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: