
KUKA.SafeRobot 1.1
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Contents
Contents
1 Introduction ...................................................................................................... 7
1.1 Target group ................................................................................................................... 7
1.2 Robot system documentation ......................................................................................... 7
1.3 Representation of warnings and notes ........................................................................... 7
1.4 Terms used ..................................................................................................................... 8
2 Product description ......................................................................................... 11
2.1 KUKA.SafeRobot overview ............................................................................................. 11
2.2 Functional principle ......................................................................................................... 12
2.3 Monitoring ranges ........................................................................................................... 12
2.3.1 Workspaces ............................................................................................................... 13
2.3.2 Safety zones .............................................................................................................. 14
2.3.3 Reference stop .......................................................................................................... 14
2.4 Velocity and acceleration monitoring .............................................................................. 14
2.5 Standstill monitoring ....................................................................................................... 15
2.6 Safe state (output OUT_STATUS) ................................................................................. 16
2.7 Mastering test ................................................................................................................. 16
2.7.1 Reference position ..................................................................................................... 17
2.7.2 Mastering test signal diagram .................................................................................... 18
2.8 Brake test ........................................................................................................................ 18
2.8.1 Parking position ......................................................................................................... 19
2.8.2 Signal diagram of the brake test ................................................................................ 20
2.9 T1 mode (safe robot retraction) ...................................................................................... 21
2.10 Monitoring functions that can be activated ..................................................................... 21
2.11 Components ................................................................................................................... 22
2.11.1 SafeRDC .................................................................................................................... 22
2.11.2 Reference group ........................................................................................................ 24
2.12 Connecting cables .......................................................................................................... 25
2.12.1 Connections on the SafeRDC box ............................................................................. 26
2.12.2 Connections on the SafeRDC box (optional) ............................................................. 26
2.12.3 Connector pin assignment of data cable X21 - X31 .................................................. 27
2.12.4 Connector pin assignment of data cable X21.1 - X41 ............................................... 27
2.12.5 Connector pin assignment of reference cable X42 - XS Ref ..................................... 28
2.12.6 Wiring diagram for 3 reference groups (optional) ...................................................... 28
2.13 Interface X40 .................................................................................................................. 29
2.13.1 Connector pin allocation X40 ..................................................................................... 30
2.13.2 Safe inputs ................................................................................................................. 33
2.13.3 Safe outputs .............................................................................................................. 35
3 Technical data .................................................................................................. 37
3.1 Technical data of the SafeRDC ...................................................................................... 37
3.2 Reference switch ............................................................................................................ 37
3.3 Reference switch hole pattern ........................................................................................ 38
3.4 Hole pattern for actuating plate ....................................................................................... 39
4 Safety ................................................................................................................ 41
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5 Installation ....................................................................................................... 43
5.1 System requirements ...................................................................................................... 43
5.2 Installing or updating KUKA.SafeRobot ......................................................................... 43
5.3 Uninstalling KUKA.SafeRobot ........................................................................................ 43
6 Start-up ............................................................................................................. 45
6.1 Start-up overview ............................................................................................................ 45
6.2 Installing the reference switch and actuating plate ......................................................... 46
6.3 Exchanging the lid of the SafeRDC box ......................................................................... 47
6.4 Connecting the connecting cables .................................................................................. 47
6.5 Connecting the Safety PLC ............................................................................................ 48
6.6 Assigning input and output signals................................................................................. 49
6.7 Defining axis-specific monitoring ranges ........................................................................ 49
6.8 Defining the reference position ....................................................................................... 50
6.9 Safety parameters .......................................................................................................... 52
6.9.1 Setting safety parameters .......................................................................................... 53
6.9.2 Parameters – General information ............................................................................. 54
6.9.3 Parameters – Monitored axes .................................................................................... 54
6.9.4 Parameters – Reduced axis velocity ......................................................................... 54
6.9.5 Parameters – Cartesian velocity ................................................................................ 54
6.9.6 Parameters – Reduced axis acceleration .................................................................. 55
6.9.7 Parameters – Axis range monitoring ......................................................................... 56
6.9.8 Parameters – Monitoring of mastering ....................................................................... 57
6.9.9 Parameters – Standstill monitoring ............................................................................ 57
6.9.10 Parameters – Interfaces ............................................................................................ 58
6.9.11 Parameters – Machine data ($ROBCOR.DAT) ......................................................... 58
6.9.12 Parameters – Machine data ($MACHINE.DAT) ........................................................ 59
6.10 Assigning external axes to the reference group ............................................................. 59
6.11 Programming the mastering test ..................................................................................... 60
6.12 Checking the reference position (actuation with tool) ..................................................... 61
6.13 Performing a mastering test manually ............................................................................ 61
6.14 Configuring robot axes for the brake test ........................................................................ 62
6.15 Configuring external axes for the brake test ................................................................... 62
6.16 Programming the brake test ........................................................................................... 63
6.17 Performing a manual brake test ...................................................................................... 63
6.18 Safety acceptance of KUKA.SafeRobot ......................................................................... 64
7 Programming .................................................................................................... 65
7.1 Programs for the mastering test ..................................................................................... 65
7.2 Programs for the brake test ............................................................................................ 65
8 Operation .......................................................................................................... 67
8.1 Displaying safety parameters ......................................................................................... 67
8.2 Verifying safety parameters ............................................................................................ 67
8.3 Reading the operating hours meter ................................................................................ 68
8.4 Archiving safety parameters ........................................................................................... 68
8.5 Restoring safety parameters ........................................................................................... 68
9 System variables .............................................................................................. 71
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Contents
9.1 Signal declarations ......................................................................................................... 71
9.2 Signals for the mastering test ......................................................................................... 71
9.3 Signals for diagnosis ....................................................................................................... 72
9.4 Robot status signals ....................................................................................................... 73
9.5 Signals for the brake test ................................................................................................ 74
9.6 Variables in BrakeTestDrv.INI ........................................................................................ 75
10 Messages .......................................................................................................... 77
10.1 Messages during operation ............................................................................................ 77
10.2 Messages during verification of the safety parameters .................................................. 81
10.3 Messages for the brake test ........................................................................................... 82
11 Diagnosis .......................................................................................................... 85
11.1 Opening diagnosis .......................................................................................................... 85
11.2 Overview of diagnosis ..................................................................................................... 85
11.2.1 Overview of the monitoring ranges ............................................................................ 86
11.2.2 Detailed information about the monitoring range ....................................................... 87
12 Troubleshooting ............................................................................................... 89
12.1 LEDs on the SafeRDC board .......................................................................................... 89
12.2 LEDs on the I/O Print board ............................................................................................ 92
13 Repair ................................................................................................................ 93
13.1 Connections on the SafeRDC board .............................................................................. 93
13.2 Connections on the I/O Print board ................................................................................ 94
13.3 Removing the SafeRDC board ....................................................................................... 94
13.4 Removing the I/O Print board ......................................................................................... 96
13.5 Installing the I/O Print board ........................................................................................... 96
13.6 Installing the SafeRDC board ......................................................................................... 97
14 Appendix ........................................................................................................... 99
14.1 Interface X40 circuit example 1 ...................................................................................... 99
14.2 Interface X40 circuit example 2 ...................................................................................... 100
14.3 Interface X40 circuit example 3 ...................................................................................... 101
14.4Checklist for robot and system ....................................................................................... 102
14.5 Checklist for safe functions ............................................................................................. 103
14.6 Checklist for reduced velocities ...................................................................................... 105
14.7 Checklist for reduced accelerations ................................................................................ 106
14.8 Checklist for standstill monitoring ................................................................................... 107
14.9 Checklist for configuration of the monitoring ranges ....................................................... 109
14.10 Applied norms and directives .......................................................................................... 112
15 KUKA Service ................................................................................................... 113
15.1 Requesting support ......................................................................................................... 113
15.2 KUKA Customer Support ................................................................................................ 113
Index .................................................................................................................. 119
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1. Introduction
1 Introduction
1.1 Target group
This documentation is aimed at users with the following knowledge and skills:
? KUKA.SafeRobot training
? Advanced KRL programming skills
? Advanced knowledge of the robot controller system
1.2 Robot system documentation
The robot system documentation consists of the following parts:
? Operating instructions for the robot
? Operating instructions for the robot controller
? Operating and programming instructions for the KUKA System Software
? Documentation relating to options and accessories
Each of these sets of instructions is a separate document.
1.3 Representation of warnings and notes
Safety Warnings marked with this pictogram are relevant to safety and must be ob-
served.
Notes Notes marked with this pictogram contain tips to make your work easier or ref-
erences to further information.
For optimal use of our products, we recommend that our customers take part 
in a course of training at KUKA College. Information about the training pro-
gram can be found at www.kuka.com or can be obtained directly from our 
subsidiaries.
Danger!
This warning means that death, severe physical injury or substantial material 
damage will occur, if no precautions are taken.
Warning!
This warning means that death, severe physical injury or substantial material 
damage may occur, if no precautions are taken.
Caution!
This warning means that minor physical injuries or minor material damage 
may occur, if no precautions are taken.
Tips to make your work easier or references to further information.
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1.4 Terms used
Term Description
Axis range Range, in degrees or millimeters, which can be 
defined for each axis to be monitored.
Axis limit An axis has 2 axis limits which define the axis 
range. There is an upper axis limit and a lower 
axis limit.
Stopping distance The stopping distance consists of the reaction 
distance and the braking distance.
Reaction distance = distance traveled between 
detection of the fault and application of the 
brakes.
Braking distance = distance traveled between 
the brakes being applied and the robot coming to 
a standstill.
Workspace The robot is allowed to move within a work-
space. The workspace is derived from the indi-
vidual axis ranges.
 (>>> 2.3.1 "Workspaces" page 13)
Brake test In the brake test, the robot controller checks the 
functionality and wear of the brakes.
 (>>> 2.8 "Brake test" page 18)
Brake test cycle time The brake test cycle time is a parameterizable 
value. When this time has elapsed, the robot 
controller initiates a brake test.
Input test pulse The input test pulse must be activated in the 
configuration window for testing the dual-chan-
nel operation of the safe inputs.
Monitoring time Within the monitoring time, the system must 
check whether a brake test or mastering test is 
requested.
Parking position If a brake is identified as being defective, the 
robot can be moved to the parking position. The 
parking position must be selected in a position 
where the robot can sag safely.
 (>>> 2.8.1 "Parking position" page 19)
Mastering test The mastering test is used to check whether the 
current position of the robot and the external 
axes corresponds to a reference position.
 (>>> 2.7 "Mastering test" page 16)
Reference group The axes required for moving to a reference 
position are listed in a reference group. Each 
configured axis must be assigned to a reference 
group. 
All robot axes are assigned to reference group 1. 
External axes can be assigned to other refer-
ence groups.
A maximum of 3 reference groups can be cre-
ated.
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1. Introduction
Term Description
Reference position In the mastering test, the robot moves to the ref-
erence position and compares the actual posi-
tion of the monitored axes with the stored 
reference position.
 (>>> 2.7.1 "Reference position" page 17)
Reference stop If a reference stop is set for one of the monitor-
ing ranges 2 to 7 and the following preconditions 
are met, the robot stops with a STOP 1.
? Monitoring range is activated.
? Mastering test is requested.
? T2, AUT or AUT EXT mode is set.
In order to be able to move the robot, deactivate 
all monitoring ranges and perform a mastering 
test.
Reference switch A reference switch is necessary for carrying out 
the mastering test. The reference switch con-
firms the reference position.
 (>>> 3.2 "Reference switch" page 37)
Safety zone The robot is not allowed to move within a safety 
zone. The safety zone is derived from the indi-
vidual axis ranges.
 (>>> 2.3.2 "Safety zones" page 14)
Standstill monitoring Standstill monitoring checks whether the moni-
tored axes are within their parameterized axis 
angle tolerance. The drives remain activated.
 (>>> 2.5 "Standstill monitoring" page 15)
STOP 0 In the case of a STOP 0, the drives are deacti-
vated immediately and the brakes are applied. 
The robot deviates from the path.
STOP 1 In the case of a STOP 1, the robot is braked on 
the programmed path for 1 second with a 
dynamic braking ramp. The drives are then 
deactivated and the brakes are applied.
STOP 2 In the case of a STOP 2, the drives are not 
deactivated and the brakes are not applied. The 
robot is braked with a dynamic braking ramp.
Monitoring range A workspace or a safety zone can be defined as 
a monitoring range.
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2. Product description
2 Product description
2.1 KUKA.SafeRobot overview
KUKA.SafeRobot is an option with software and hardware components.
Functions ? Connection to an external safety logic
? Monitoring that can be activated using safe inputs
? Up to 10 freely definable axis-specific monitoring ranges
? Combinable workspaces and safety zones
? Safe monitoring of Cartesian velocities at the mounting flange
? Safe monitoring of axis-specific velocities and accelerations
? Safe standstill monitoring
? Safe stop via Electronic Safety Circuit (ESC) with safe disconnection of the 
drives
? Monitoring of the mastering
? Brake test
Areas of application ? Human-robot cooperation
? Direct loading of workpieceswithout an intermediate support
? Replacement of conventional axis range monitoring systems
This option may only be retrofitted after consultation with the KUKA Robot 
Group.
Fig. 2-1: Example of a cell with KUKA.SafeRobot
1 Installed reference switch
2 Robot
3 Loading station
4 Safety mat
5 System control panel
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6 Robot controller
Communication The safety functions are activated via safe inputs of interface X40. The safe 
outputs of interface X40 can be wired externally.
2.2 Functional principle
Description The robot moves within the limits that have been configured and activated. 
The actual position is continuously calculated and monitored against the safe-
ty parameters that have been set.
The SafeRDC monitors the robot system by means of the safety parameters 
that have been set. If the robot violates a monitoring limit or a safety parame-
ter, it is stopped.
The safe inputs and outputs of the SafeRDC are of a redundant design and 
LOW active.
2.3 Monitoring ranges
Description Up to 10 freely definable monitoring ranges are available.
Inversion Inversion defines the nature of the monitoring range within the axis limits. A 
monitoring range can be defined as a workspace or safety zone.
Level of the safe outputs and inversion-specific reactions:
7 Bending machine
Caution!
In order to allow safe retraction of the robot, the monitoring ranges are not 
subjected to safe monitoring in T1 mode. If a limit is exceeded in T1 mode, 
the robot is not stopped safely and there is a risk of personal injury and ma-
terial damage.
 (>>> 2.9 "T1 mode (safe robot retraction)" page 21)
Monitoring 
range
Description Stop reaction
1
Permanently monitored and always 
active. It can be modified, but not 
deactivated. Trigger a stop.
2...7 Activated using safe inputs.
8...10
These are always active and set 
safe outputs which can be wired 
externally.
Do not trigger a 
stop.
Monitoring 
range
Inversion = FALSE Inversion = TRUE
Workspace Safety zone
2...7
Robot stops if the work-
space is active and at 
least one axis has exceed-
ed the limit.
Robot stops if the safety 
zone is active and at least 
one axis has exceeded 
the limit.
8...10
HIGH = all axes are locat-
ed in the workspace.
HIGH = no axis is located 
in the safety zone.
LOW = at least one axis is 
not located in the work-
space.
LOW = at least one axis is 
located in the safety zone.
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2. Product description
Stop reactions Stop reaction Description Example
2.3.1 Workspaces
Description KUKA.SafeRobot can be used for the separate software setting and monitor-
ing of the axis limits of each individual axis. The resulting axis range is the per-
missible range of an axis within which the robot may move. The individual axis 
ranges together make up the overall workspace, which may consist of up to 8 
axis ranges. The 6 robot axes and 2 external axes can be defined in a work-
space.
Example The diagram (>>> Fig. 2-2) shows an example of an axis-specific workspace. 
The workspace of axis 1 is configured from –110° to +130° and corresponds 
to the permissible motion range of the robot.
STOP 0
The stop is triggered if a moni-
toring function is already acti-
vated and the robot then 
exceeds the monitoring limit.
Robot exceeds the 
axis limit of an acti-
vated workspace in 
Automatic mode.
STOP 1
The stop is triggered if a moni-
toring function is just being 
activated and the robot has 
already exceeded the monitor-
ing limit.
A safety zone in which 
the robot is currently 
situated is activated by 
a safety mat.
STOP 2 The stop is triggered by the KUKA System Software.
Robot exceeds the 
axis limit of an acti-
vated workspace in T1 
mode.
Caution!
If the robot is stopped by a monitoring function, it requires a certain stopping 
distance before coming to a standstill. The stopping distance depends on the 
robot type, the velocity of the robot, the payload and other parameters. The 
stopping distances must be determined for the specific application by means 
of trials.
Fig. 2-2: Example workspace
1 Workspace 3 Stopping distance
2 Robot 4 Safeguarded zone
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2.3.2 Safety zones
Description KUKA.SafeRobot can be used for the separate software setting and monitor-
ing of the axis limits of each individual axis. The resulting axis range is the per-
missible range of an axis within which the robot may not move. The individual 
axis ranges together make up the overall safety zone, which may consist of up 
to 8 axes ranges. The 6 robot axes and 2 external axes can be defined in a 
safety zone.
Example The diagram (>>> Fig. 2-3) shows an example of an axis-specific safety zone. 
The protected range and the stopping distances correspond to the parameter-
ized safety zone. The motion range of axis 1 is limited to –185° to +185° by 
means of software limit switches. The safety zone is configured from –110° to 
–10°. This results in 2 permissible motion ranges for the robot, separated by 
the configured safety zone.
2.3.3 Reference stop
Description If a reference stop is set for one of the monitoring ranges 2 to 7 and the follow-
ing preconditions are met, the robot stops with a STOP 1.
? Monitoring range is activated.
? Mastering test is requested.
? T2, AUT or AUT EXT mode is set.
In order to be able to move the robot, deactivate all monitoring ranges and per-
form a mastering test.
2.4 Velocity and acceleration monitoring
Description The following velocity and acceleration monitoring functions can be set in the 
configuration window:
Fig. 2-3: Example safety zone
1 Permissible motion range 1 4 Safety zone
2 Robot 5 Permissible motion range 2
3 Stopping distance
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2. Product description
Reduced axis velocity
The velocity of every robot axis can be monitored against a limit value.
? Axis velocity limit value that can be activated by means of the safe inputs 
“Safe reduced velocity” and/or “Standstill monitoring”.
? Axis velocity limit value for T1 mode
Cartesian velocity
The Cartesian velocity at the center of the mounting flange on the robot can 
be monitored.
? Flange center point velocity limit value that can be activated by means of 
the safe inputs “Safe reduced velocity” and/or “Standstill monitoring”.
? Flange center point velocity limit value for T1 mode
Reduced axis acceleration
The acceleration of every robot axis can be monitored against a limit value. 
The axis acceleration can be activated in the configuration window.
? Axis acceleration limit value that can be activated by means of the safe in-
puts “Safe reduced velocity” and/or “Standstill monitoring”.
? Axis acceleration limit value for T1 mode
Stop reactions If the limit set in the configuration window is exceeded, the robot stops with a 
STOP 0.
2.5 Standstill monitoring
Description The robot is at a monitored standstill, but may nonetheless move within the pa-
rameterized axis angle tolerances. If the standstill monitoring is active, the ve-
locity and acceleration monitoring are also activated.
An axis angle tolerance limit value can be set for standstill monitoring; this limit 
value is activated via the safe input “Standstill monitoring”.
Stop reactions If the limit set in the configuration window is exceeded, the robot stops with a 
STOP 0.
Caution!
In order to allow safe retraction of the robot, standstill monitoring is not sub-
jected to safe monitoring in T1 mode. The robot is not safely stopped and 
there is a risk of personal injury and material damage.
 (>>> 2.9 "T1 mode (safe robot retraction)" page 21)
Caution!
If the robot isstopped by a monitoring function, it requires a certain stopping 
distance before coming to a standstill. The stopping distance depends on the 
robot type, the velocity of the robot, the payload and other parameters. The 
stopping distances must be determined for the specific application by means 
of trials.
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2.6 Safe state (output OUT_STATUS)
Description The following conditions must be met for a safe state (OUT_STATUS=HIGH). 
If at least one of the conditions is not met, the safe state is violated 
(OUT_STATUS=LOW).
2.7 Mastering test
Description The mastering test is used to check whether the current position of the robot 
and the external axes corresponds to a reference position. If the deviation is 
too great, the mastering test has failed. The robot stops with a STOP 1 and 
can now only be moved in T1 mode. In this case, the robot controller gener-
ates the message "Mastering test failed". If the mastering test run was suc-
cessful, the robot can be safely monitored using the SafeRDC.
The mastering test must be carried out in the following cases:
? After the robot controller has booted
Once the robot controller has booted, the robot can be moved normally for 
2 hours without a reference test. Once this time has elapsed, the robot 
stops with a STOP 2.
? After mastering
The mastering test can be called in the following ways:
? External request via a signal and automatic call of the program MasRe-
fReq.SRC
? Internal request caused by lack of mastering or booting of the robot con-
troller and automatic call of the program MasRefReq.SRC
? Manual selection of the program MasRefReq.SRC
Condition
Operating 
mode
Stop 
reaction
Hardware and software components are 
in flawless condition and in good work-
ing order.
T1 STOP 0
T2, AUT, 
AUT EXT STOP 0
Safety parameters are confirmed.
T1 STOP 0
T2, AUT, 
AUT EXT STOP 0
There are no encoder errors.
T1 STOP 0
T2, AUT, 
AUT EXT STOP 0
Safe inputs and outputs are free from 
errors.
T1 No stop
T2, AUT, 
AUT EXT STOP 0
Robot is mastered.
T1 No stop
T2, AUT, 
AUT EXT No stop
Mastering test has been performed suc-
cessfully.
T1 No stop
T2, AUT, 
AUT EXT No stop
Caution!
If there is a LOW level signal at output OUT_STATUS, the robot system is 
not safely monitored and suitable system-specific safety precautions must be 
taken.
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2. Product description
If, during operation, the mastering test is requested via the external signal, the 
mastering test is performed next time the program MasRefReq.SRC is auto-
matically called. The message “Mastering test required” is generated.
2.7.1 Reference position
The reference position must be taught in the program MasRefStart.SRC and 
in the configuration window (>>> 6.11 "Programming the mastering test" 
page 60). 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 must not hinder normal program exe-
cution.
? The reference position must not be a position in which the axes are in a 
singularity.
? In the reference position, both proximity switch surfaces of the reference 
switch must be actuated by the switching surface (actuating plate or tool).
Fig. 2-4: 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
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? In the reference position, the robot axes must be at least ±5° away from 
the mastering position.
2.7.2 Mastering test signal diagram
The signal diagram for the mastering test applies in the following case:
? One reference switch is connected.
? No fault signal at reference switch.
? Mastering test is requested internally because of lack of mastering or boot-
ing of the robot controller.
2.8 Brake test
Description In the brake test, the robot controller checks the functionality and wear of the 
brakes. During the brake test, all robot axes and up to 2 external axes are test-
ed one after the other. All axes configured in the machine data and contained 
in the first DSE are tested. The brake test starts with axis A 1.
1. The robot accelerates to a defined velocity.
2. Once the robot has reached the defined velocity, the brakes are applied 
and the results of the brake test are displayed for each axis in the message 
window.
Fig. 2-5: Signal diagram of the mastering test
Item Description
1 Mastering test is requested internally.
2 Automatic call of the program MasRefReq.SRC
Start of the mastering test
3 Actual position is identical to the reference position and the ref-
erence switch is actuated.
4 Reference switch is no longer actuated.
End of the mastering test
The message “Mastering test has been performed successfully” 
is generated.
Decouplable axes cannot be safely monitored.
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2. Product description
3. If a brake is identified as being defective, the brake test can be repeated 
or the robot can be moved to the parking position. If a brake has reached 
the wear limit, the robot controller generates a message. The robot can be 
moved without restrictions.
The brake test must be carried out in the following cases:
? After the robot controller has booted
? Cyclically during operation, every 46 h at the latest
The brake test can be called in the following ways:
? As a subprogram after the parameterized brake test cycle time
? Via an external signal
? Manually
The brake test cycle time can be set in BrakeTestDrv.INI.
 (>>> 9.6 "Variables in BrakeTestDrv.INI" page 75)
The remaining brake test cycle time can be displayed using the timer 
$BREMSENTEST_TIMER. When this time has elapsed, a brake test is re-
quested and the robot controller generates the following message: “Brake test 
required”. The monitoring time is started and the robot can still be moved for 
another 2 hours. Once the monitoring time has elapsed, the robot stops and 
the robot controller generates the following acknowledgement message: “Test 
cycle for brake test request exceeded”. Once this message has been acknowl-
edged, the robot can be moved for 2 hours.
2.8.1 Parking position
The parking position must be taught in the program BrakeTestPark.SRC. If a 
brake is identified as being defective, the robot can be moved to the parking 
position. The parking position must be selected in a position where the robot 
can sag safely.
The parking position can correspond to the transport position, for example.
Warning!
If a brake has been identified as being defective, the drives remain under ser-
vo-control for 2 hours following the start of the brake test (monitoring time). 
Once this time has elapsed, the drives are deactivated.
For the brake test, every robot axis requires a range of motion of ±10°, start-
ing from the start position of the brake test.
The motion range of ±10° is preconfigured as a default value in the file 
BrakeTestDrv.INI and may only be modified in consultation with the KUKA 
Robot Group.
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2.8.2 Signal diagram of the brake test
The signal diagram for the brake test applies in the following case:
? Each monitored axis is OK.
? Brake test is successful.
? No brake has reached the wear limit.
? Brake test is requested internally when the brake test cycle time has 
elapsed or when the robot controller is booted.
Fig. 2-6: Transport position of the robot
Fig. 2-7: Signal diagram of the brake test
Item Description1 The brake test is requested internally.
2 Automatic call of the program BrakeTestReq.SRC
Start of the brake test
3 End of the brake test
The message “Brake test has been performed successfully” is 
generated.
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2. Product description
2.9 T1 mode (safe robot retraction)
Description If the robot has violated a monitoring range and been stopped, it can only be 
moved out of the violated workspace in T1 mode. The monitoring ranges re-
main active and messages are displayed in the message window. In T1 mode, 
the robot can be moved to any position, irrespective of what monitoring ranges 
are active.
The robot can be moved free in T1 mode in the following cases:
? Safe input/output error
? Error in the cross comparison (system error 3000/3001/3002)
? Monitoring range is violated or has been exceeded
? Standstill monitoring is violated or has been exceeded
? Mastering test was not successful
? In an activated monitoring range, the reference stop has been activated 
and no mastering test has been carried out
The following monitoring functions are active in T1 mode:
? Flange center point velocity for T1
? Axis velocity for T1 is active if “Safe axis monitoring” is activated.
? Axis acceleration for T1 is active if “Safe axis monitoring” is activated and 
“Monitoring axis acceleration for T1” is activated.
If “Standstill monitoring” and/or “Safe reduced velocity” is activated in T1 
mode, the lower limit value in the configuration window is recognized as the 
limit by the SafeRDC.
Reaction of the robot if an axis limit is exceeded:
If the robot exceeds an axis limit in T1 mode, the robot stops with a STOP 2 
and a message is generated. Once the message has been acknowledged, ro-
bot motion can be resumed. Every time an axis limit is subsequently exceed-
ed, the robot stops.
Reaction of the robot if standstill monitoring is activated:
If standstill monitoring is active in T1 mode, the robot stops with a STOP 2 af-
ter the configured axis angle tolerance has been reached and a message is 
generated. Once the message has been acknowledged, the robot can be 
moved freely.
2.10 Monitoring functions that can be activated
Description Depending on the mode that has been set and the signal level at the safe in-
put, the monitoring functions are activated:
In order not to violate the monitoring functions in T1 mode, the setting for jog 
override must not exceed 90%. Alternatively, reduce the maximum possible 
velocity in T1 mode from 250 mm/s to 225 mm/s in the machine data.
Input Level T1 T2, AUT, AUT EXT
E0...E5
Monitoring range 2 to 7 LOW
? Monitoring ranges 2 to 7 
are not safely moni-
tored.
? Monitoring ranges 2 to 7 
are safely monitored.
HIGH ? Monitoring ranges 2 to 7 are not monitored.
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Input Level T1 T2, AUT, AUT EXT
If monitoring functions are violated, the following outputs can be activated or 
deactivated:
2.11 Components
Software These software components are included in the KUKA.SafeRobot package:
? KUKA.SafeRobot 1.1
Hardware These hardware components are included in the KUKA.SafeRobot package:
? Reference group
 (>>> 2.11.2 "Reference group" page 24)
? Data cable X21 - X31
? Data cable X21.1 - X41
2.11.1 SafeRDC
Description The SafeRDC consists of the following components:
? SafeRDC board
? I/O Print board
? SafeRDC box
E_HALT
Standstill monitoring
LOW
? Not safe standstill mon-
itoring
? Axis velocity is subject-
ed to safe monitoring.
? Flange center point ve-
locity is subjected to 
safe monitoring.
? Axis acceleration is sub-
jected to safe monitoring 
(if active).
? Safe standstill monitor-
ing
? Axis velocity is subject-
ed to safe monitoring.
? Flange center point ve-
locity is subjected to 
safe monitoring.
? Axis acceleration is sub-
jected to safe monitoring 
(if active).
HIGH ? No standstill monitoring. 
E_DV
Safe reduction of velocity
LOW
? Axis velocity is subjected to safe monitoring.
? Flange center point velocity is subjected to safe moni-
toring.
? Axis acceleration is subjected to safe monitoring (if ac-
tive).
HIGH ? Safe reduced velocity is not monitored.
Output Level T1 T2, AUT, AUT EXT
OUT_A0...OUT_A2
Monitoring range 8 to 10
LOW ? Monitoring ranges 8 to 10 have been violated.
HIGH ? Monitoring ranges 8 to 10 have not been violated.
OUT_STATUS
Status of the monitoring 
functions
LOW ? Safe robot monitoring is not activated.
HIGH
? Safe robot monitoring is activated.
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2. Product description
The SafeRDC board redundantly evaluates the resolver signals and monitors 
the position of the robot axes. The resolver signals are compared with the 
safety parameters that have been set.
The I/O Print board is plugged onto the SafeRDC board and provides the 24-
volt input and output signals.
The SafeRDC box contains the SafeRDC board with the I/O Print board and 
is mounted on the base frame of the robot.
Functions ? Monitoring of the robot according to the safety parameters that have been 
set and the signals at the safe inputs
? Monitoring of the safe inputs and outputs for violation of dual-channel op-
eration
? Safe evaluation of the actual position
? Safe disconnection of the drives
Fig. 2-8: SafeRDC hardware components
1 SafeRDC box
2 SafeRDC board with I/O Print board
Fig. 2-9: SafeRDC box on base frame
1 SafeRDC box
2 Robot
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? Communication with the robot controller
? Pulsing of the safe inputs and outputs
2.11.2 Reference group
Description A reference group consists of the following components:
? Reference switch
? Actuating plate
? Reference cable and reference connector
? Accessories
Fig. 2-10: Reference group hardware components
1 Inductive reference switch for 1 reference group
2 Actuating plate
3 Mechanical reference switches for 3 reference groups 
(optional)
Reference group Standard Optional
Number of refer-
ence groups 1 3
Number of actuat-
ing plates 1 3
Reference switch
Inductive
? XS Ref
Mechanical
? XS Ref.1
? XS Ref.2
? XS Ref.3
Reference cable ? X42 - XS Ref
? X42.1 - XS Ref.1
? X42.2 - XS Ref.2
? X42.3 - XS Ref.3
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2. Product description
Reference group Standard Optional
2.12 Connecting cables
Overview The diagram (>>> Fig. 2-11) shows an example of the connecting cables of 
the robot system. One mechanical reference group is used.
Reference con-
nector ? X42
? X42.1
? X42.2
? X42.3
Accessories - - -
? Electrical installations 
X904 - X902
? SafeRDC box lid (optional)
Number of refer-
ence groups 1 3
Fig. 2-11: Overview of connecting cables
Item Description
1 Robot controller
2 Robot
3 Reference switch XS Ref
Alternatively, 3 reference switches XS Ref.1, XS Ref.2 and XS 
Ref.3 can be used.
4 Reference cable X42 - XS Ref
Alternatively, 3 reference cables X42.1 - XS Ref.1, X42.2 - XS 
Ref.2 and X42.3 - XS Ref.3 can be used.
5 Connecting cable X40 - external safety logic
6 Data cable X21 - X31
7 Data cable X21.1 - X41
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2.12.1 Connections on the SafeRDC box
Overview
2.12.2 Connections on the SafeRDC box (optional)
Description If 3 reference groups are used, additional connections are available on the 
SafeRDC box.
Overview
Fig. 2-12: Connections on the SafeRDC box
X02 Junction box on SafeRDC box
X31 Connection for data cable X21 - X31
X32 Connection for electronic measuring tool (EMT)
X40 Connection for safe inputs and outputs
X41 Connection for data cable X21.1 - X41
X42 Connection for referencecable X42 - XS Ref
Fig. 2-13: Connections on the SafeRDC box (optional)
X02 Junction box on SafeRDC box
X31 Connection for data cable X21 - X31
X32 Connection for electronic measuring tool (EMT)
X40 Connection for safe inputs and outputs
X41 Connection for data cable X21.1 - X41
X42.1 Connection for reference cable X42.1 - XS Ref.1
X42.2 Connection for reference cable X42.2 - XS Ref.2
X42.3 Connection for reference cable X42.3 - XS Ref.3
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2. Product description
2.12.3 Connector pin assignment of data cable X21 - X31
Description
2.12.4 Connector pin assignment of data cable X21.1 - X41
Description
Pin Signal designation Pin Signal designation
1 +24V_CR 10 A_FSR1 inverted
2 GND_P 11 A_FSR1
3 +24V 12 A_DR1 inverted
4 A_CLKR1 inverted 13 A_DR1
5 A_CLKR1 14 A_CLKX1 inverted
6 A_FSX1 15 A_CLKX1
7 A_FSX1 inverted 16 Coding pin or hole
8 A_DX1 17 GND_CR
9 A_DX1 inverted
Pin Signal designation Pin Signal designation
1 TA24V(A)-ESC 10 E_T1_A_24V
2 GND ESC 11 E_T1_B_24V
3 TA24V(B)-ESC 12 COROB_EN_A_24V
4 ENA_A_24V 13 COROB_EN_B_24V
5 ENA_B_24V 14 GND_E
6 QE_A_24V 15 GND_P
7 QE_B_24V 16 Coding pin or hole
8 TA24V(B) inverted 17 Not used.
9 TA24V(A) inverted
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2.12.5 Connector pin assignment of reference cable X42 - XS Ref
Description
2.12.6 Wiring diagram for 3 reference groups (optional)
Description If 3 reference groups are used, all 3 reference switches must be connected to 
the SafeRDC box.
Pin Signal designation Pin Signal designation
1 /TA24V_A 4 /TA24V_B
2 E_REF_A_24V 5 E_REF_B_24V
3 GND 6 Not used.
Fig. 2-14: Wiring diagram for 3 reference groups (optional)
1 SafeRDC box
2 Reference switch 3
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2. Product description
3 Reference switch 2
2.13 Interface X40
Overview
Module a Module a contains the safe inputs of the SafeRDC for activating the monitoring 
ranges.
Channels A and B of the safe inputs must have a LOW level signal to activate 
the monitoring ranges.
Module b Module b contains the connections for the internal and external supply voltag-
es of the safe inputs and outputs.
Module c Module c contains the connections for the standstill monitoring and the re-
duced axis velocity and acceleration.
Channels A and B of the safe inputs must have a LOW level signal to activate 
the monitoring ranges.
Module d Module d contains the safe outputs of the SafeRDC that can be wired exter-
nally and are only used for communication. The voltage supplied via pins b5 
and b6 is present at the safe outputs.
4 Reference switch 1
Fig. 2-15: Interface X40
1 Module a (pins)
2 Module b (female contacts)
3 Module c (pins)
4 Module d (female contacts)
The safe outputs have a max. load rating of 100 mA per output.
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2.13.1 Connector pin allocation X40
Module a Pin Signal designation Description
a1 E0_A_24V LOW = input 0 channel A for monitoring 
range 2 is activated.
HIGH = input 0 channel A for monitoring 
range 2 is deactivated.
a2 E0_B_24V LOW = input 0 channel B for monitoring 
range 2 is activated.
HIGH = input 0 channel B for monitoring 
range 2 is deactivated.
a3 E1_A_24V LOW = input 1 channel A for monitoring 
range 3 is activated.
HIGH = input 1 channel A for monitoring 
range 3 is deactivated.
a4 E1_B_24V LOW = input 1 channel B for monitoring 
range 3 is activated.
HIGH = input 1 channel B for monitoring 
range 3 is deactivated.
a5 E2_A_24V LOW = input 2 channel A for monitoring 
range 4 is activated.
HIGH = input 2 channel A for monitoring 
range 4 is deactivated.
a6 E2_B_24V LOW = input 2 channel B for monitoring 
range 4 is activated.
HIGH = input 2 channel B for monitoring 
range 4 is deactivated.
a7 E3_B_24V LOW = input 3 channel B for monitoring 
range 5 is activated.
HIGH = input 3 channel B for monitoring 
range 5 is deactivated.
a8 E3_A_24V LOW = input 3 channel A for monitoring 
range 5 is activated.
HIGH = input 3 channel A for monitoring 
range 5 is deactivated.
a9 E4_B_24V LOW = input 4 channel B for monitoring 
range 6 is activated.
HIGH = input 4 channel B for monitoring 
range 6 is deactivated.
a10 E4_A_24V LOW = input 4 channel A for monitoring 
range 6 is activated.
HIGH = input 4 channel A for monitoring 
range 6 is deactivated.
a11 E5_B_24V LOW = input 5 channel B for monitoring 
range 7 is activated.
HIGH = input 5 channel B for monitoring 
range 7 is deactivated.
a12 E5_A_24V LOW = input 5 channel A for monitoring 
range 7 is activated.
HIGH = input 5 channel A for monitoring 
range 7 is deactivated.
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2. Product description
Module b Pin Signal designation Description
b1 /TA24V_A Pulsed voltage channel A for input test
Connect pin b1 via floating contacts to 
channel A of the safe inputs.
b2 /TA24V_B Pulsed voltage channel B for input test
Connect pin b2 via floating contacts to 
channel B of the safe inputs.
b3 GND-E Reference potential for safe inputs
Connect pin b4 to pin b3.
b4 GND-P Reference potential for safe inputs with 
internal power supply
Connect pin b4 to pin b3.
b5 +24V_AUSG_A +24 V connection, channel A, for supply-
ing the safe outputs A0...A2
In the case of operation with an external 
safety logic, connect pin b5 to external 
+24 V.
In the case of operation without an 
external safety logic, connect pin b5 to 
pin b8.
If the safe outputs are routed to the safe 
inputs, connect pin b5 to pin b1.
The safe outputs are pulsed.
b6 +24V_AUSG_B +24 V connection, channel B, for supply-
ing the safe outputs A0...A2
In the case of operation with an external 
safety logic, connect pin b6 to external 
+24 V.
In the case of operation without an 
external safety logic, connect pin b6 to 
pin b8.
If the safe outputs are routed to the safe 
inputs, connect pin b6 to pin b3.
The safe outputs are pulsed.
b7 GND-A1 Reference potential for the safe outputs, 
channels A and B
If the safe outputs A0...A2 are supplied 
with the internal +24 V, connect pin b7 to 
pin b9.
If the safe outputs A0...A2 are supplied 
externally with internal +24 V, connect 
pin b7 to the reference potential of the 
external supply.
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Pin Signal designation Description
Module c
b8 +24V-P Internal +24 V supply of the SafeRDC for 
the safe outputs A0...A2
The internal +24 V supply is required for 
operation without an external safety 
logic.
If the outputs are supplied with the inter-
nal 24 V of the SafeRDC, connect pin b8 
to pin b5 and pin b6.
b9 GND-P Reference potential for the safe outputs, 
channels A and B
This GND-P is required if the safe out-
puts A0...A2 are supplied with the inter-
nal +24 V of the SafeRDC.
In this case, connect pin b9 to pin b7.
b10 GND-P Reference potential for the safe outputs, 
channels A and B
This GND-P is required if the safe out-
puts A0...A2 are supplied with the inter-
nal +24 V of the SafeRDC. It serves as 
an additional connection for the refer-
ence potential if pin b9 is not sufficient.
In this case, connect pin b10 to pins b9 
and b7.
b11 +24V_AUSG_B_2 Not used.
b12 +24V_AUSG_A_2 Not used.
Pin Signal designation Description
c1 E6_A_24V Not used.
c2 E6_B_24V Not used.
c3 E_HALT_A_24V LOW = input channel A for safe standstill 
monitoring is activated.
HIGH = input channel A for safe stand-
still monitoring is deactivated.
c4 E_HALT_B_24V LOW = input channel B for safe standstill 
monitoring is activated.
HIGH = input channel B for safe stand-
still monitoring is deactivated.
c5 E_DV_A_24V LOW = input channel A for reduced 
velocityis activated.
HIGH = input channel A for reduced 
velocity is deactivated.
c6 E_DV_B_24V LOW = input channel B for reduced 
velocity is activated.
HIGH = input channel B for reduced 
velocity is deactivated.
c7 N. C. N. C.
c8 N. C. N. C.
c9 N. C. N. C.
c10 N. C. N. C.
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2. Product description
Pin Signal designation Description
Module d
2.13.2 Safe inputs
Description Monitoring functions on the SafeRDC can be activated and deactivated by 
means of safe inputs. The inputs can be connected via a safety PLC or floating 
contacts.
The safe inputs of the SafeRDC are of a redundant design and LOW active. 
All safety functions are retained in the event of a break in the cable, a short-
circuit or a power failure and an error is detected at a safe input.
c11 N. C. N. C.
c12 N. C. N. C.
Pin Signal designation Description
d1 OUT_A0_A LOW = output 0 channel A for monitoring 
range 8 is violated.
HIGH = output 0 channel A for monitor-
ing range 8 is not violated.
d2 OUT_A0_B LOW = output 0 channel B for monitoring 
range 8 is violated.
HIGH = output 0 channel B for monitor-
ing range 8 is not violated.
d3 OUT_A1_A LOW = output 1 channel A for monitoring 
range 9 is violated.
HIGH = output 1 channel A for monitor-
ing range 9 is not violated.
d4 OUT_A1_B LOW = output 1 channel B for monitoring 
range 9 is violated.
HIGH = output 1 channel B for monitor-
ing range 9 is not violated.
d5 OUT_A2_A LOW = output 2 channel A for monitoring 
range 10 is violated.
HIGH = output 2 channel A for monitor-
ing range 10 is not violated.
d6 OUT_A2_B LOW = output 2 channel B for monitoring 
range 10 is violated.
HIGH = output 2 channel B for monitor-
ing range 10 is not violated.
d7 OUT_STATUS_B LOW = output channel B for status is not 
subjected to safe monitoring.
HIGH = output channel B for status is 
subjected to safe monitoring.
d8 OUT_STATUS_A HIGH = output channel A for status is 
subjected to safe monitoring.
LOW = output channel A for status is not 
subjected to safe monitoring.
d9 OUT_5_B Not used.
d10 OUT_5_A Not used.
d11 N. C. N. C.
d12 N. C. N. C.
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If an error occurs at a safe input, the SafeRDC triggers a STOP 0 and goes to 
the state “Safety mode not possible”. The message “Failure safety input no. 
XXX” appears.
Overview
Characteristics Electrical characteristics of the safe inputs:
? Voltage: 24 V DC
? Rated current: 3 mA (with special external circuit max. 10 mA)
? Channels per safe input: 2
? Check of dual-channel operation:
? The 6 channels may differ within a tolerance of 2 s.
? If one channel twice fails to follow the other, this is considered a dual-
channel violation.
Example: Channel A switches to HIGH then back to LOW, but channel 
B remains LOW.
? The signal level must change at both input channels; only then does the 
SafeRDC accept the new state.
Caution!
In order to allow safe retraction of the robot, the safe inputs are not subjected 
to safe monitoring in T1 mode. If an error occurs at a safe input in T1 mode, 
the robot is not stopped safely and there is a risk of personal injury and ma-
terial damage.
 (>>> 2.9 "T1 mode (safe robot retraction)" page 21)
Input Description
0
E0_A_24V and E0_B_24V at X40
Monitoring range 2
1
E1_A_24V and E1_B_24V at X40
Monitoring range 3
2
E2_A_24V and E2_B_24V at X40
Monitoring range 4
3
E3_A_24V and E3_B_24V at X40
Monitoring range 5
4
E4_A_24V and E4_B_24V at X40
Monitoring range 6
5
E5_A_24V and E5_B_24V at X40
Monitoring range 7
6
E_REF_A_24V and E_REF_B_24V at X42
Mastering test
7
E6_A_24V and E6_B_24V at X40
Not used.
8
E_HALT_A_24V and E_HALT_B_24V at X40
Standstill monitoring
9
E_DV_A_24V and E_DV_B_24V at X40
Safe reduced velocity and acceleration
10 Not used.
11 Not used.
12
E_T1_A_24V and E_T1_B_24V at X41
T1 mode
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2. Product description
? Pulse duration T(LOW) of the pulsed voltage /TA24V: 2 ms if check suc-
cessful, max. 4 ms if check fails
? Pulse duration T(HIGH) of the pulsed voltage /TA24V: 330 ms
? Pulse duty factor T(HIGH):T(LOW) of the pulsed voltage /TA24V: 165:1 if 
check successful, max. 82.5:1 if check fails
? Delay time when switching signal level:
? HIGH/LOW: 5 ms
? LOW/HIGH: 10 ms
2.13.3 Safe outputs
Description The safe outputs are used to signal the safety states on the SafeRDC to the 
Electronic Safety Circuit (ESC) and a safety PLC:
The safe outputs of the SafeRDC are of a redundant design and LOW active. 
All safety functions are retained in the event of a break in the cable, a short-
circuit or a power failure and an error is detected at a safe output.
Overview
Characteristics Electrical characteristics of the safe outputs:
? Voltage: 24 V DC
Caution!
If an error occurs at a safe output, the robot stops with a STOP 0 and the out-
put switches to the safe state (LOW level). As soon as the error is eliminated 
and the output is set, the output state switches back to the HIGH level. If ac-
tuators whose automatic reactivation would be hazardous are connected to 
the safe outputs, additional measures, such as a reclosing lockout, must be 
implemented in order to avoid this risk.
Caution!
In order to allow safe retraction of the robot, the safe outputs are not subject-
ed to safe monitoring in T1 mode. If an error occurs at a safe output in T1 
mode, the robot is not stopped safely and there is a risk of personal injury and 
material damage.
 (>>> 2.9 "T1 mode (safe robot retraction)" page 21)
Output Description
0
OUT_A0_A and OUT_A0_B at X40
Monitoring range 8
1
OUT_A1_A and OUT_A1_B at X40
Monitoring range 9
2
OUT_A2_A and OUT_A2_B at X40
Monitoring range 10
3
QE_A_24V and QE_B_24V at X41
Qualifying inputs (STOP 0)
4
ENA_A_24V and ENA_B_24V at X41
External E-STOP (STOP 1)
5
OUT_STATUS_A and OUT_STATUS_B at X40
Safe state
6
OUT_A5_A and OUT_A5_B at X40
Not used.
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? Maximum load rating: 100 mA
? Channels per safe output: 2
? Pulse duration T(LOW) of the pulsed voltage /TA24V: 375 μs
? Pulse duration T(HIGH) of the pulsed voltage /TA24V: 330 ms
? Pulse duty factor T(HIGH):T(LOW) of the pulsed voltage /TA24V: 825:7
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3. Technical data
3 Technical data
3.1 Technical data of the SafeRDC
3.2 Reference switch
Designation Values
Permissible ambient 
temperature
? transportation -25 °C to +70 °C
? Storage: -25 °C to +60 °C
? Operation: +10 °C to +55 °C
Supply voltage DC 18 V to 33 V
Relative atmospheric 
humidity
Class 3K3 to EN 50178 (non-condensing)
Shock sensitivity ? Duration: 5 ms
? Strength: 20 g
Vibration resistance ? Amplitude: 1 mm at ≤ 13.2 Hz
? Acceleration: 0.7 g at 13.2 Hz to 100 Hz
Electromagnetic com-
patibility (EMC)
Immunity from interference with mains filter to 
EN 61800-3
Degree of fouling Degree of fouling 2 to VDE 0110 part 2
Altitude 1000 m with no reduction in power
Protection classifica-
tion
IP 65
Permissible cable 
length for data cable 
X21 - X31
With internal power supply to the safe inputs and 
outputs:
? 7 m
? 15 m
With external power supply to the safe inputs 
and outputs:
? 25 m
? 35 m
Designation Values
Ambient temperature -25 °C to +70 °C
Switching function Break contact
DC operating voltage or HIGH level in the case 
of pulsed operating voltage of the reference 
switch
24 V
Permissible range for the DC operating voltage 
or HIGH level for pulsed voltage
20 to 33 V
Required pulse duty factor T(HIGH):T(LOW) for 
pulsed voltage
Min. 4:1
Supported pulseduration T(LOW) for pulsed 
voltage
0.1 to 20 ms
Operating current (power consumption) without 
load
5 mA
Permissible load current max. 250 mA
Permissible switching frequency max. 500 Hz
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Designation Values
3.3 Reference switch hole pattern
Description
Permissible switching distance at the proximity 
switch surfaces
0 to 4 mm
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
1 2 holes for fastening elements, Ø 6.6 mm
2 2 holes for roll pins, Ø 4 mm
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3. Technical data
3.4 Hole pattern for actuating plate
Description
1 2 M6 threaded holes for fastening elements
2 2 holes for fastening elements, Ø 9 mm
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4. Safety
4 Safety
Personnel ? All persons working with the robot system must have read and understood 
the robot system documentation, including the safety chapter.
? A KUKA.SafeRobot training course is recommended for all persons work-
ing on the robot system.
? Start-up work, maintenance and repairs may only be carried out by trained 
personnel.
? The safety parameters may only be set and modified by authorized per-
sonnel. No other persons may modify the safety parameters.
Robot system ? This robot system must be operated in accordance with the applicable na-
tional laws, regulations and standards.
? The user must ensure that the system can be operated in complete safety.
? The maximum permissible service life of safety-relevant hardware compo-
nents is 40 000 operating hours as counted by the operating hours meter. 
The operating hours meter is running as long as the drives are under ser-
vo-control. Once this time has been reached, the safety-relevant hardware 
components must be exchanged.
? Decouplable axes cannot be safely monitored.
? All axes configured in the machine data and contained in the first DSE can 
be monitored. One DSE contains a maximum of 8 axes. External axes in 
the top-mounted cabinet cannot be monitored.
? The Cartesian positions and velocities at the robot mounting flange are 
calculated with robot axes A 1 to A 6. External axes are not taken into con-
sideration.
Mastering test ? When a mastering test is carried out, all external axes must be switched 
to synchronous.
? All robot axes and all monitored external axes are included in the master-
ing test.
? If the reference switch is actuated by a ferromagnetic part of the tool, the 
accuracy requirements on the reference position must be met and must 
not be exceeded.
 (>>> 6.12 "Checking the reference position (actuation with tool)" page 61)
? If the tool is exchanged, the reference position and the accuracy of the ref-
erence position must be checked.
 (>>> 6.12 "Checking the reference position (actuation with tool)" page 61)
Brake test ? During the brake test, all robot axes and up to 2 external axes are tested. 
All axes configured in the machine data and contained in the first DSE are 
moved.
? If a brake has been identified as being defective, the parking position must 
be approached with a maximum velocity of 10%.
? Robot axes A 1 to A 6 are preconfigured for the brake test in the file 
BrakeTestDrv.INI. The parameters for robot axes A 1 to A 6 in the file 
BrakeTestDrv.INI may only be modified in consultation with the KUKA Ro-
bot Group.
? For the brake test, any external axes used must be configured in the file 
BrakeTestDrv.INI.
 (>>> 6.15 "Configuring external axes for the brake test" page 62)
Further information is contained in the robot operating instructions and in the 
robot controller operating instructions.
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Cables ? Do not connect and disconnect cables or hoses during operation.
? Only the data cables and reference cable X42 - XS Ref supplied by the 
KUKA Robot Group may be used.
? The data cables and reference cable X42 - XS Ref are suitable for instal-
lation in a cable carrier. The minimum bending radii must be observed 
when routing cables.
? The connectors of the data cables and reference cable X42 - XS Ref are 
coded and cannot be interchanged.
Start-up ? Start-up must be carried out and checked as described in Chapter 
(>>> 6 "Start-up" page 45).
? Before the robot is moved, it must be ensured that the correct machine 
data for the robot system have been transferred to the SafeRDC and con-
firmed.
? The values in the machine data may only be modified by authorized per-
sonnel. Modifying values in the machine may deactivate monitoring func-
tions.
? The password for logging onto the KUKA System Software as “Safety 
Maintenance” must be changed before start-up and must only be commu-
nicated to authorized personnel.
Operation ? KUKA.SafeRobot may not be operated until after safety acceptance has 
been carried out in accordance with the checklists in the Appendix. The 
checklists must be completed fully and confirmed in writing.
? If there is a LOW level at output signal OUT_STATUS, the robot system is 
not subjected to safe monitoring.
? If the robot violates one of the axis limits of monitoring ranges 8 to 10, the 
robot continues its motion without slowing down and the corresponding 
output is set.
? If the robot is stopped by a monitoring function, it requires a certain stop-
ping distance before coming to a standstill. The stopping distance de-
pends on the robot type, the velocity of the robot, the position of the robot 
axes, the payload and other parameters. The stopping distances of the ro-
bot axes are generally max. 30° and must be determined for the specific 
application by means of trials. In these trials, the monitoring ranges must 
be violated with the maximum load and maximum process velocity in order 
to be able to determine and set the correct monitoring limits.
? When the brake test is carried out, the program override is automatically 
set to 100%.
? If a brake is identified as being defective, the robot may sag. Slowly move 
the robot to the parking position without executing any safety functions 
(e.g. E-STOP, opening the safety gate, change of operating mode, etc.).
 (>>> 2.8 "Brake test" page 18)
? If an error occurs at a safe output, the robot stops with a STOP 0 and the 
output switches to the safe state (LOW level). As soon as the error is elim-
inated and the output is set, the output state switches back to the HIGH 
level. If actuators whose automatic reactivation would be hazardous are 
connected to the safe outputs, additional measures, such as a reclosing 
lockout, must be implemented in order to avoid this risk.
Type of routing Bending radius
Fixed installation Min. 5xØ of cable
Installation in cable carrier Min. 10xØ of cable
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5. Installation
5 Installation 
5.1 System requirements
Hardware ? KUKA robot with SafeRDC
? KR C2 edition05 robot controller with SafeRobot option
Software ? KUKA System Software (KSS) 5.4
? The following KRL resources must be free:
5.2 Installing or updating KUKA.SafeRobot 
Precondition ? KUKA.SafeRobot 1.1 installation CD must be in the CD-ROM drive.
Procedure 1. Select the menu sequence Setup > Install Additional Software.
2. Press the New SW softkey. If a software package on the CD-ROM in the 
drive is not yet displayed, press the Refresh softkey.
3. Select the software to be installed and press the softkey Install. Answer 
the request for confirmation with Yes. The files are copied onto the hard 
drive.
4. If another additional software package is to be installed, repeatstep 3.
5. Depending on the specific additional software, it may be necessary to re-
boot the controller. In this case, a corresponding message will be dis-
played. Confirm with OK and restart the robot controller. The installation is 
resumed and completed.
LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.
5.3 Uninstalling KUKA.SafeRobot
Precondition ? KUKA.SafeRobot 1.1 must be installed.
Procedure 1. Select the menu sequence Setup > Install Additional Software. All in-
stalled additional programs are displayed.
2. Select the software to be uninstalled and press the softkey Uninstall. An-
swer the request for confirmation with Yes. Uninstallation is prepared.
3. Reboot the robot controller. Uninstallation is resumed and completed.
More detailed information about the availability of robots with SafeRDC can 
be obtained from the KUKA Robot Group.
KRL resource Number
Interrupt 19
Flag 1010
It is advisable to archive all relevant data before updating or uninstalling a 
software package.
It is advisable to archive all relevant data before updating or uninstalling a 
software package.
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LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.
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6. Start-up
6 Start-up
6.1 Start-up overview
Overview Step Description
1 Install reference switch and actuating plate.
 (>>> 6.2 "Installing the reference switch and actuating plate" 
page 46)
2 Exchange lid of SafeRDC box (if 3 reference groups are used).
 (>>> 6.3 "Exchanging the lid of the SafeRDC box" page 47)
3 Connect connecting cables.
 (>>> 6.4 "Connecting the connecting cables" page 47)
4 Connect safety PLC (if a safety PLC is used).
 (>>> 6.5 "Connecting the Safety PLC" page 48)
5 Master the robot.
6 Assign input and output signals.
 (>>> 6.6 "Assigning input and output signals" page 49)
7 Define axis-specific monitoring ranges.
 (>>> 6.7 "Defining axis-specific monitoring ranges" page 49)
8 Define reference position.
 (>>> 6.8 "Defining the reference position" page 50)
9 Set safety parameters via the tree structure in the configuration 
window.
 (>>> 6.9 "Safety parameters" page 52)
10 Assign external axes to the reference group (if external axes 
are being used).
 (>>> 6.10 "Assigning external axes to the reference group" 
page 59)
11 Program mastering test.
 (>>> 6.11 "Programming the mastering test" page 60)
12 Check reference position (if the reference switch is actuated by 
the tool).
 (>>> 6.12 "Checking the reference position (actuation with 
tool)" page 61)
13 Perform mastering test.
 (>>> 6.13 "Performing a mastering test manually" page 61)
14 Configure external axes for brake test (if external axes are 
being used).
 (>>> 6.15 "Configuring external axes for the brake test" 
page 62)
15 Program brake test.
 (>>> 6.16 "Programming the brake test" page 63)
16 Perform brake test.
 (>>> 6.17 "Performing a manual brake test" page 63)
17 Carry out safety acceptance.
 (>>> 6.18 "Safety acceptance of KUKA.SafeRobot" page 64)
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Danger!
6.2 Installing the reference switch and actuating plate
Precondition ? The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
? A tool must be mounted on the mounting flange.
? For axes A 1 to A 6, the axis-specific coordinates of the reference position 
must be at least 5° away from the mastering position.
? The reference position must not result in a singularity of the robot.
? The reference position must be situated within the motion range of the ro-
bot.
? The installation position of the reference switch must not hinder the work 
sequence of the robot.
Procedure 1. Prepare a mechanical mounting fixture for mounting the reference switch.
 (>>> 3.3 "Reference switch hole pattern" page 38)
2. Attach the reference switch to the mounting fixture.
3. If the actuating plate is being used, fasten the actuating plate to the tool. 
The mounting position of the actuating plate depends on the specific tool 
that is mounted.
4. If more than one reference group is being used, repeat steps 1 to 3 for 
each additional reference group.
Example
The robot is not subjected to safe monitoring during start-up and can cause 
personal injury or material damage. Only move the robot in T1 mode during 
start-up.
Exception: Perform brake test (>>> 6.17 "Performing a manual brake test" 
page 63).
Fig. 6-1: Example of an actuating plate mounted on the tool
1 Robot
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6. Start-up
2 Actuating plate mounted on the tool
6.3 Exchanging the lid of the SafeRDC box
Precondition ? 3 reference groups are being used.
? The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
? The SafeRDC and I/O Print boards must be protected against static 
charge.
Procedure 1. Unscrew the 4 screws on the lid of the SafeRDC box.
2. Carefully open the lid of the SafeRDC box forwards.
3. Unscrew the 4 screws on the lid hinge.
4. Carefully remove the lid of the SafeRDC box.
5. Fit the lid with 3 reference switches on the SafeRDC box and screw it firmly 
in place with 4 screws on the lid hinge.
6. Connect and route electrical installations X904 - X902. Connect X904 to 
the SafeRDC box and X902 to the lid.
7. Carefully close the lid of the SafeRDC box.
8. Screw the lid firmly in place using the 4 screws on the housing.
6.4 Connecting the connecting cables
Precondition ? The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
? The reference switch must be installed.
3 Tool
Fig. 6-2: Screws on the lid of the SafeRDC box
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Danger!
Procedure 1. Connect and route data cable X21 - X31. Connect X21 to the robot con-
troller and X31 to the SafeRDC box.
2. Connect and route data cable X21.1 - X41. Connect X21.1 to the robot 
controller and X41 to the SafeRDC box.
3. Connect and route reference cable X42 - XS Ref. Connect X42 to the Saf-
eRDC box and XS Ref to the reference switch.
Alternatively, connect and route 3 reference cables X42.1 - XS Ref.1, 
X42.2 - XS Ref.2 and X42.3 - XS Ref.3. Connect X42.X to the SafeRDC 
box and XS Ref.X to the reference switch.
6.5 Connecting the Safety PLC
Description The safety PLC must be connected to interface X40 via a safe field bus mod-
ule and optocoupler.
Preconditions for the safe outputs of the safe field bus module:
? Channel A of the safe outputs at the safe field bus module is HIGH-active.
? Channel B of the safe outputs at the safe field bus module is LOW-active.
The robot controller is preconfigured for specific robots. If cables are inter-
changed, the robot may receive incorrect data and can thus cause personal 
injury or material damage. If a system consists of more than one robot, al-
ways connect the connecting cables to the robots and their corresponding ro-
bot controllers.
Fig. 6-3: Connecting the safety PLC
1 Optocoupler
2 Safe field bus module
3 Safe field bus system
4 Safety PLC
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6. Start-up
6.6 Assigning input and output signals
Description All signals are declared in the file $MACHINE.DAT in the directory 
C:\KRC\ROBOTER\KRC\STEU\MADA.
By default, the input signals are routed to $IN[1026]. The output signals are 
preset to FALSE and must be assigned to an output. The output signals can-
not be used until they have been assigned to an output.
All system variables are listed in Chapter (>>> 9 "System variables" page 71).
Example $MACHINE.DAT file without comments:6.7 Defining axis-specific monitoring ranges
Precondition ? The monitoring ranges may only be defined or modified by authorized per-
sonnel.
? User group “Safety Maintenance” is set.
? Axis-specific jogging is set.
? T1 mode is set.
Procedure 1. Select the menu sequence Setup > Service > Safe Robot > Configura-
tion. The data are loaded.
2. Press the Areas softkey.
3. Select the monitoring range by pressing the softkeys Area + and Area -.
4. Select an axis in the configuration window.
5. Move the selected axis to the upper axis limit.
6. Press the Touch Up + softkey and confirm the message.
7. Move the selected axis to the lower axis limit.
8. Press the Touch Up - softkey and confirm the message.
9. Repeat steps 4 to 8 to define the axis ranges for further axes.
10. Press the Inversion softkey to invert the selected monitoring range.
11. To toggle between the table and the input box, press the Table softkey.
Caution!
These signals are not redundant in design and can supply incorrect informa-
tion. Do not use these signals for safety-relevant applications.
If the output signals are not assigned to outputs, the mastering test and brake 
test cannot be performed.
 (>>> 9.2 "Signals for the mastering test" page 71)
 (>>> 9.5 "Signals for the brake test" page 74)
&PARAM VERSION=6.0.1
DEFDAT $MACHINE PUBLIC
CHAR $V_STEUMADA[32]
$V_STEUMADA[]="V6.0.1/KUKA5.4"
SIGNAL $MASTERINGTEST_REQ_EX $IN[1]
SIGNAL $BRAKETEST_REQ_EX $IN[2]
SIGNAL $MASTERINGTEST_REQ_INT $OUT[1]
SIGNAL $MASTERINGTESTSWITCH_OK $OUT[2]
SIGNAL $BRAKETEST_REQ_INT $OUT[3]
ENDDAT
Danger!
Inversion affects all the axis ranges in a monitoring range. The unintentional 
inversion of a monitoring range to a safety zone or vice versa can result in 
personal injury or material damage.
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12. Enter the name of the monitoring range. The name is saved in 
KUKA_CON.MDB.
13. Close the configuration window and save the changes. The data are 
saved.
Description
6.8 Defining the reference position
Precondition ? The reference position may only be defined or modified by authorized per-
sonnel.
The maximum length of the text is 24 characters.
Fig. 6-4: Defining axis-specific monitoring ranges
Column Description
Axis number Indicates the status of the axes for the selected 
monitoring range.
 The axis is located inside the configured axis 
range.
 The axis is located outside the configured 
axis range or on an axis limit.
 Axis is not configured or is not monitored.
Lower bound Contains the lower axis limits of the axis ranges.
Current position Contains the axis-specific actual position of the 
axes.
Upper bound Contains the upper axis limits of the axis ranges.
Inverting Indicates the nature of the monitoring range 
within the axis limits.
? FALSE = monitoring range is a workspace.
? TRUE = monitoring range is a safety zone.
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6. Start-up
? User group “Safety maintenance”
? Operating mode T1
Procedure 1. Move robot to the reference position.
2. Select the menu sequence Setup > Service > Safe Robot > Configura-
tion. The data are loaded.
3. Press the softkey Ref. Pos..
4. Press the Touch Up softkey to accept the current position of the robot as 
the reference position.
5. Close the configuration window and save the changes. The data are 
saved.
Fig. 6-5: Defining the reference position
Column Description
Axis number Indicates the status of the axes.
 Minimum distance between the current position of 
the axis and the mastering position is maintained.
 Minimum distance between the current position of 
the axis and the mastering position is not main-
tained.
 Axis is not configured or is not monitored.
 If this icon appears, the minimum axis distance 
between the reference position and the mastering 
position has not been maintained.
Reference group Each configured axis must be assigned to a refer-
ence group.
All robot axes are assigned to reference group 1. 
External axes can be assigned to other reference 
groups.
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Column Description
6.9 Safety parameters
Description The safety parameters contain all the values and settings for the robot with 
safe monitoring. The safety parameters are displayed as a tree structure in the 
configuration window.
Reference position To monitor the mastering, the axis angles of all robot 
axes are defined for a specific reference position. At 
defined time intervals, the robot moves to this posi-
tion and a comparison is made between the setpoint 
position and the actual position on the SafeRDC.
Range of values for rotational axes = -360° to +360°
Current position Contains the axis-specific actual position of the 
axes.
Master position The axis angles at the mastering position are per-
manently defined. 
Min. distance For every axis, the reference position must be at 
least a defined minimum distance away from the 
mastering position.
Minimum value for rotational axes = 5°
Safety parameters Description
General information Display only
 (>>> 6.9.2 "Parameters – General 
information" page 54)
Monitored axes Configurable
 (>>> 6.9.3 "Parameters – Moni-
tored axes" page 54)
Reduced axis velocity Configurable
 (>>> 6.9.4 "Parameters – Reduced 
axis velocity" page 54)
Cartesian velocity Configurable
 (>>> 6.9.5 "Parameters – Carte-
sian velocity" page 54)
Reduced axis acceleration Configurable
 (>>> 6.9.6 "Parameters – Reduced 
axis acceleration" page 55)
Axis range monitoring Configurable
 (>>> 6.9.7 "Parameters – Axis 
range monitoring" page 56)
Monitoring of mastering Configurable
 (>>> 6.9.8 "Parameters – Monitor-
ing of mastering" page 57)
Standstill monitoring Configurable
 (>>> 6.9.9 "Parameters – Standstill 
monitoring" page 57)
Interfaces Configurable
 (>>> 6.9.10 "Parameters – Inter-
faces" page 58)
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6. Start-up
Safety parameters Description
6.9.1 Setting safety parameters
Precondition ? The safety parameters may only be defined or modified by authorized per-
sonnel.
? User group “Safety maintenance”
? Operating mode T1
Procedure 1. Select the menu sequence Setup > Service > Safe Robot > Configura-
tion. The data are loaded.
2. In the tree structure in the configuration window, open the desired safety 
parameter and enter or select the values.
3. Press the Enter key.
4. For all further relevant parameters and sub-entries, repeat steps 2 and 3.
5. Close the configuration window and save the changes.
Machine data ($robcor.dat) Display only
 (>>> 6.9.11 "Parameters – 
Machine data ($ROBCOR.DAT)" 
page 58)
Machine data ($machine.dat) Display only
 (>>> 6.9.12 "Parameters – 
Machine data ($MACHINE.DAT)" 
page 59)
Only values indicated in red will be applied and saved.
Fig. 6-6: Setting safety parameters
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6.9.2 Parameters – General information
Description Contains the version of the configuration file and the time stamp indicating 
when the safety parameters were last saved.
6.9.3 Parameters – Monitored axes
Description Axes 1 to 8 can be activated individually. An activated axis is monitored in all 
monitoring ranges. An axis that is not being monitored is crossed out in the dis-
play.
6.9.4 Parameters – Reduced axis velocity
Description Freely selectable limits can be defined for the axis velocity of axes 1 to 8.
6.9.5 Parameters – Cartesian velocity
Description Freely selectable limits can be defined for the Cartesian velocity at the center 
of the mounting flange.
Parameter Description
Time stamp Date and time parameters last saved
Version Version of the configurationfile with the safety 
parameters
Sub-entry Value
Safe axis monitoring TRUE = axis is monitored.
FALSE = axis is not monitored.
Sub-entry Value
Axis velocity Axis velocity limit value that can be activated by 
means of the safe inputs “Safe reduced velocity” 
and/or “Standstill monitoring”.
? Range of values for rotational axes: 0.5 to 
1000°/s
? Range of values for linear axes: 1.5 to 3000 
mm/s
? Default value for rotational axes: 100°/s
? Default value for linear axes: 100 mm/s
Axis velocity for T1 Axis velocity limit value for T1 mode
? Range of values for rotational axes: 0.5 to 
1000°/s
? Range of values for linear axes: 1.5 to 
3000 mm/s
? Default value for rotational axes: 100°/s
? Default value for linear axes: 100 mm/s
The monitoring depends on the mode that has been set and the signal level 
at the safe input.
 (>>> 2.13.2 "Safe inputs" page 33)
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6. Start-up
The Cartesian velocity at the mounting flange refers to the 6 robot axes A 1 
6.9.6 Parameters – Reduced axis acceleration
Description Freely selectable limits can be defined for the axis acceleration of axes 1 to 8.
Axis acceleration can only be monitored if reduced velocity is active.
to A 6.
Sub-entry Value
Flange center point 
velocity
Flange center point velocity limit value that can 
be activated by means of the safe inputs “Safe 
reduced velocity” and/or “Standstill monitoring”.
? Range of values: 5 to 10,000 mm/s
? Default value: 250 mm/s
Flange center point 
velocity for T1
Flange center point velocity limit value for T1 
mode
? Range of values: 5 to 250 mm/s
? Default value: 250 mm/s
The value for the reduced axis acceleration can be modified in order, for ex-
ample, to carry out a risk analysis for special applications.
Sub-entry Value
Axis acceleration Axis acceleration limit value that can be acti-
vated by means of the safe inputs “Safe reduced 
velocity” and/or “Standstill monitoring”.
? Range of values for rotational axes: 25 to 
15,000°/s²
? Range of values for linear axes: 75 to 
15,000 mm/s²
? Default value for rotational axes: 
200°/s²
? Default value for linear axes: 200 mm/s²
Axis acceleration for 
T1
Axis acceleration limit value for T1 mode
? Range of values for rotational axes: 25 to 
15,000°/s²
? Range of values for linear axes: 75 to 
15,000 mm/s²
? Default value for rotational axes: 
200°/s²
? Default value for linear axes: 200 mm/s²
Monitoring axis accel-
eration
TRUE = axis acceleration can be activated by 
means of the safe inputs “Safe reduced velocity” 
and/or “Standstill monitoring”.
FALSE = axis acceleration cannot be activated.
Monitoring axis accel-
eration for T1
TRUE = axis acceleration is monitored in T1 
mode.
FALSE = axis acceleration is not monitored in T1 
mode.
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The monitoring depends on the mode that has been set and the signal level 
6.9.7 Parameters – Axis range monitoring
Description The parameters and values of axes 1 to 8 can be defined for each monitoring 
range.
The values for the lower and upper axis angles can be taught.
 (>>> 6.7 "Defining axis-specific monitoring ranges" page 49)
at the safe input.
 (>>> 2.13.2 "Safe inputs" page 33)
Parameter Description
Axis lower bound The lower axis angle of a workspace must be at 
least 0.5° or 1.5 mm less than the upper axis 
angle.
The lower axis angle of a safety zone must be at 
least 5° or 15 mm less than the upper axis angle.
Range of values for rotational axes: 
-360° to +360°
Range of values for linear axes: 
-30,000 to +30,000 mm
Default value for rotational axes: -180°
Default value for linear axes: -10,000 mm
Axis upper bound The upper axis angle of a workspace must be at 
least 0.5° or 1.5 mm greater than the lower axis 
angle.
The upper axis angle of a safety zone must be at 
least 5° or 15 mm greater than the lower axis 
angle.
Range of values for rotational axes: 
-360° to +360°
Range of values for linear axes: 
-30,000 to +30,000 mm
Default value for rotational axes: 180°
Default value for linear axes: 10,000 mm
Range inversion FALSE = monitoring range is a workspace.
TRUE = monitoring range is a safety zone.
Digital input Indicates the input assigned to the range.
? -1 = No input is assigned to the range.
? 0 = E0 on X40
? 1 = E1 on X40
? 2 = E2 on X40
? 3 = E3 on X40
? 4 = E4 on X40
? 5 = E5 on X40
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6. Start-up
Parameter Description
6.9.8 Parameters – Monitoring of mastering
Description The Cartesian and axis-specific coordinates of the reference position are de-
fined for the mastering monitoring. The Cartesian coordinates refer to the cent-
er point of the mounting flange.
The axes required for moving to a reference position are listed in a reference 
group. These reference positions contain the coordinates of all axes. During a 
mastering test, only the axes of a reference group may be situated in their ref-
erence position, otherwise there is a risk of the mastering test being falsified.
The coordinates of the reference position can be taught.
 (>>> 6.8 "Defining the reference position" page 50)
6.9.9 Parameters – Standstill monitoring
Description The robot is at a monitored standstill, but may nonetheless move within the pa-
rameterized axis angle tolerances. If the standstill monitoring is active, the ve-
locity and acceleration monitoring are also activated.
The axis angle tolerance is specified separately for all configured axes.
Digital output Indicates the output assigned to the range.
? -1 = No output is assigned to the range.
? 0 = A0 on X40
? 1 = A1 on X40
? 2 = A2 on X40
Reference stop TRUE = reference stop is activated for the moni-
toring range.
FALSE = reference stop is deactivated for the 
monitoring range.
The monitoring depends on the mode that has been set and the signal level 
at the safe input.
 (>>> 2.13.2 "Safe inputs" page 33)
Parameter Description
Cartesian position X
Cartesian position Y
Cartesian position Z
X, Y and Z coordinates of the reference position 
relative to the ROBROOT coordinate system
Reference position Contains the axis-specific coordinates of the ref-
erence position
Reference group Each configured axis must be assigned to a ref-
erence group. 
All robot axes are assigned to reference group 1. 
External axes can be assigned to other refer-
ence groups.
A maximum of 3 reference groups can be cre-
ated.
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Sub-entry Value
6.9.10 Parameters – Interfaces
Description The input test pulse must be activated in the configuration window for testing 
the dual-channel operation of the safe inputs.
6.9.11 Parameters – Machine data ($ROBCOR.DAT)
Description The machine data in $ROBCOR.DAT that are displayed are for internal pur-
poses and make it possible to check the geometry of the robot used.
Axis angle tolerance Limit value for the axis angle tolerance of the 
standstill monitoring that can be activated by 
means of the safe input “Standstill monitoring”.
? Range of values for rotational axes: 0.001 to 
1°
? Range of values for linear axes: 0.003 to 
3 mm
? Default value for rotational axes: 0.01°
? Default value for linear axes: 0.01 mm
The monitoring depends on the mode that has been set and the signal level 
at the safe input.
 (>>> 2.13.2 "Safe inputs" page 33)
Warning!
The input test pulse must not be deactivated. If the input test pulse is deacti-
vated, the inputs are not pulsed and the robot is not in a safe state. This can 
result in personal injury or material damage.
Parameter Description
Input test pulse TRUE = input test pulse is activated.
FALSE = inputtest pulse is deactivated.
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6. Start-up
6.9.12 Parameters – Machine data ($MACHINE.DAT)
Description The sub-entries in the safety parameter “Machine data ($MACHINE.DAT)” are 
described in the KR C2 machine data documentation.
6.10 Assigning external axes to the reference group
Description Each axis that is to be subjected to safe monitoring must be assigned to a ref-
erence group. 
Fig. 6-7: Machine data ($ROBCOR.DAT)
Fig. 6-8: Machine data ($MACHINE.DAT)
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All robot axes are assigned to reference group 1. External axes can be as-
signed to other reference groups.
Precondition ? The external axes may only be assigned to the reference group by author-
ized personnel.
? User group “Safety maintenance”
? Operating mode T1
Procedure 1. Select the menu sequence Setup > Service > Safe Robot > Configura-
tion. The data are loaded.
2. In the tree structure in the configuration window, open the safety parame-
ter Monitoring of mastering.
3. Under Axis 7, in the box Reference group, enter the number for the ref-
erence group that is to be assigned to axis 7.
4. Press the Enter key.
5. To assign a second external axis to a reference group, open Axis 8 and 
enter, in the box Reference group, the number for the reference group 
that is to be assigned to axis 8.
6. Press the Enter key.
7. Close the configuration window and save the changes.
6.11 Programming the mastering test
Precondition ? The mastering test may only be programmed by authorized personnel.
? Reference switch is installed and connected.
? User group “Safety maintenance”
? Operating mode T1
Procedure 1. Open the program MasRefStart.SRC in the directory C:\KRC\ROBOT-
ER\KRC\R1\TP\SAFEROBOT.
2. Program a motion to a point approx. 10 cm before the reference switch 
and teach the required points.
3. Program a LIN motion to the reference switch so that it is actuated. This 
position is the reference position.
4. Teach reference position in the program MasRefStart.SRC.
5. Do not move the robot.
6. Close and save the program MasRefStart.SRC.
7. Define the reference position in the configuration window.
 (>>> 6.8 "Defining the reference position" page 50)
8. Open the program MasRefBack.SRC.
9. Program the motion to the end position of the mastering test and teach the 
required points.
A maximum of 3 reference groups can be created.
Only values indicated in red will be applied and saved.
The distance from the supplied reference switch must not exceed 2 mm. If 
the distance is greater, the reference switch will not be actuated.
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6. Start-up
10. Close and save the program MasRefBack.SRC.
11. Integrate the program MasRefReq.SRC in the application and run it, at the 
latest, 2 hours after the internal request.
6.12 Checking the reference position (actuation with tool)
Precondition ? The accuracy of the mastering test may only be checked by authorized 
personnel.
? Reference switch is installed and connected.
? The reference position has been taught in the program MasRefStart.SRC 
and in the configuration window.
? Axis-specific jogging
? User group “Safety maintenance”
? Operating mode T1
Procedure 1. Select the program MasRefStart.SRC in the directory C:\KRC\ROBOT-
ER\KRC\R1\TP\SAFEROBOT.
2. Move to reference position.
3. All axes subjected to safe monitoring must be moved in the positive and 
negative directions until the reference switch is no longer actuated.
The maximum values by which the axes may deviate from the reference 
position are as follows:
4. If a safely monitored axis has a greater deviation, the reference position 
must be corrected.
 (>>> 6.11 "Programming the mastering test" page 60)
6.13 Performing a mastering test manually
Precondition ? The reference switch is installed and connected.
? The reference position has been taught in the program MasRefStart.SRC 
and in the configuration window.
 (>>> 6.11 "Programming the mastering test" page 60)
? The connecting cables are connected.
 (>>> 6.4 "Connecting the connecting cables" page 47)
Warning!
The robot can collide at the reference position and cause material damage. 
The axes that are to be checked must only be moved in the directions in 
which no collision is possible.
Type of axis
Maximum permissible tolerance per 
axis
Robot axes A 1 to A 3 ±1.5°
Robot axes A 4 to A 6 ±3.0°
Linear axis ±10 mm
Warning!
The robot can move beyond the configured limits and cause personal injury 
or material damage if the accuracy requirements on the reference position 
are not met. Check the tolerance of the reference position for each safely 
monitored axis where this is possible without collision. If the reference posi-
tion tolerances are exceeded, a different reference position must be select-
ed.
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? All output signals are assigned to outputs.
 (>>> 6.6 "Assigning input and output signals" page 49)
 (>>> 9.2 "Signals for the mastering test" page 71)
? Operating mode T1 or T2.
Procedure 1. Select the program MasRefReq.SRC in the directory C:\KRC\ROBOT-
ER\KRC\R1\TP\SAFEROBOT.
2. Execute the program MasRefReq.SRC to the end of the program.
6.14 Configuring robot axes for the brake test
Robot axes A1 to A6 are preconfigured to ±10° for the brake test in the file 
C:\KRC\ROBOTER\INIT\BrakeTestDrv.INI.
6.15 Configuring external axes for the brake test
Precondition ? The external axes may only be configured by authorized personnel.
? Operating mode T1
Procedure 1. Open the file BrakeTestDrv.INI in the directory C:\KRC\ROBOTER\INIT.
2. Set the parameters TRAVANGLEE1 and TRAVANGLEE2 for the external 
axes with the value for the required motion range of the external axis in the 
brake test. E 1 corresponds to axis 7 and E 2 to axis 8.
3. Set the parameters NMBRAKEMINE1 and NMBRAKEMINE2 for the ex-
ternal axes with the value for the holding torque of the brake specified in 
the customer data sheet. E 1 corresponds to axis 7 and E 2 to axis 8.
4. Set the parameters AUTOCURRREDE1 and AUTOCURRREDE2 for the 
external axes to TRUE in order to protect the motors of the external axes 
with the automatic current limitation function. E 1 corresponds to axis 7 
and E 2 to axis 8.
5. If the brake test is not performed successfully with automatic current limi-
tation, carry out the following steps:
? Set the parameters AUTOCURRREDE1 and AUTOCURRREDE2 to 
FALSE.
Danger!
The robot moves in T2 mode at the programmed velocity and can cause per-
sonal injury or material damage. Make sure that the robot cannot collide and 
that no persons are in the motion range of the robot.
If the actuating plate is actuated, the reference position must be reached 
within 3 seconds. If the actuating plate is moved away from the reference po-
sition again, the actuated range must be exited within 3 seconds.
The parameters for robot axes A 1 to A 6 in the file BrakeTestDrv.INI may 
only be modified in consultation with the KUKA Robot Group.
The parameters for robot axes A 1 to A 6 in the file BrakeTestDrv.INI may 
only be modified in consultation with the KUKA Robot Group.
Type of axis Value Range of motion
Rotational 10 ±10°
Translational 10 ±10 mm
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6. Start-up
? Set the parameters CURRREDPERCENTE1 and 
CURRREDPERCENTE2 to the lowest values with which the brake 
test can still be carried out successfully. To do so, reduce the values 
for CURRREDPERCENTE1 and CURRREDPERCENTE2 gradually 
and carry out the brake test.
6. Save the file BrakeTestDrv.INI.
7. Perform a cold start of the robot controller to save the changes.
6.16 Programming the brake testPrecondition ? The brake test may only be programmed by authorized personnel.
? The connecting cables are connected.
 (>>> 6.4 "Connecting the connecting cables" page 47)
? All output signals are assigned to outputs.
 (>>> 6.6 "Assigning input and output signals" page 49)
 (>>> 9.5 "Signals for the brake test" page 74)
? User group “Safety maintenance”
? Operating mode T1
Procedure 1. Open the program BrakeTestStart.SRC in the directory C:\KRC\ROBOT-
ER\KRC\R1\TP\SAFEROBOT.
2. Program the motion to the start position of the brake test and teach the re-
quired points.
3. Close and save program.
4. Open the program BrakeTestEnd.SRC in the directory C:\KRC\ROBOT-
ER\KRC\R1\TP\SAFEROBOT.
5. Program the motion to the end position of the brake test and teach the re-
quired points.
6. Close and save program.
7. Open the program BrakeTestPark.SRC in the directory C:\KRC\ROBOT-
ER\KRC\R1\TP\SAFEROBOT.
8. Program the motion to the parking position of the robot and teach the re-
quired points.
9. Close and save program.
10. Open the file BrakeTestDrv.INI in the directory C:\KRC\ROBOTER\INIT 
and set the brake test cycle time in the variable 
$BRAKETEST_CYCLETIME.
 (>>> 9.6 "Variables in BrakeTestDrv.INI" page 75)
11. Integrate the program BrakeTestReq.SRC in the application and run it, at 
the latest, 2 hours after an internal request.
6.17 Performing a manual brake test
Precondition ? It must be ensured that no persons or objects are present within the motion 
range of the robot.
? The parking position is taught in the program BrakeTestPark.SRC.
 (>>> 6.16 "Programming the brake test" page 63)
The start and end position of the brake test can be identical.
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? The safe inputs for the standstill monitoring and the safe reduced velocity 
must be wired.
 (>>> 14.1 "Interface X40 circuit example 1" page 99)
? Operating mode T2
Procedure 1. Select the program BrakeTestReq.SRC in the directory C:\KRC\ROBOT-
ER\KRC\R1\TP\SAFEROBOT.
2. Execute the program BrakeTestReq.SRC to the end of the program.
3. If a brake is identified as being defective, a dialog message appears.
? Press the Repeat softkey to repeat the brake test.
? Press the Park pos. softkey to move the robot to the parking position.
6.18 Safety acceptance of KUKA.SafeRobot
Description Following start-up, the acceptance procedures for KUKA.SafeRobot must be 
carried out in accordance with the checklists in the Appendix. For successful 
safety acceptance, the points in the checklists must be completed fully and 
confirmed in writing. KUKA.SafeRobot must not be put into operation until the 
safety acceptance procedure has been completed successfully.
The safety acceptance checklists must also be completed fully and confirmed 
in writing in the following cases:
? After reinstallation
? After maintenance work
? After a change to the robot system
? After exchanging safety-relevant components
The safety acceptance checklists can be found in the Appendix of this docu-
mentation:
? (>>> 14.4 "Checklist for robot and system" page 102)
? (>>> 14.5 "Checklist for safe functions" page 103)
? (>>> 14.6 "Checklist for reduced velocities" page 105)
? (>>> 14.7 "Checklist for reduced accelerations" page 106)
? (>>> 14.8 "Checklist for standstill monitoring" page 107)
? (>>> 14.9 "Checklist for configuration of the monitoring ranges" 
page 109)
Danger!
Program override is automatically set to 100%. The robot moves at high 
speed and can cause personal injury or material damage. Make sure that the 
robot cannot collide and that no persons are in the motion range of the robot.
Warning!
If a brake has been identified as being defective, the drives remain under ser-
vo-control for 2 hours following the start of the brake test (monitoring time). 
Once this time has elapsed, the drives are deactivated.
The completed checklists, confirmed in writing, must be kept as documentary 
evidence.
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7. Programming
7 Programming
7.1 Programs for the mastering test
Description The programs for the mastering test are located in the directory C:\KRC\RO-
BOTER\KRC\R1\TP\SAFEROBOT.
The following programs are required for the mastering test:
7.2 Programs for the brake test
Description The programs for the brake test are located in the directory C:\KRC\ROBOT-
ER\KRC\R1\TP\SAFEROBOT.
The following programs are required for the brake test:
Program Description
MasRefReq.SRC The program checks whether a mastering test is 
required and must be executed, at the latest, 2 
hours after an internal request. If the program is 
not executed within 2 hours, the robot stops and 
the robot controller generates a message.
If a mastering test is required, the robot performs 
it immediately.
MasRefStart.SRC The program contains the reference position of 
the robot.
MasRefBack.SRC The program contains the end position of the 
robot. The robot moves to this position after the 
mastering test.
If the end position is not taught, the robot 
remains at the actual position after the mastering 
test and the robot controller generates an error 
message.
Program Description
BrakeTestReq.SRC The program checks whether a brake test is 
required and must be executed, at the latest, 2 
hours after an internal request. If the program is 
not executed within 2 hours, the robot stops and 
the robot controller generates a message.
If a brake test is required, the robot performs it 
immediately.
BrakeTestPark.SRC The program contains the parking position of the 
robot, to which the robot moves if a brake is 
identified as being defective.
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Program Description
BrakeTestStart.SRC The program contains the start position of the 
brake test. The robot starts the brake test from 
this position.
If the start position is not taught, the robot per-
forms the brake test at the actual position.
BrakeTestBack.SRC The program contains the end position of the 
brake test. The robot moves to this position after 
the brake test.
If the end position is not taught, the robot 
remains at the actual position after the brake 
test.
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8. Operation
8 Operation
8.1 Displaying safety parameters
Precondition ? No program may be selected.
Procedure 1. Select the menu sequence Setup > Service > Safe Robot > Configura-
tion. The data are loaded.
2. Open the desired safety parameters in the tree structure in order to display 
the sub-entries, parameters and values.
3. Press the Areas softkey to display the ranges.
4. Press the Ref. Pos. softkey to display the axis-specific coordinates of the 
reference position.
8.2 Verifying safety parameters
Description During verification of the safety parameters, the consistency of the following 
data is checked:
? Machine data
? Safety parameters in the configuration file on the hard drive
? Safety parameters on the SafeRDC
During verification of the data, the safe output OUT_STATUS is set to LOW. 
If, before verification, the safe output OUT_STATUS was HIGH, it is reset to 
HIGH once the data verification has been successfully completed. The config-
uration window cannot be opened during the verification.
Procedure 1. Select the menu sequence Setup > Service > Safe Robot > Examina-
tion. The data are verified.
2. If the verification was successful and the message “Ackn. Invalid configu-
ration on SafeRDC” appears, acknowledge the message.
3. If the verification was unsuccessful, various data can be accepted.
Fig. 8-1: Displaying safety parameters
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 (>>> 10.2 "Messages during verification of the safety parameters"page 81)
8.3 Reading the operating hours meter
Procedure 1. Select the menu sequence Help > Info.
2. Open the Robot tab.
3. The parameter Robot runtime indicates the operating hours of the robot.
8.4 Archiving safety parameters
Voraussetzung ? Storage medium is present.
? User group "Safety maintenance"
? Directory set in KRC Configurator.
Procedure 1. Select the menu sequence File > Archive > Configuration > SafeRobot.
2. Confirm the message by pressing the Yes softkey. The safety parameters 
are saved in the file KUKASafeRobot.CONFIG in the directory that has 
been set.
8.5 Restoring safety parameters
Precondition ? Safety parameters have been archived.
? The configuration file containing the safety parameters has not been ma-
nipulated.
? The storage medium containing the archived safety parameters is present.
? User group “Safety maintenance”
Procedure 1. Select the menu sequence File > Restore > Configuration > SafeRobot.
2. Confirm the message by pressing the Yes softkey. The configuration file 
containing the safety parameters is copied to the hard drive.
3. Select the menu sequence Setup > Service > Safe Robot > Configura-
tion. The data are loaded.
4. If the safety parameters in the configuration file are not identical to the 
safety parameters on the SafeRDC, the following selection appears:
The operating hours meter is running as long as the drives are switched on.
Alternatively, the operating hours meter can also be displayed via the varia-
ble $ROBRUNTIME.
Further information is contained in the operating and programming instruc-
tions.
The file has a digital signature and must not be manipulated.
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8. Operation
Softkey Description
Hard disk The safety parameters from the restored con-
figuration file are transferred to the SafeRDC.
RDC The current safety parameters from the Safe-
RDC are transferred to the configuration file.
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9. System variables
9 System variables
9.1 Signal declarations
Description All signals are declared in the file $MACHINE.DAT in the directory 
C:\KRC\ROBOTER\KRC\STEU\MADA.
By default, the input signals are routed to $IN[1026]. The output signals are 
preset to FALSE and must be assigned to an output. The output signals can-
not be used until they have been assigned to an output.
9.2 Signals for the mastering test
Caution!
These signals are not redundant in design and can supply incorrect informa-
tion. Do not use these signals for safety-relevant applications.
The maximum number of available inputs and outputs is dependent on the 
system variable $SET_IO_SIZE in the file $OPTION.DAT in the directory 
C:\KRC\ROBOTER\KRC\STEU\MADA.
Signal Description Range of values I/O
$MASTERINGTEST_
MONTIME
TRUE = robot was stopped due to 
elapsed monitoring time.
FALSE = monitoring time has not yet 
elapsed.
TRUE|FALSE O
$MASTERINGTEST_OK TRUE = mastering test has been 
performed successfully.
FALSE = mastering test has not 
been performed successfully.
TRUE|FALSE O
$MASTERINGTEST_
REQ_EX
TRUE = mastering test is being 
requested externally and is to be 
started (e.g. by Safety PLC).
FALSE = mastering test is not being 
requested.
TRUE|FALSE I
$MASTERINGTEST_
REQ_INT
TRUE = robot controller is internally 
requesting a mastering test.
FALSE = robot controller is not 
requesting a mastering test.
TRUE|FALSE O
$MASTERINGTEST_WORK TRUE = mastering test is being per-
formed.
FALSE = mastering test is not being 
performed.
TRUE|FALSE O
$MASTERINGTEST
SWITCH_OK
TRUE = no reference switch mal-
function.
FALSE = reference switch malfunc-
tion.
TRUE|FALSE O
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9.3 Signals for diagnosis
Signal Description Range of values I/O
$AXISRANGE1_OK TRUE = monitoring space 1 has not 
been violated.
FALSE = monitoring space 1 has 
been violated.
TRUE|FALSE O
$AXISRANGE2_OK TRUE = monitoring space 2 has not 
been violated.
FALSE = monitoring space 2 has 
been violated.
TRUE|FALSE O
$AXISRANGE3_OK TRUE = monitoring space 3 has not 
been violated.
FALSE = monitoring space 3 has 
been violated.
TRUE|FALSE O
$AXISRANGE4_OK TRUE = monitoring space 4 has not 
been violated.
FALSE = monitoring space 4 has 
been violated.
TRUE|FALSE O
$AXISRANGE5_OK TRUE = monitoring space 5 has not 
been violated.
FALSE = monitoring space 5 has 
been violated.
TRUE|FALSE O
$AXISRANGE6_OK TRUE = monitoring space 6 has not 
been violated.
FALSE = monitoring space 6 has 
been violated.
TRUE|FALSE O
$AXISRANGE7_OK TRUE = monitoring space 7 has not 
been violated.
FALSE = monitoring space 7 has 
been violated.
TRUE|FALSE O
$AXISRANGE8_OK TRUE = monitoring space 8 has not 
been violated.
FALSE = monitoring space 8 has 
been violated.
TRUE|FALSE O
$AXISRANGE9_OK TRUE = monitoring space 9 has not 
been violated.
FALSE = monitoring space 9 has 
been violated.
TRUE|FALSE O
$AXISRANGE10_OK TRUE = monitoring space 10 has 
not been violated.
FALSE = monitoring space 10 has 
been violated.
TRUE|FALSE O
$AXISRANGE2_ACTIVE TRUE = monitoring space 2 is acti-
vated and monitored.
FALSE = monitoring space 2 is not 
monitored.
TRUE|FALSE O
$AXISRANGE3_ACTIVE TRUE = monitoring space 3 is acti-
vated and monitored.
FALSE = monitoring space 3 is not 
monitored.
TRUE|FALSE O
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9. System variables
Signal Description Range of values I/O
9.4 Robot status signals
$AXISRANGE4_ACTIVE TRUE = monitoring space 4 is acti-
vated and monitored.
FALSE = monitoring space 4 is not 
monitored.
TRUE|FALSE O
$AXISRANGE5_ACTIVE TRUE = monitoring space 5 is acti-
vated and monitored.
FALSE = monitoring space 5 is not 
monitored.
TRUE|FALSE O
$AXISRANGE6_ACTIVE TRUE = monitoring space 6 is acti-
vated and monitored.
FALSE = monitoring space 6 is not 
monitored.
TRUE|FALSE O
$AXISRANGE7_ACTIVE TRUE = monitoring space 7 is acti-
vated and monitored.
FALSE = monitoring space 7 is not 
monitored.
TRUE|FALSE O
Signal Description Range of values I/O
$AXISACC_OK TRUE = reduced axis acceleration 
has not been exceeded.
FALSE = reduced axis acceleration 
has been exceeded.
TRUE|FALSE O
$AXISSPEED_OK TRUE = reduced axis velocity has 
not been exceeded.
FALSE = reduced axis velocity has 
been exceeded.
TRUE|FALSE O
$CARTSPEED_OK TRUE = Cartesian velocity at the 
robot flange has not been exceeded.
FALSE = Cartesian velocity at the 
robot flange has been exceeded.
TRUE|FALSE O
$SAFEMON_ACTIVE TRUE = safe robot monitoring is 
activated.
FALSE = safe robot monitoring is not 
activated.
TRUE|FALSE O
$SAFEOPSTOP_ACTIVE TRUE = standstill monitoring is mon-
itored.
FALSE = standstill monitoring is not 
monitored.
TRUE|FALSE O
$SAFEOPSTOP_OK TRUE = standstill monitoring has not 
been violated.
FALSE = standstill monitoring has 
been violated.
TRUE|FALSE O
$SAFEREDSPEED_
ACTIVE
TRUE = the velocities and accelera-
tions are monitored.
FALSE = the velocities and accelera-
tions are not monitored.
TRUE|FALSE O
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Signal Description Range of values I/O
9.5 Signals for the brake test
$STOP0 TRUE = robot has been stopped 
with a STOP 0.
FALSE = robot has not been 
stopped with a STOP 0.
TRUE|FALSE O
$STOP1 TRUE = robot has been stopped 
with a STOP 1.
FALSE = robot has not been 
stopped with a STOP 1.
TRUE|FALSE O
$STOP2 TRUE = robot has been stopped 
with a STOP 2.
FALSE = robot has not been 
stopped with a STOP 2.
TRUE|FALSE OSignal Description Range of values I/O
$BRAKES_OK TRUE = all brakes are OK.
FALSE = at least one brake is defec-
tive.
TRUE|FALSE O
$BRAKETEST_MONTIME TRUE = robot was stopped due to 
elapsed monitoring time.
FALSE = monitoring time has not yet 
elapsed.
TRUE|FALSE O
$BRAKETEST_REQ_EX TRUE = brake test is being 
requested externally and is to be 
started (e.g. by Safety PLC).
FALSE = brake test is not being 
requested externally.
TRUE|FALSE I
$BRAKETEST_REQ_INT TRUE = robot controller is internally 
requesting a brake test.
FALSE = robot controller is not 
requesting a brake test.
TRUE|FALSE O
$BRAKETEST_WARN TRUE = at least one brake has 
reached the wear limit.
FALSE = all brakes are OK.
TRUE|FALSE O
$BRAKETEST_WORK TRUE = brake test is being per-
formed.
FALSE = brake test is not being per-
formed.
TRUE|FALSE O
Variable Description Range of values
$BRAKETEST_
CYCLETIME
INT value for the brake test cycle 
time in hours.
1 to 46
Default: 46
$BRAKETEST_
TIMER
INT value for the remaining brake 
test cycle time in hours.
1 to 46
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9. System variables
9.6 Variables in BrakeTestDrv.INI
Description The file BrakeTestDrv.INI in the directory C:\KRC\ROBOTER\INIT contains 
the parameters of the axes for the brake test. If external axes are used, they 
must be configured for the brake test in the file BrakeTestDrv.INI.
The parameters for robot axes A 1 to A 6 in the file BrakeTestDrv.INI may 
only be modified in consultation with the KUKA Robot Group.
Variable Description Range of values
AUTOCURRRED Current limitation to protect the 
brake. The brake is thus loaded in a 
targeted manner in the brake test.
TRUE = current is automatically lim-
ited.
FALSE = current is limited to the 
value in the variable CURRRED-
PERCENT.
TRUE|FALSE
Default:
AUTOCURRREDA1 ... A6: 
TRUE
AUTOCURRREDE1 ... E6: 
FALSE
AXISVEL INT value for the axis velocity during 
the brake test.
The value is a percentage and refers 
to the rated speed.
1 ... 10
Default:
AXISVELA1 ... A6: 3
AXISVELE1 ... E6: 3
BRAKETEST_CYCTIME INT value for the brake test cycle 
time in hours.
1 ... 46
Default: 46
CURRREDPERCENT Value for limiting the maximum cur-
rent of the brake.
The value is only taken into consid-
eration if the variable AUTO-
CURRRED is set to FALSE for the 
axis in question.
5.0 ... 75.0
Default: 75.0
MOVEMENTSTOP
FLAG
Flag for the brake test.
The configured flag must not be 
used for any other application in the 
KUKA System Software.
1 ... 1024
Default: 1010
MOVEMENTSTOP
INTERRUPT
Priority of the interrupt for the brake 
test.
The configured interrupt must not be 
used for any other application in the 
KUKA System Software.
1, 2, 4 ... 39 and 81 ... 128
Default: 19
NMBRAKEMIN FLOAT value with 2 decimal places 
for the holding torque of the brake in 
Nm
This is the minimum value that must 
be reached in the brake test. If this 
value is not reached, the brake is 
identified as being defective.
Default:
NMBRAKEMINA1 ... A6: 1.0
NMBRAKEMINE1 ... E6: 
Must be set, for each exter-
nal axis used, with the mini-
mum rated brake torque 
from the motor data sheet.
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KUKA.SafeRobot 1.1
Variable Description Range of values
NMSAFETYFACTOR Safety factor for the holding torque 
of the brake in the brake test.
If this value is reached, the robot 
controller generates the following 
message: “Brake XXX reached the 
wear barrier”.
1.1 = 110 % holding torque = 10 % 
safety factor
1.0 ... 2.0
Default: 1.1
TRAVANGLE INT value for the motion range of the 
axis during the brake test.
For rotational axes: 
10 = 10°
For translational axes: 
10 = 10 mm
2 ... 100
Default:
TRAVANGLEA1 ... A6: 10
TRAVANGLEE1 ... E6: Must 
be configured for each exter-
nal axis used.
76 / 123 V6.2 03.08.2007 KST-AD-SafeRobot11 en
V6.2
10. Messages
10 Messages
10.1 Messages during operation
Configuration or operator errors may result in error messages in an applica-
tion.
No. Message Cause Remedy
390 Mastering test required Robot is unmastered. Perform mastering test.
Robot controller has been 
rebooted.
391 Mastering test failed The spatial position of the 
robot and/or the external 
axes has changed.
1. Teach reference posi-
tion in the program Mas-
RefStart.SRC.
2. Select the menu se-
quence Setup > Serv-
ice > Safe Robot > 
Configuration.
3. Press the softkey Ref. 
Pos..
4. Press the Touch Up 
softkey and confirm the 
message. The actual 
position is applied as the 
reference position.
5. Perform mastering test.
The actuating plate is too 
far from the reference 
switch. The distance 
between the actuating plate 
and the reference switch 
must not exceed 2 mm.
Robot stops at the refer-
ence position and the refer-
ence switch has been 
actuated for too long.
1. Open MasRefBack.src.
2. Teach end point of the 
robot.
External axes are safely 
monitored, but are assigned 
to the wrong reference 
group or no reference group 
at all.
Assign external axes to the 
reference group.
392 Workspace no. XXX 
exceeded
The limit of monitoring 
range XXX has been 
exceeded.
1. Perform safe retraction 
of the robot in operating 
mode T1.
2. Check the configuration 
of the monitoring range 
and adapt if required.
Deactivate monitoring 
range XXX.
393 Safe operational stop vio-
lated
Robot has exceeded the 
axis angle tolerance of the 
standstill monitoring.
1. Perform safe retraction 
of the robot in operating 
mode T1.
2. Check the configuration 
of the standstill monitor-
ing and adapt if re-
quired.
Deactivate standstill moni-
toring.
The robot started moving 
erroneously.
Check motion program and 
adapt if required.
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KUKA.SafeRobot 1.1
No. Message Cause Remedy
394 Safety parameters incor-
rect XXX
At least one safety parame-
ter in the configuration win-
dow is incorrect.
1. Open the configuration 
window.
2. Verify the correctness of 
the safety parameters.
397 Assertion failed: XXX A serious exceptional error 
has occurred.
Cold start of the robot con-
troller. If the message is still 
present after the cold start, 
contact KUKA Service.
398 Maximum speed of XXX 
exceeded
The maximum axis velocity 
of axis XXX has been 
exceeded.
Check the configuration of 
the axis velocity and adapt 
if required.
Deactivate axis velocity.
399 Maximum Cartesian veloc-
ity exceeded
The Cartesian velocity at 
the flange center point has 
been exceeded.
Check the configuration of 
the Cartesian velocity and 
adapt if required.
Deactivate Cartesian veloc-
ity.
401 SafeRDC system error 
3000.
Error in cross comparison 1. Check inputs/outputs 
and eliminate error.
2. Verify the safety param-
eters.
3. Master the robot.
4. Reboot robot controller 
and force a cold restart.
5. If the error persists, ex-
change the SafeRDC 
board.
SafeRDC system error 
3001.
SafeRDC system error 
3002.
SafeRDC system error XXX All other system errors are 
due to a faulty SafeRDC 
board.
1. Reboot robot controller 
and force a cold restart.
2. If the error persists, ex-
change the SafeRDC 
board.
3. Reconfigure robot sys-
tem or restore archived 
safety parameters. 
402 Maximum acceleration of 
XXX exceeded
The maximum axis acceler-
ation of axis XXX has been 
exceeded.
Check the configuration of 
the axis acceleration and 
adapt if required.
404 EMERGENCY STOP Safe-
RDC.
The SafeRDC has caused 
an EMERGENCY STOP.
This message is always 
generated together with at 
least one other message. 
Observe the other mes-
sagesto eliminate the fault.
411 Safety mode not possible Safety parameters are not 
confirmed.
Check safety parameters.
SafeRDC is not correctly 
initialized or is not running 
without errors.
Check SafeRDC.
Mastering test was not suc-
cessful or referencing is not 
current.
Perform mastering test.
Safe inputs and outputs are 
not free from errors.
Check wiring and eliminate 
fault and/or exchange Safe-
RDC board.
78 / 123 V6.2 03.08.2007 KST-AD-SafeRobot11 en
V6.2
10. Messages
No. Message Cause Remedy
414 Error while starting the 
SafeRDC
The SafeRDC was not cor-
rectly booted.
1. Reboot robot controller 
and force a cold restart.
2. If the error persists, ex-
change the SafeRDC 
board.
437 Calibration reference switch 
defect
The reference switch and/or 
the reference cable X42 - 
XS Ref is defective.
1. Inspect reference switch 
and/or reference cable 
visually for damage.
2. Check whether the ref-
erence switch is actuat-
ed during the mastering 
test.
3. If the error persists, ex-
change the reference 
switch and/or reference 
cable X42 - XS Ref.
440 SafeRDC memory failure in 
area XXX
Memory area XXX of the 
SafeRDC is defective.
1. Reboot robot controller 
and force a cold restart.
2. If the error persists, ex-
change the SafeRDC 
board.
3. Reconfigure robot sys-
tem or restore archived 
safety parameters. 
441 Invalid configuration on 
SafeRDC
At least one safety parame-
ter in the configuration win-
dow is incorrect.
1. Open the configuration 
window.
2. Verify the correctness of 
the safety parameters.
442 Encoder failure monitored 
resolver channel XXX on 
SafeRDC.
The encoder cable from the 
affected motor to the Safe-
RDC is defective.
Exchange the encoder 
cable from the affected 
motor to the SafeRDC.
Resolver is defective. Exchanging the motor.
443 Failure safety input no. XXX I/O Print board is faulty. 1. Reboot robot controller 
and force a cold restart.
2. If the error persists, shut 
down the robot control-
ler and exchange the I/O 
Print board.
SafeRDC board is faulty. 1. Reboot robot controller 
and force a cold restart.
2. If the error persists, shut 
down the robot control-
ler and exchange the 
SafeRDC board. 
Defective wiring 1. Reboot robot controller 
and force a cold restart.
2. Check wiring of safe in-
put/output XXX and 
eliminate error.
Short-circuit
Open circuit
Cross-connection
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KUKA.SafeRobot 1.1
No. Message Cause Remedy
444 Failure safety output no. 
XXX
I/O Print board is faulty. 1. Reboot robot controller 
and force a cold restart.
2. If the error persists, shut 
down the robot control-
ler and exchange the I/O 
Print board. 
SafeRDC board is faulty. 1. Reboot robot controller 
and force a cold restart.
2. If the error persists, shut 
down the robot control-
ler and exchange the 
SafeRDC board. 
Defective wiring 1. Reboot robot controller 
and force a cold restart.
2. Check wiring of safe in-
put/output XXX and 
eliminate error.
Short-circuit
Open circuit
Cross-connection
449 Workspace no. XXX vio-
lated.
Monitoring range XXX has 
been violated.
1. Perform safe retraction 
of the robot in operating 
mode T1.
2. Check the configuration 
of the monitoring range 
and adapt if required.
Deactivate monitoring 
range XXX.
2981 Ackn. Maximum accelera-
tion of XXX exceeded.
Follow-up message to mes-
sage 402.
Acknowledge message.
2983 Ackn. Maximum speed of 
XXX exceeded.
Follow-up message to mes-
sage 398.
Acknowledge message.
2986 Ackn. Maximum Cartesian 
speed exceeded.
Follow-up message to mes-
sage 399.
Acknowledge message.
2989 Ackn. SafeRDC system 
error XXX.
Follow-up message to mes-
sage 404.
Acknowledge message.
2990 Ackn. Safety parameters 
incorrect XXX
Follow-up message to mes-
sage 394.
Acknowledge message.
2991 Ackn. Safety position vio-
lated
Follow-up message to mes-
sage 393.
Acknowledge message.
3056 Ackn. Cyclic check of 
request for calibration not 
done.
Mastering test not per-
formed within 2 hours of the 
request.
1. Acknowledge message.
2. Perform mastering test.
3057 Ackn. SafeRDC memory 
failure in area XXX
Follow-up message to mes-
sage 440.
Acknowledge message.
3058 Ackn. Invalid configuration 
on SafeRDC
Follow-up message to mes-
sage 441.
Acknowledge message.
3060 Ackn. Failure safety input 
no. XXX
Follow-up message to mes-
sage 443.
Acknowledge message.
3061 Ackn. Failure safety output 
no. XXX
Follow-up message to mes-
sage 444.
Acknowledge message.
3067 Ack. stopp because work-
space no. XXX exceeded
Follow-up message to mes-
sage 449 or 392.
Acknowledge message.
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V6.2
10. Messages
10.2 Messages during verification of the safety parameters
Configuration or operator errors may result in error messages in an applica-
tion.
No. Message Cause Remedy
103 All data sources are differ-
ent (XML, RDC and 
machine data).
All data are inconsistent. 1. Select the menu se-
quence Setup > Serv-
ice > Safe Robot > 
Configuration. The 
data are loaded.
2. Press the RDC softkey 
to accept the data from 
the SafeRDC or the 
Hard disk softkey to ac-
cept the data from the 
.xml file.
3. Press the Machine data 
softkey to accept the 
data from the machine 
data.
105 Difference between XML 
and RDC data.
The safety parameters in 
the .xml file on the hard 
drive do not match those on 
the SafeRDC.
1. Select the menu se-
quence Setup > Serv-
ice > Safe Robot > 
Configuration. The 
data are loaded.
2. Press the RDC softkey 
to accept the data from 
the SafeRDC or the 
Hard disk softkey to ac-
cept the data from the 
.xml file.
114 Difference between XML 
and RDC data and between 
XML and machine data.
The machine data do not 
match the data in the .xml 
file and the data on the Saf-
eRDC.
1. Select the menu se-
quence Setup > Serv-
ice > Safe Robot > 
Configuration.
2. Press the Machine data 
softkey to accept the 
data from the machine 
data.
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KUKA.SafeRobot 1.1
No. Message Cause Remedy
10.3 Messages for the brake test
Configuration or operator errors may result in error messages in an applica-
tion.
119 Nonexistent or invalid con-
figuration file.
The safety parameters in 
the .xml file on the hard 
drive do not match those on 
the SafeRDC.
1. Select the menu se-
quence Setup > Serv-
ice > Safe Robot > 
Configuration. The 
data are loaded.
2. Press the RDC softkey 
to accept the data from 
the SafeRDC or the 
Hard disk softkey to ac-
cept the data from the 
.xml file.
The .xml file containing the 
safety parameters is not 
present.
1. Select the menu se-
quence Setup > Serv-
ice > Safe Robot > 
Configuration. The 
data are loaded.
2. Press the RDC softkey 
to accept the data from 
the SafeRDC.
No. Message Cause Remedy
27001 Brake XXX reached the 
wear barrier.
The brake of the axis XXX 
will soon be identified as 
defective.
Perform brake test.
The brake of axis XXX must 
soon be exchanged.
27002 Cyclic check for the brake-
test requirement not per-
formed.
Brake test cycle time 
elapsed.
No brake test performed 
within 2 hours of the 
request.
1. Acknowledge message.
2. Perform brake test.
Robot controller has been 
rebooted.
No brake test performed 
within 2 hours of the 
request.
27004 Brake test required Brake test cycle time 
elapsed.
Perform brake test.
Robot controller has been 
rebooted.
27007 Brake test failed XXX The brake on axis XXX has 
insufficient braking torque.
1. Perform brake test.
2. Exchange the motor of 
axis XXX.
27010Evaluation brake XXX failed Calculation of the brake test 
was incorrect.
Perform brake test.
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V6.2
10. Messages
No. Message Cause Remedy
27011 Braketest for brake XXX not 
completed.
Brake test for brake XXX 
was not completed or was 
completed with errors.
Perform brake test.
- - - Maximum motion of axis 
XXX exceeded
During the brake test, the 
robot exceeded the maxi-
mum motion range of axis 
XXX.
1. Open the file BrakeTest-
Drv.INI in the directory 
C:\KRC\ROBOTER\IN-
IT.
2. Set the value of the var-
iable AxisVelA6 from 3 
to 5.
3. Reboot robot controller 
and force a cold restart.
4. Perform brake test.
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84 / 123 V6.2 03.08.2007 KST-AD-SafeRobot11 en
V6.2
11. Diagnosis
11 Diagnosis
11.1 Opening diagnosis
Precondition ? All output signals are assigned to outputs.
 (>>> 6.6 "Assigning input and output signals" page 49)
 (>>> 9.3 "Signals for diagnosis" page 72)
Procedure 1. Select the menu sequence Monitor > Diagnosis > Safe Robot. The di-
agnostic window opens.
2. Press the Range + or Range - softkey to toggle to a different monitoring 
range.
3. Diagnosis can be closed at any time using the Close softkey.
11.2 Overview of diagnosis
Overview
Description The following information can be displayed in the diagnosis for each monitor-
ing range:
? Status of the monitoring ranges
? Inversion
? Status of the axis ranges
? Status of the safe inputs/outputs, channels A and B
The displayed information is refreshed using the Refresh softkey.
Fig. 11-1: Diagnosis
In order for the information to be displayed correctly in the diagnosis, the out-
put signals must be assigned to outputs.
 (>>> 6.6 "Assigning input and output signals" page 49)
 (>>> 9.3 "Signals for diagnosis" page 72)
85 / 12303.08.2007 KST-AD-SafeRobot11 en
KUKA.SafeRobot 1.1
2 windows are displayed.
11.2.1 Overview of the monitoring ranges
Overview
Description The status of all monitoring ranges is displayed in the overview.
No. Window
1 Overview of the monitoring ranges
 (>>> 11.2.1 "Overview of the monitoring ranges" page 86)
2 Detailed information about the selected monitoring range
 (>>> 11.2.2 "Detailed information about the monitoring range" 
page 87)
Fig. 11-2: Diagnosis: overview of the monitoring ranges
No. Description
1 Status of the monitoring ranges:
 Monitoring range is active and not violated.
 Monitoring range is active and violated.
 Monitoring range is not active.
86 / 123 V6.2 03.08.2007 KST-AD-SafeRobot11 en
V6.2
11. Diagnosis
11.2.2 Detailed information about the monitoring range
Overview
Description The following detailed information about the selected monitoring range is dis-
played.
Fig. 11-3: Diagnosis: option window
No. Description
1 Number and name of the selected monitoring range
2 Inversion:
FALSE = monitoring range is a workspace.
TRUE = monitoring range is a safety zone.
3 Status of the axis ranges:
 The axis is located inside the configured axis range.
 The axis is located outside the configured axis range.
 Axis is not configured or is not monitored.
4 Status of the safe inputs/outputs, channels A and B:
 HIGH level at input/output, channel A/B
 LOW level at input/output, channel A/B
If no LED is displayed, there is no input/output assigned to the 
monitoring range.
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88 / 123 V6.2 03.08.2007 KST-AD-SafeRobot11 en
V6.2
12. Troubleshooting
12 Troubleshooting
12.1 LEDs on the SafeRDC board
Description
If the LEDs indicate faulty operation, reboot the robot controller and force a 
cold start. If the error persists, exchange the SafeRDC board.
Fig. 12-1: LEDs on the SafeRDC board
Item Designation Color Description
1 H1700 Red LED for self-test of the SafeRDC, channel B
During boot-up of the SafeRDC board
? On = Faulty operation
? Off = Normal operation
? Flashing = Faulty operation
After boot-up of the SafeRDC board
? On = Faulty operation
? Off = Faulty operation
? Flashing = Normal operation
2 H1701 Green LED for self-test of the SafeRDC, channel B
During boot-up of the SafeRDC board
? On = Normal operation
? Off = Faulty operation
? Flashing = Faulty operation
After boot-up of the SafeRDC board
? On = Faulty operation
? Off = Faulty operation
? Flashing = Normal operation
3 H1702 Green Not used.
4 H1502 Green Busy LED, channel B
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Item Designation Color Description
5 H1501 Green Status LED, channel B
During boot-up of the SafeRDC board
? On = Normal operation
? Off = Faulty operation
? Flashing = Faulty operation
After boot-up of the SafeRDC board
? On = Faulty operation
? Off = Normal operation
? Flashing = Faulty operation
6 H1500 Green Operation LED, channel B
During boot-up of the SafeRDC board
? On = Faulty operation
? Off = Faulty operation
? Flashing = Normal operation (software running)
After boot-up of the SafeRDC board
? On = Faulty operation
? Off = Faulty operation
? Flashing = Normal operation (software running)
7 H1402 Green Busy LED, channel A
8 H1401 Green Status LED, channel A
During boot-up of the SafeRDC board
? On = Normal operation
? Off = Faulty operation
? Flashing = Faulty operation
After boot-up of the SafeRDC board
? On = Faulty operation
? Off = Normal operation
? Flashing = Faulty operation
9 H1400 Green Operation LED, channel A
During boot-up of the SafeRDC board
? On = Faulty operation
? Off = Faulty operation
? Flashing = Normal operation (software running)
After boot-up of the SafeRDC board
? On = Faulty operation
? Off = Faulty operation
? Flashing = Normal operation (software running)
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V6.2
12. Troubleshooting
Item Designation Color Description
10 H1800 Red LED for self-test of the SafeRDC, channel A
During boot-up of the SafeRDC board
? On = Faulty operation
? Off = Normal operation
? Flashing = Faulty operation
After boot-up of the SafeRDC board
? On = Faulty operation
? Off = Faulty operation
? Flashing = Normal operation
11 H1801 Green LED for self-test of the SafeRDC, channel A
During boot-up of the SafeRDC board
? On = Normal operation
? Off = Faulty operation
? Flashing = Faulty operation
After boot-up of the SafeRDC board
? On = Faulty operation
? Off = Faulty operation
? Flashing = Normal operation
12 H2100 Green ? On = HIGH level at output QE_A_24V
? Off = LOW level at output QE_A_24V
13 H2101 Green ? On = HIGH level at output ENA_A_24V
? On = LOW level at output ENA_A_24V
14 H2102 Green ? On = HIGH level at output QE_B_24V
? Off = LOW level at output QE_B_24V
15 H2103 Green ? On = HIGH level at output ENA_B_24V
? Off = LOW level at output ENA_B_24V
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12.2 LEDs on the I/O Print board
Description
Fig. 12-2: LEDs on the I/O Print board
Item Designation Color Description
1 H800 Green Not used.
2 H801 Green Not used.
3 H703 Green ? On = HIGH level at OUT_STATUS_B
? Off = LOW level at OUT_STATUS_B
4 H702 Green ? On = HIGH level at OUT_A2_B
? Off = LOW level at OUT_A2_B
5 H602 Green ? On = HIGH level at OUT_A0_B
? Off = LOW level at OUT_A0_B
6 H603 Green ? On = HIGH level at OUT_A1_B
? Off = LOW level at OUT_A1_B
7 H701 Green ? On = HIGH level at OUT_STATUS_A
? Off = LOW level at OUT_STATUS_A
8 H600 Green ? On = HIGH level at OUT_A0_A
? Off = LOW level at OUT_A0_A
9 H601 Green ? On = HIGH level at OUT_A1_A
? Off = LOW level at OUT_A1_A
10 H700 Green ? On = HIGH level at OUT_A2_A
? Off = LOW level at OUT_A2_A
11 H1 Green ? On = Pulsed voltage /TA24V_Apresent
? Off = Pulsed voltage /TA24V_A not present
12 H2 Green ? On = Pulsed voltage /TA24V_B present
? Off = Pulsed voltage /TA24V_B not present
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V6.2
13. Repair
13 Repair
13.1 Connections on the SafeRDC board
Description
Fig. 13-1: Connections on SafeRDC board
Item Designation Description
1 X2000 Connection for I/O Print expansion board
2 X1900 Not used.
3 X1700 Not used.
4 X1500 Not used.
5 X901 Connection of safe inputs and outputs to the 
ESC circuit
6 X1600 Not used.
7 X1800 Not used.
8 X900 SSI interface A to first DSE
9 X1000 Not used.
10 X9 Connection for RoboTeam lamp
11 X1...X8 Connections for resolvers (X1 for resolver of axis 
1)
12 X1200 Connection for external sensor 1
Not supported
13 X1201 Connection for external sensor 2
Not supported
14 X1202 Connection for external sensor 3
Not supported
15 X1203 Connection for external sensor 4
Not supported
16 X1204 Slot for sensor module 1
Not supported
17 X1205 Slot for sensor module 2
Not supported
18 X1207 Slot for sensor module 3
Not supported
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Item Designation Description
13.2 Connections on the I/O Print board
Description
13.3 Removing the SafeRDC board
Precondition ? The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
? The SafeRDC and I/O Print boards must be protected against static 
charge.
Procedure 1. Unscrew the 4 screws on the lid of the SafeRDC box.
19 X1208 Slot for sensor module 4
Not supported
20 X1301 Fast measurement connection
21 X10 Connection for electronic measuring tool (EMT)
22 X1400 Not used.
23 - - - Ground conductor connection
The contact to the SafeRDC box is established 
using a screw.
Fig. 13-2: Connections on the I/O Print board
Item Designation Description
1 X902 Connection of safe inputs and outputs
2 X1 Not used.
3 X905 Connection for enabling input for KUKA Guiding 
Device (KGD)
4 X904 Connection for reference switch input
5 X901 Connection for SafeRDC board
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V6.2
13. Repair
2. Carefully open the lid of the SafeRDC box forwards.
3. Carefully disconnect all cables leading to the SafeRDC and I/O Print 
boards. Pull the cables out of the SafeRDC box, if possible, or bend them 
out of the way to the sides.
4. Loosen and remove the 6 fastening screws of the SafeRDC board.
5. Carefully pull the SafeRDC board out of the SafeRDC box without tilting it.
Fig. 13-3: Screws on the lid of the SafeRDC box
Fig. 13-4: Fastening screws on the SafeRDC board
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13.4 Removing the I/O Print board
Precondition ? The SafeRDC and I/O Print boards must be protected against static 
charge.
Procedure 1. Remove SafeRDC board.
 (>>> 13.3 "Removing the SafeRDC board" page 94)
2. Loosen and remove the 5 hexagon nuts on the I/O Print board.
3. Carefully remove the I/O Print board from the SafeRDC board.
13.5 Installing the I/O Print board
Precondition ? The SafeRDC and I/O Print boards must be protected against static 
charge.
Procedure 1. Carefully plug the I/O Print board onto the SafeRDC board.
2. Screw the I/O Print board onto the SafeRDC board with 5 hexagon nuts.
Tightening torque 0.9 Nm
3. Install SafeRDC board.
Fig. 13-5: Hexagon nuts on the I/O Print board
Fig. 13-6: Hexagon nuts on the I/O Print board
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V6.2
13. Repair
 (>>> 13.6 "Installing the SafeRDC board" page 97)
13.6 Installing the SafeRDC board
Precondition ? The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
? The SafeRDC and I/O Print boards must be protected against static 
charge.
? The I/O Print board must be fastened to the SafeRDC board.
Procedure 1. Securely screw the SafeRDC board into the SafeRDC box.
2. Connect all cables that were unplugged during removal.
3. Carefully close the lid of the SafeRDC box.
4. Screw the lid of the SafeRDC box firmly in place using the 4 screws on the 
housing.
Caution!
If the fastening screws are screwed in too tightly, this can damage the thread, 
resulting in material damage. Screw in the M4 fastening screws all the way 
to the stop without exerting major force.
Fig. 13-7: Fastening screws on the SafeRDC board
1 2 Allen screws M6x10 8.8 with lock washers
Tightening torque: 6.0 Nm
2 Plastic screw M4x6
3 2 Allen screws M4x8 8.8 with lock washers
Tightening torque: 1.5 Nm
4 Allen screw M6x30 8.8 with lock washer
Tightening torque: 6.0 Nm
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5. Switch on the robot controller and let it run up.
6. Verify the safety parameters.
 (>>> 8.2 "Verifying safety parameters" page 67)
7. Carry out new safety acceptance.
 (>>> 6.18 "Safety acceptance of KUKA.SafeRobot" page 64)
Fig. 13-8: Screws on the lid of the SafeRDC box
98 / 123 V6.2 03.08.2007 KST-AD-SafeRobot11 en
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14. Appendix
14 Appendix
14.1 Interface X40 circuit example 1
The circuit example of connector X40 applies in the following case:
? Operation without external safety logic
? Monitoring ranges 2 to 10 are monitored.
? Standstill monitoring is deactivated.
? Reduced velocities and accelerations that can be activated are not moni-
tored.
Fig. 14-1: Interface X40, circuit example 1
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14.2 Interface X40 circuit example 2
The circuit example of connector X40 applies in the following case:
? Operation without external safety logic
? Monitoring ranges 2 and 3 are activated with floating contacts.
? Monitoring ranges 4 to 10 are monitored.
? Standstill monitoring is activated with floating contacts.
? Reduced velocities and accelerations that can be activated are not moni-
tored.
Fig. 14-2: Interface X40, circuit example 2
100 / 123 V6.2 03.08.2007 KST-AD-SafeRobot11 en
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14. Appendix
14.3 Interface X40 circuit example 3
The circuit example of connector X40 applies in the following case:
? Operation without external safety logic
? Pulsed output voltage as supply voltage for safe outputs
? Monitoring ranges 2, 3 and 5 to 10 are monitored.
? Safe input (monitoring range 4) can be activated via safe output (monitor-
ing range 9).
? Standstill monitoring is not activated.
? Reduced velocities and accelerations that can be activated are activated 
via safe output (monitoring range 8).
Fig. 14-3: Interface X40, circuit example 3
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14.4 Checklist for robot and system
Precondition ? Mechanical and electrical installation of the robot system have been com-
pleted.
? KUKA.SafeRobot is configured.
Checklist ? Serial number of the robot: ____________________
? Time stamp of the configuration window: ____________________
By signing, the signatory confirms the correct and complete performance of 
the safety acceptance test.
No. Activity Yes
Not 
relevant
1 Robot and tool are in flawless mechanical 
condition and correctly installed? - - -
2 The permissible rated payload of the robot has 
not been exceeded? - - -
3 All connections and connectors are in flawless 
condition? - - -
4 All connecting cables are in flawless condition 
and connected correctly? - - -
5 The system meets all the relevant laws, regu-
lations and norms valid for the installation 
site?
- - -
6 All system safety equipment is in flawless con-
dition and in good working order? - - -
7 All safety equipment used corresponds to the 
safety level required in the system? - - -
8 Ground conductor connection on robot con-
troller and on robot has beenchecked in 
accordance with DIN EN 60204-1 and is in 
good working order?
- - -
Place, date
Signature
102 / 123 V6.2 03.08.2007 KST-AD-SafeRobot11 en
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14. Appendix
14.5 Checklist for safe functions
Precondition ? Mechanical and electrical installation of the robot system have been com-
pleted.
? KUKA.SafeRobot is configured.
Checklist ? Serial number of the robot: ____________________
? Time stamp of the configuration window: ____________________
No
.
Activity
Ye
s
Not 
relevant
1 The machine data $ROBCOR.DAT and 
$MACHINE.DAT have been checked and match 
the robot used?
- - -
Designation of the robot on the rating plate is iden-
tical to the value in the system variable $TRAFO-
NAME[].
- - -
All data in $ROBCOR.DAT and $MACHINE.DAT 
are identical to the data on the CD supplied.
User-specific changes must be taken into consid-
eration.
- - -
2 All configuration data have been transferred to the 
SafeRDC and confirmed?
 (>>> 8.2 "Verifying safety parameters" page 67)
- - -
3 Robot is mastered? - - -
4 The reference position has been taught in the pro-
gram for the mastering test and in the configura-
tion window?
- - -
5 Was the mastering test successful? - - -
6 Message “Ackn. Safety mode not possible” 
acknowledged? - - -
7 Was the brake test successful? - - -
8 The correct configuration of the monitoring ranges 
used was checked by moving to all the axis limits?
The checklist (>>> 14.9 "Checklist for configura-
tion of the monitoring ranges" page 109) must be 
completed and confirmed in writing for each moni-
toring range used.
- - -
Monitoring range 1
Monitoring range 2
Monitoring range 3
Monitoring range 4
Monitoring range 5
Monitoring range 6
Monitoring range 7
Monitoring range 8
Monitoring range 9
Monitoring range 10
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No Ye Not 
By signing, the signatory confirms the correct and complete performance of 
the safety acceptance test.
9 The correct configuration of the reduced velocities 
has been checked?
The checklist (>>> 14.6 "Checklist for reduced 
velocities" page 105) must be completed and con-
firmed in writing for the reduced velocities.
10 The correct configuration of the reduced accelera-
tions has been checked?
The checklist (>>> 14.7 "Checklist for reduced 
accelerations" page 106) must be completed and 
confirmed in writing for the reduced accelerations.
11 The correct configuration of the standstill monitor-
ing has been checked?
The checklist (>>> 14.8 "Checklist for standstill 
monitoring" page 107) must be completed and 
confirmed in writing for the standstill monitoring.
12 The input test pulse in the safety parameter 'Inter-
faces' has been set to TRUE? - - -
13 Output OUT_STATUS safely monitored?
Place, date
Signature
.
Activity
s relevant
104 / 123 V6.2 03.08.2007 KST-AD-SafeRobot11 en
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14. Appendix
14.6 Checklist for reduced velocities
Precondition ? Mechanical and electrical installation of the robot system have been com-
pleted.
? KUKA.SafeRobot is configured.
? A test program has been created that successively violates the configured 
limit values to verify the correct functioning of the KUKA.SafeRobot moni-
toring function.
Checklist ? Serial number of the robot: ____________________
? Time stamp of the configuration window: ____________________
By signing, the signatory confirms the correct and complete performance of 
the safety acceptance test.
No
.
Activity
Ye
s
Not 
relevant
1 The configuration of the Cartesian velocity has 
been checked and is correct?
Value determined: __________ mm/s
Configured value: __________ mm/s
2 The configuration of the Cartesian velocity for T1 
has been checked and is correct? - - -
Value determined: __________ mm/s
Configured value: __________ mm/s
3 The configuration of the reduced axis velocity has 
been checked and is correct?
Value for axis 1: __________ °/s or mm/s
Value for axis 2: __________ °/s
Value for axis 3: __________ °/s
Value for axis 4: __________ °/s
Value for axis 5: __________ °/s
Value for axis 6: __________ °/s
Value for axis 7: __________ °/s or mm/s
Value for axis 8: __________ °/s or mm/s
4 The configuration of the reduced axis velocity for 
T1 has been checked and is correct?
Value for axis 1: __________ °/s or mm/s
Value for axis 2: __________ °/s
Value for axis 3: __________ °/s
Value for axis 4: __________ °/s
Value for axis 5: __________ °/s
Value for axis 6: __________ °/s
Value for axis 7: __________ °/s or mm/s
Value for axis 8: __________ °/s or mm/s
Place, date
Signature
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14.7 Checklist for reduced accelerations
Precondition ? Mechanical and electrical installation of the robot system have been com-
pleted.
? KUKA.SafeRobot is configured.
Checklist ? Serial number of the robot: ____________________
? Time stamp of the configuration window: ____________________
By signing, the signatory confirms the correct and complete performance of 
the safety acceptance test.
No. Activity Yes
Not 
relevant
1 The configuration of the reduced axis acceler-
ation has been checked and is correct?
Value for axis 1: __________ °/s² or mm/s²
Value for axis 2: __________ °/s²
Value for axis 3: __________ °/s²
Value for axis 4: __________ °/s²
Value for axis 5: __________ °/s²
Value for axis 6: __________ °/s²
Value for axis 7: __________ °/s² or mm/s²
Value for axis 8: __________ °/s² or mm/s²
2 The configuration of the reduced axis acceler-
ation for T1 has been checked and is correct?
Value for axis 1: __________ °/s² or mm/s²
Value for axis 2: __________ °/s²
Value for axis 3: __________ °/s²
Value for axis 4: __________ °/s²
Value for axis 5: __________ °/s²
Value for axis 6: __________ °/s²
Value for axis 7: __________ °/s² or mm/s²
Value for axis 8: __________ °/s² or mm/s²
Place, date
Signature
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14. Appendix
14.8 Checklist for standstill monitoring
Precondition ? Mechanical and electrical installation of the robot system have been com-
pleted.
? KUKA.SafeRobot is configured.
? Standstill monitoring is active.
? T2 mode is set.
Checklist ? Serial number of the robot: ____________________
? Time stamp of the configuration window: ____________________
The configured limit values for all axes must successively be violated in the 
positive and negative direction in order to demonstrate the correct functioning 
of the standstill monitoring.
Danger!
The robot moves in T2 mode at the programmed velocity and can cause per-
sonal injury or material damage. Make sure that the robot cannot collide and 
that no persons are in the motion range of the robot.
No. Activity Yes
Not 
relevant
1 Axis 1 has been correctly configured and 
checked?
Determined positive axis angle tolerance: 
__________ ° or mm
Determined negative axis angle tolerance: 
__________ ° or mm
Configured axis angle tolerance: __________ 
° or mm
2 Axis 2 has been correctly configured and 
checked?
Determined positive axis angle tolerance: 
__________ °
Determined negative axis angle tolerance: 
__________ °
Configured axis angle tolerance: __________ 
°
3 Axis 3 has been correctly configured and 
checked?
Determined positive axis angle tolerance: 
__________ °
Determined negative axis angle tolerance: 
__________ °
Configured axis angle tolerance: __________ 
°
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Not 
By signing, the signatory confirms the correct and complete performance of 
the safety acceptance test.
4 Axis 4 has been correctly configured and 
checked?
Determined positive axis angle tolerance: 
__________ °
Determined negativeaxis angle tolerance: 
__________ °
Configured axis angle tolerance: __________ 
°
5 Axis 5 has been correctly configured and 
checked?
Determined positive axis angle tolerance: 
__________ °
Determined negative axis angle tolerance: 
__________ °
Configured axis angle tolerance: __________ 
°
6 Axis 6 has been correctly configured and 
checked?
Determined positive axis angle tolerance: 
__________ °
Determined negative axis angle tolerance: 
__________ °
Configured axis angle tolerance: __________ 
°
7 Axis 7 has been correctly configured and 
checked?
Determined positive axis angle tolerance: 
__________ ° or mm
Determined negative axis angle tolerance: 
__________ ° or mm
Configured axis angle tolerance: __________ 
° or mm
8 Axis 8 has been correctly configured and 
checked?
Determined positive axis angle tolerance: 
__________ ° or mm
Determined negative axis angle tolerance: 
__________ ° or mm
Configured axis angle tolerance: __________ 
° or mm
Place, date
Signature
No. Activity Yes
relevant
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14. Appendix
14.9 Checklist for configuration of the monitoring ranges
Precondition ? Mechanical and electrical installation of the robot system have been com-
pleted.
? KUKA.SafeRobot is configured.
? The monitoring range to be checked is activated. All other monitoring rang-
es are deactivated.
? T2 mode is set.
Checklist ? Serial number of the robot: ____________________
? Time stamp of the configuration window: ____________________
? Monitoring range checked: __________
? Range inversion (TRUE|FALSE): __________
The configured limit values must successively be violated to demonstrate the 
correct functioning of the monitoring ranges.
? Monitoring range 2 to 7: robot must stop at the limit.
? Monitoring range 8 to 10: level of the output must switch to LOW.
Danger!
The robot moves in T2 mode at the programmed velocity and can cause per-
sonal injury or material damage. Make sure that the robot cannot collide and 
that no persons are in the motion range of the robot.
No. Activity Yes
Not 
relevant
1 Axis 1 has been correctly configured and 
checked?
Determined lower axis limit: __________ ° or 
mm
Configured lower axis limit: __________ ° or 
mm
Determined upper axis limit: __________ ° or 
mm
Configured upper axis limit: __________ ° or 
mm
2 Axis 2 has been correctly configured and 
checked?
Determined lower axis limit: __________ °
Configured lower axis limit: __________ °
Determined upper axis limit: __________ °
Configured upper axis limit: __________ °
3 Axis 3 has been correctly configured and 
checked?
Determined lower axis limit: __________ °
Configured lower axis limit: __________ °
Determined upper axis limit: __________ °
Configured upper axis limit: __________ °
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Not 
The following preconditions must be met to demonstrate the correct function-
ing of the reference stop.
? Reference stop is activated.
? Mastering test is requested.
? Checked monitoring range is not violated.
? Robot stops with a reference stop.
4 Axis 4 has been correctly configured and 
checked?
Determined lower axis limit: __________ °
Configured lower axis limit: __________ °
Determined upper axis limit: __________ °
Configured upper axis limit: __________ °
5 Axis 5 has been correctly configured and 
checked?
Determined lower axis limit: __________ °
Configured lower axis limit: __________ °
Determined upper axis limit: __________ °
Configured upper axis limit: __________ °
6 Axis 6 has been correctly configured and 
checked?
Determined lower axis limit: __________ °
Configured lower axis limit: __________ °
Determined upper axis limit: __________ °
Configured upper axis limit: __________ °
7 Axis 7 has been correctly configured and 
checked?
Determined lower axis limit: __________ ° or 
mm
Configured lower axis limit: __________ ° or 
mm
Determined upper axis limit: __________ ° or 
mm
Configured upper axis limit: __________ ° or 
mm
8 Axis 8 has been correctly configured and 
checked?
Determined lower axis limit: __________ ° or 
mm
Configured lower axis limit: __________ ° or 
mm
Determined upper axis limit: __________ ° or 
mm
Configured upper axis limit: __________ ° or 
mm
No. Activity Yes
relevant
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14. Appendix
No Ye Not 
By signing, the signatory confirms the correct and complete performance of 
the safety acceptance test.
.
Activity
s relevant
9 The correct functioning of the reference stop has 
been checked?
Place, date
Signature
111 / 12303.08.2007 KST-AD-SafeRobot11 en
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14.10 Applied norms and directives
The functional safety of KUKA.SafeRobot complies with the specifications of 
Category 3 in accordance with EN 954-1.
112 / 123 V6.2 03.08.2007 KST-AD-SafeRobot11 en
V6.2
15. KUKA Service
15 KUKA Service
15.1 Requesting support
Introduction The KUKA Robot Group documentation offers information on operation and 
provides assistance with troubleshooting. For further assistance, please con-
tact your local KUKA subsidiary.
Information The following information is required for processing a support request:
? Model and serial number of the robot
? Model and serial number of the controller
? Model and serial number of the linear unit (if applicable)
? Version of the KUKA System Software
? Optional software or modifications
? Archive of the software
? Application used
? Any external axes used
? Description of the problem, duration and frequency of the fault
15.2 KUKA Customer Support
Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.
Argentina Ruben Costantini S.A. (Agency)
Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com
Australia Marand Precision Engineering Pty. Ltd. (Agency)
153 Keys Road
Moorabbin
Victoria 31 89
Australia
Tel. +61 3 8552-0600
Fax +61 3 8552-0605
robotics@marand.com.au
Faults leading to production downtime are to be reported to the local KUKA 
subsidiary within one hour of their occurrence.
113 / 12303.08.2007 KST-AD-SafeRobot11 en
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Austria KUKA Roboter GmbH
Vertriebsbüro Österreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
office@kuka-roboter.at
www.kuka-roboter.at
Belgium KUKA Automatisering + Robots N.V.
Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
info@kuka.be
www.kuka.be
Brazil KUKA Roboter do Brasil Ltda.
Avenida Franz Liszt, 80
Parque Novo Mundo
Jd. Guançã
CEP 02151 900 São Paulo
SP Brazil
Tel. +55 11 69844900
Fax +55 11 62017883
info@kuka-roboter.com.br
Chile Robotec S.A. (Agency)
Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
robotec@robotec.cl
www.robotec.cl
China KUKA Flexible Manufacturing Equipment (Shanghai) Co., Ltd.
Shanghai Qingpu Industrial Zone
No. 502 Tianying Rd.
201712 Shanghai
P.R. China
Tel. +86 21 5922-8652
Fax +86 21 5922-8538
Franz.Poeckl@kuka-sha.com.cn
www.kuka.cn
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15. KUKA Service
France KUKA Automatisme + Robotique SAS
Techvallée
6 Avenue du Parc
91140 Villebon s/Yvette
France
Tel. +33 1 6931-6600
Fax +33 1 6931-6601
commercial@kuka.fr
www.kuka.fr
Germany KUKA Roboter GmbH
Blücherstr. 144
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
info@kuka-roboter.de
www.kuka-roboter.de
Hungary KUKA Robotics Hungaria Kft.
Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.huIndia KUKA Robotics, Private Limited
621 Galleria Towers
DLF Phase IV
122 002 Gurgaon
Haryana
India
Tel. +91 124 4148574
info@kuka.in
www.kuka.in
Italy KUKA Roboter Italia S.p.A.
Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
kuka@kuka.it
www.kuka.it
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Korea KUKA Robot Automation Korea Co. Ltd.
4 Ba 806 Sihwa Ind. Complex
Sung-Gok Dong, Ansan City
Kyunggi Do
425-110
Korea
Tel. +82 31 496-9937 or -9938
Fax +82 31 496-9939
info@kukakorea.com
Malaysia KUKA Robot Automation Sdn Bhd
South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 3 8061-0613 or -0614
Fax +60 3 8061-7386
info@kuka.com.my
Mexico KUKA de Mexico S. de R.L. de C.V.
Rio San Joaquin #339, Local 5
Colonia Pensil Sur
C.P. 11490 Mexico D.F.
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx
Norway KUKA Sveiseanlegg + Roboter
Bryggeveien 9
2821 Gjövik
Norway
Tel. +47 61 133422
Fax +47 61 186200
geir.ulsrud@kuka.no
Portugal KUKA Sistemas de Automatización S.A.
Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
kuka@mail.telepac.pt
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15. KUKA Service
Russia KUKA-VAZ Engineering
Jushnoje Chaussee, 36 VAZ, PTO
445633 Togliatti
Russia
Tel. +7 8482 391249 or 370564
Fax +7 8482 736730
Y.Klychkov@VAZ.RU
South Africa Jendamark Automation LTD (Agency)
76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za
Spain KUKA Sistemas de Automatización S.A.
Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 814-2353
Fax +34 93 814-2950
Comercial@kuka-e.com
www.kuka-e.com
Sweden KUKA Svetsanläggningar + Robotar AB
A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
info@kuka.se
Switzerland KUKA Roboter Schweiz AG
Riedstr. 7
8953 Dietikon
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
info@kuka-roboter.ch
www.kuka-roboter.ch
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Taiwan KUKA Robot Automation Taiwan Co. Ltd.
136, Section 2, Huanjung E. Road
Jungli City, Taoyuan
Taiwan 320
Tel. +886 3 4371902
Fax +886 3 2830023
info@kuka.com.tw
www.kuka.com.tw
Thailand KUKA Robot Automation (M)SdnBhd
Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
atika@ji-net.com
www.kuka-roboter.de
UK KUKA Automation + Robotics
Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
sales@kuka.co.uk
USA KUKA Robotics Corp.
22500 Key Drive
Clinton Township
48036 Michigan
USA
Tel. +1 866 8735852
Fax +1 586 5692087
info@kukarobotics.com
www.kukarobotics.com
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Index
Index
Symbols
/TA24A, pulse duty factor 36
/TA24V, pulse duration T(HIGH) 35, 36
/TA24V, pulse duration T(LOW) 35, 36
/TA24V, pulse duty factor 35
A
Acceleration monitoring 14
Accuracy requirements, reference position 41
Actuating plate, hole pattern 39
Altitude 37
Ambient temperature 37
Ambient temperature, reference switch 37
Appendix 99
Archiving safety parameters 68
Areas of application 11
Assigning input signals 49
Assigning output signals 49
Atmospheric humidity 37
Availability, robots 43
Axes, decouplable 18, 41
Axes, synchronous 41
Axis acceleration 55
Axis acceleration for T1 55
Axis angle tolerance 58
Axis limits 8, 13, 14
Axis lower bound 56
Axis number 51
Axis range monitoring 56
Axis ranges 8, 13, 14
Axis upper bound 56
Axis velocity 54
Axis velocity for T1 54
Axis-specific monitoring ranges, defining 49
B
Brake test 8
Brake test cycle time 8, 19
Brake test, external axes 62
Brake test, overview 18
Brake test, programming 63
Brake test, robot axes 62
Brake test, safety 41
Brake test, signals 74
Brake, defective 42
BrakeTestDrv.INI, variables 75
Braking distance 8
C
Cable carrier 42
Cable length, data cable X21 - X31 37
Cables, safety 42
Cartesian position X 57
Cartesian position Y 57
Cartesian position Z 57
Cartesian velocity 41, 54
Checking the reference position 61
Checklists, acceptance 102, 103, 105, 106, 107, 
109
Circuit example, X40 99, 100, 101
Components 22
Connecting cables, connecting 47
Connecting cables, overview 25
Connecting the connecting cables 47
Connection, electronic measuring tool 26
Connections, I/O Print board 94
Connections, SafeRDC board 93
Connections, SafeRDC box 26
Connector pin allocation X40 30
Connector pin assignment, data cable X21 - X31 
27
Connector pin assignment, data cable X21.1 - X41 
27
Connector pin assignment, reference cable X42 - 
XS Ref 28
Criteria, reference position 17
Current position, reference position 52
D
Decouplable axes 18, 41
Defective brake 42
Defining ranges 49
Degree of fouling 37
Description, signal declarations 49, 71
Detailed information, monitoring range 87
Diagnosis 85
Diagnosis, overview 85
Diagnosis, signals 72
Digital input 56
Digital output 57
Directives 112
Displaying safety parameters 67
Documentation, robot system 7
E
E_DV 22
E_HALT 22
E0 21
E0...E5 21
E1 21
E2 21
E3 21
E4 21
E5 21
Electromagnetic compatibility 37
Electronic measuring tool, connection 26
EMC conformity, reference switch 38
EN 954-1, Category 3 112
Exchanging the tool 41
External axes, brake test 41, 62
External axes, reference group 59
F
Fixed installation 42
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Flag 43 Messages, brake test 82
Flange center point velocity 55
Flange center point velocity for T1 55
Functional principle 12
Functions, KUKA.SafeRobot 11
Functions, SafeRDC 23
G
General information 54
H
Hardware 43
Hardware components 22
Hardware components, scope of supply 22
Hole pattern, actuating plate 39
Hole pattern, reference switch 38
Hysteresis, reference switch 38
I
I/O Print board, connections 94
I/O Print board, installing 96
I/O Print board, LEDs 92
I/O Print board, removing 96
Input signals 49
Input test pulse 8, 58
Installation 43
Installation, fixed 42
Installation, KUKA.SafeRobot 43
Installing the actuating plate 46
Installing the I/O Print board 96
Installing the reference switch 46
Installing the SafeRDC board 97
Interface X40 29
Interfaces 58
Interrupt 43
Introduction 7
Inversion 12
K
Knowledge, required 7
KUKA Customer Support 113
KUKA.SafeRobot overview 11
L
LEDs, I/O Print board 92
LEDs, SafeRDC board 89
Level, safe outputs 12
M
Machine data ($MACHINE.DAT) 59
Machine data ($ROBCOR.DAT) 58
Maintenance, personnel 41
Master position, reference position 52
Mastering test 8
Mastering test, overview 16
Mastering test, performing manually 61
Mastering test, programming 60
Mastering test, safety 41
Mastering test, signals 71
Messages 77
Messages, operation 77
Messages, verification of the safety parameters 81
Min. distance, reference position 52
Module a, X40 29, 30
Module b, X40 29, 31
Module c, X40 29, 32
Module d, X40 29, 33
Monitored axes 54
Monitoring axis acceleration 55
Monitoring axis acceleration for T1 55
Monitoring functions that can be activated 21
Monitoring of mastering 57
Monitoring range 9
Monitoring ranges 12
Monitoring ranges, overview 86
Monitoring ranges, status 86
Monitoring time 8, 19
N
Norms 112
O
Opening SafeRobot diagnosis 85
Operating current, reference switch 37
Operating hours meter, reading 68
Operating voltage, reference switch 37
Operation 67
Operation, safety 42
Optocoupler 48
OUT_A0 22
OUT_A1 22
OUT_A2 22
OUT_STATUS16, 22
Output signals 49
Outputs, reference switch 38
Overview of connecting cables 25
Overview of safety parameters 52
Overview of the brake test 18
Overview, KUKA.SafeRobot 11
Overview, mastering test 16
P
Parameters, axes 75
Parking position 8, 19
Parking position, velocity 41
Performing a manual brake test 63
Permissible load current, reference switch 37
Permissible switching distance, reference switch 
38
Permissible switching frequency, reference switch 
37
Personnel, safety 41
Product description 11
Programming 65
Programming the brake test 63
Programming the mastering test 60
Programs, brake test 65
Programs, mastering test 65
Protection classification 37
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Index
Pulse duration T(HIGH), /TA24V 35, 36 Service, KUKA Roboter 113
Pulse duration T(LOW), /TA24V 35, 36
Pulse duration, reference switch 37
Pulse duty factor, /TA24V 35, 36
Pulse duty factor, reference switch 37
R
Range inversion 56
Reaction distance 8
Reactions, robot 12
Reduced axis acceleration 55
Reduced axis velocity 54
Reference group 8, 24, 51, 57
Reference group, external axes 59
Reference position 9, 17, 52, 57
Reference position, defining 50
Reference stop 9, 14, 57
Reference switch 9
Reference switch, installation 46
Reference switch, technical data 37
Removing the I/O Print board 96
Removing the SafeRDC board 94
Repairs, personnel 41
Restoring safety parameters 68
Retraction, robot 21
Robot axes, brake test 41, 62
Robot status signals 73
Robot system, safety 41
S
Safe axis monitoring 54
Safe field bus module 48
Safe field bus system 48
Safe inputs 33
Safe outputs 35
Safe outputs, load rating 29
Safe robot retraction 21
SafeRDC 22
SafeRDC board, connections 93
SafeRDC board, installing 97
SafeRDC board, LEDs 89
SafeRDC board, removing 94
SafeRDC box 28
SafeRDC box, connections 26
SafeRDC lid, exchanging 47
SafeRDC, technical data 37
Safety 41
Safety acceptance, KUKA.SafeRobot 42, 64
Safety instructions 7
Safety parameters 41
Safety parameters, archiving 68
Safety parameters, displaying 67
Safety parameters, overview 52
Safety parameters, restoring 68
Safety parameters, setting 53
Safety parameters, verifying 67
Safety PLC 48
Safety PLC, connecting 48
Safety zones 9, 12, 14
Service life, SafeRDC 41
Shock sensitivity 37
Signal declarations 71
Signal diagram, brake test 20
Signal diagram, mastering test 18
Signals for the brake test 74
Signals, diagnosis 72
Signals, mastering test 71
Signals, robot status 73
Software components 22
Software components, scope of supply 22
Standstill monitoring 9, 15, 57
Start-up 45
Start-up, overview 45
Start-up, personnel 41
Start-up, safety 42
STOP 0 9
STOP 1 9
STOP 2 9
Stop reactions 13, 15
Stopping distance 8
Supply voltage 37
Support request 113
Switching function, reference switch 37
Synchronous axes 41
System requirements 43
System variables 71
T
Target group 7
Technical data 37
Technical data, reference switch 37
Technical data, SafeRDC 37
Terms 8
Terms used 8
Time stamp 54
Tool, exchanging 41
Training program 7
Troubleshooting 89
U
Uninstalling KUKA.SafeRobot 43
Update, KUKA.SafeRobot 43
V
Variables, BrakeTestDrv.INI 75
Velocity monitoring 14
Velocity, Cartesian 41
Verifying safety parameters 67
Version 54
Vibration resistance 37
W
Warnings 7
Wiring diagram, reference group 28
Workspaces 8, 12, 13
X
X40 circuit example 99, 100, 101
X40, connector pin allocation 30
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X40, interface 29
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	KUKA.SafeRobot 1.1
	1 Introduction
	1.1 Target group
	1.2 Robot system documentation
	1.3 Representation of warnings and notes
	Safety
	Notes
	1.4 Terms used
	2 Product description
	2.1 KUKA.SafeRobot overview
	Functions
	Areas of application
	Communication
	2.2 Functional principle
	Description
	2.3 Monitoring ranges
	Description
	Inversion
	Stop reactions
	2.3.1 Workspaces
	Description
	Example
	2.3.2 Safety zones
	Description
	Example
	2.3.3 Reference stop
	Description
	2.4 Velocity and acceleration monitoring
	Description
	Stop reactions
	2.5 Standstill monitoring
	Description
	Stop reactions
	2.6 Safe state (output OUT_STATUS)
	Description
	2.7 Mastering test
	Description
	2.7.1 Reference position
	2.7.2 Mastering test signal diagram
	2.8 Brake test
	Description
	2.8.1 Parking position
	2.8.2 Signal diagram of the brake test
	2.9 T1 mode (safe robot retraction)
	Description
	2.10 Monitoring functions that can be activated
	Description
	2.11 Components
	Software
	Hardware
	2.11.1 SafeRDC
	Description
	Functions
	2.11.2 Reference group
	Description
	2.12 Connecting cables
	Overview
	2.12.1 Connections on the SafeRDC box
	Overview
	2.12.2 Connections on the SafeRDC box (optional)
	Description
	Overview
	2.12.3 Connector pin assignment of data cable X21 - X31
	Description
	2.12.4 Connector pin assignment of data cable X21.1 - X41
	Description
	2.12.5 Connector pin assignment of reference cable X42 - XS Ref
	Description
	2.12.6 Wiring diagram for 3 reference groups (optional)
	Description
	2.13 Interface X40
	Overview
	Module a
	Module b
	Module c
	Module d
	2.13.1 Connector pin allocation X40
	Module a
	Module b
	Module c
	Module d
	2.13.2 Safe inputs
	Description
	Overview
	Characteristics
	2.13.3 Safe outputs
	Description
	Overview
	Characteristics
	3 Technical data
	3.1 Technical data of the SafeRDC
	3.2 Reference switch
	3.3 Reference switch hole pattern
	Description
	3.4 Hole pattern for actuating plate
	Description
	4 Safety
	Personnel
	Robot system
	Mastering test
	Brake test
	Cables
	Start-up
	Operation
	5 Installation
	5.1 System requirements
	Hardware
	Software
	5.2 Installing or updating KUKA.SafeRobot
	Precondition
	Procedure
	LOG file
	5.3 Uninstalling KUKA.SafeRobot
	Precondition
	Procedure
	LOG file
	6 Start-up
	6.1 Start-up overview
	Overview
	6.2 Installing the reference switch and actuating plate
	Precondition
	Procedure
	Example
	6.3 Exchanging the lid of the SafeRDC box
	Precondition
	Procedure
	6.4 Connecting the connecting cables
	Precondition
	Procedure
	6.5 Connecting the Safety PLC
	Description
	6.6 Assigning input and output signals
	Description
	Example
	6.7 Defining axis-specific monitoring ranges
	Precondition
	Procedure
	Description
	6.8 Defining the reference position
	Precondition
	Procedure
	6.9 Safety parameters
	Description
	6.9.1 Setting safety parameters
	Precondition
	Procedure
	6.9.2 Parameters - General information
	Description
	6.9.3 Parameters - Monitored axes
	Description
	6.9.4 Parameters - Reduced axis velocity
	Description
	6.9.5 Parameters - Cartesian velocity
	Description
	6.9.6 Parameters - Reduced axis acceleration
	Description
	6.9.7 Parameters - Axis range monitoring
	Description
	6.9.8 Parameters - Monitoring of mastering
	Description
	6.9.9 Parameters - Standstill monitoring
	Description
	6.9.10 Parameters - Interfaces
	Description
	6.9.11 Parameters - Machine data ($ROBCOR.DAT)
	Description
	6.9.12 Parameters - Machine data ($MACHINE.DAT)
	Description
	6.10 Assigning external axes to the reference group
	Description
	Precondition
	Procedure
	6.11 Programming the mastering test
	Precondition
	Procedure
	6.12 Checking the reference position (actuation with tool)
	Precondition
	Procedure
	6.13 Performing a mastering test manually
	Precondition
	Procedure
	6.14 Configuring robot axes for the brake test
	6.15 Configuring external axes for the brake test
	Precondition
	Procedure
	6.16 Programming the brake test
	Precondition
	Procedure
	6.17 Performing a manual brake test
	Precondition
	Procedure6.18 Safety acceptance of KUKA.SafeRobot
	Description
	7 Programming
	7.1 Programs for the mastering test
	Description
	7.2 Programs for the brake test
	Description
	8 Operation
	8.1 Displaying safety parameters
	Precondition
	Procedure
	8.2 Verifying safety parameters
	Description
	Procedure
	8.3 Reading the operating hours meter
	Procedure
	8.4 Archiving safety parameters
	Voraussetzung
	Procedure
	8.5 Restoring safety parameters
	Precondition
	Procedure
	9 System variables
	9.1 Signal declarations
	Description
	9.2 Signals for the mastering test
	9.3 Signals for diagnosis
	9.4 Robot status signals
	9.5 Signals for the brake test
	9.6 Variables in BrakeTestDrv.INI
	Description
	10 Messages
	10.1 Messages during operation
	10.2 Messages during verification of the safety parameters
	10.3 Messages for the brake test
	11 Diagnosis
	11.1 Opening diagnosis
	Precondition
	Procedure
	11.2 Overview of diagnosis
	Overview
	Description
	11.2.1 Overview of the monitoring ranges
	Overview
	Description
	11.2.2 Detailed information about the monitoring range
	Overview
	Description
	12 Troubleshooting
	12.1 LEDs on the SafeRDC board
	Description
	12.2 LEDs on the I/O Print board
	Description
	13 Repair
	13.1 Connections on the SafeRDC board
	Description
	13.2 Connections on the I/O Print board
	Description
	13.3 Removing the SafeRDC board
	Precondition
	Procedure
	13.4 Removing the I/O Print board
	Precondition
	Procedure
	13.5 Installing the I/O Print board
	Precondition
	Procedure
	13.6 Installing the SafeRDC board
	Precondition
	Procedure
	14 Appendix
	14.1 Interface X40 circuit example 1
	14.2 Interface X40 circuit example 2
	14.3 Interface X40 circuit example 3
	14.4 Checklist for robot and system
	Precondition
	Checklist
	14.5 Checklist for safe functions
	Precondition
	Checklist
	14.6 Checklist for reduced velocities
	Precondition
	Checklist
	14.7 Checklist for reduced accelerations
	Precondition
	Checklist
	14.8 Checklist for standstill monitoring
	Precondition
	Checklist
	14.9 Checklist for configuration of the monitoring ranges
	Precondition
	Checklist
	14.10 Applied norms and directives
	15 KUKA Service
	15.1 Requesting support
	Introduction
	Information
	15.2 KUKA Customer Support
	Availability
	Index