KUKA_System_Software_8.3_RMUTT

KUKA System Software KUKA Roboter GmbH KUKA System Software 8.3 Operating and Programming Instructions for RMUTT Only by Alex Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

KUKA System Software 8.3 © Copyright 2013 KUKA Roboter GmbH Zugspitzstraße 140 D-86165 Augsburg Germany This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of KUKA Roboter GmbH. Other functions not described in this documentation may be operable in the controller. The user has no claims to these functions, however, in the case of a replacement or service work. We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, how- ever, and necessary corrections will be incorporated in the subsequent edition. Subject to technical alterations without an effect on the function. Translation of the original documentation KIM-PS5-DOC Publication: Pub KSS 8.3 END (PDF) en Bookstructure: KSS 8.3 END V1.1 Version: KSS 8.3 END V1 en (PDF) 2 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

Contents Contents 11 1 Introduction .................................................................................................. 11 11 1.1 Target group .............................................................................................................. 11 1.2 Industrial robot documentation ................................................................................... 12 1.3 Representation of warnings and notes ...................................................................... 1.4 Trademarks ................................................................................................................ 13 2 Product description ..................................................................................... 13 13 2.1 Overview of the industrial robot ................................................................................. 14 2.2 Overview of KUKA System Software (KSS) .............................................................. 14 2.3 System requirements ................................................................................................. 14 2.4 Intended use of the KUKA System Software ............................................................. 2.5 KUKA USB sticks ....................................................................................................... 17 3 Safety ............................................................................................................ 17 17 3.1 General ...................................................................................................................... 17 3.1.1 Liability .................................................................................................................. 18 3.1.2 Intended use of the industrial robot ...................................................................... 18 3.1.3 EC declaration of conformity and declaration of incorporation ............................. 20 3.1.4 Terms used ........................................................................................................... 22 3.2 Personnel ................................................................................................................... 22 3.3 Workspace, safety zone and danger zone ................................................................. 23 3.4 Triggers for stop reactions ......................................................................................... 23 3.5 Safety functions ......................................................................................................... 24 3.5.1 Overview of the safety functions ........................................................................... 24 3.5.2 Safety controller .................................................................................................... 25 3.5.3 Mode selection ...................................................................................................... 25 3.5.4 Operator safety ..................................................................................................... 26 3.5.5 EMERGENCY STOP device ................................................................................ 26 3.5.6 Logging off from the higher-level safety controller ................................................ 27 3.5.7 External EMERGENCY STOP device .................................................................. 27 3.5.8 Enabling device .................................................................................................... 27 3.5.9 External enabling device ....................................................................................... 27 3.5.10 External safe operational stop .............................................................................. 28 3.5.11 External safety stop 1 and external safety stop 2 ................................................. 28 3.5.12 Velocity monitoring in T1 and CRR ....................................................................... 28 3.6 Additional protective equipment ................................................................................. 28 3.6.1 Jog mode .............................................................................................................. 28 3.6.2 Software limit switches ......................................................................................... 28 3.6.3 Mechanical end stops ........................................................................................... 29 3.6.4 Mechanical axis range limitation (optional) ........................................................... 29 3.6.5 Axis range monitoring (optional) ........................................................................... 30 3.6.6 Devices for moving the manipulator without the robot controller (options) ........... 31 3.6.7 Labeling on the industrial robot ............................................................................. 31 3.6.8 External safeguards .............................................................................................. 32 3.7 Overview of operating modes and safety functions ................................................... 32 3.8 Safety measures ........................................................................................................ 3.8.1 General safety measures ...................................................................................... 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KUKA System Software 8.3 33 33 3.8.2 Transportation ...................................................................................................... 34 35 3.8.3 Start-up and recommissioning .............................................................................. 36 37 3.8.3.1 Checking machine data and safety-relevant control configuration ....................... 37 37 3.8.3.2 Start-up mode ....................................................................................................... 39 39 3.8.4 Manual mode ........................................................................................................ 40 3.8.5 Simulation ............................................................................................................. 43 3.8.6 Automatic mode ................................................................................................... 43 43 3.8.7 Maintenance and repair ........................................................................................ 45 46 3.8.8 Decommissioning, storage and disposal .............................................................. 47 3.8.9 Safety measures for “single point of control” ........................................................ 48 49 3.9 Applied norms and regulations .................................................................................. 50 50 4 Operation ...................................................................................................... 50 51 4.1 KUKA smartPAD teach pendant ................................................................................ 54 54 4.1.1 Front view ............................................................................................................. 55 55 4.1.2 Rear view ............................................................................................................. 55 58 4.1.3 Disconnecting and connecting the smartPAD ...................................................... 59 60 4.2 KUKA smartHMI user interface ................................................................................. 61 62 4.2.1 Status bar ............................................................................................................. 63 4.2.2 “Submit interpreter” status indicator ..................................................................... 63 64 4.2.3 Keypad ................................................................................................................. 65 65 4.3 Switching on the robot controller and starting the KSS ............................................. 66 66 4.4 Calling the main menu ............................................................................................... 66 67 4.5 Exiting or restarting KSS ........................................................................................... 67 67 4.6 Switching the robot controller off ............................................................................... 69 70 4.7 Setting the user interface language ........................................................................... 71 72 4.8 Online documentation and online help ...................................................................... 4.8.1 Calling online documentation ............................................................................... 4.8.2 Calling online help ................................................................................................ 4.9 Changing user group ................................................................................................. 4.10 Changing operating mode ......................................................................................... 4.11 Coordinate systems ................................................................................................... 4.12 Jogging the robot ....................................................................................................... 4.12.1 “Jog options” window ............................................................................................ 4.12.1.1 “General” tab ........................................................................................................ 4.12.1.2 “Keys” tab ............................................................................................................. 4.12.1.3 “Mouse” tab .......................................................................................................... 4.12.1.4 “KCP pos.” tab ...................................................................................................... 4.12.1.5 “Cur. tool/base” tab ............................................................................................... 4.12.2 Activating the jog mode ........................................................................................ 4.12.3 Setting the jog override (HOV) ............................................................................. 4.12.4 Selecting the tool and base .................................................................................. 4.12.5 Axis-specific jogging with the jog keys ................................................................. 4.12.6 Cartesian jogging with the jog keys ...................................................................... 4.12.7 Configuring the Space Mouse .............................................................................. 4.12.8 Defining the alignment of the Space Mouse ......................................................... 4.12.9 Cartesian jogging with the Space Mouse ............................................................. 4.12.10 Incremental jogging .............................................................................................. 4.13 Jogging external axes 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Contents 4.14 Bypassing workspace monitoring .............................................................................. 72 4.15 Monitor functions ........................................................................................................ 73 4.15.1 Measuring and displaying energy consumption .................................................... 73 4.15.2 Displaying the actual position ............................................................................... 75 4.15.3 Displaying digital inputs/outputs ........................................................................... 75 4.15.4 Displaying analog inputs/outputs .......................................................................... 77 4.15.5 Displaying inputs/outputs for Automatic External ................................................. 77 4.15.6 Displaying cyclical flags ........................................................................................ 78 4.15.7 Displaying flags ..................................................................................................... 79 4.15.8 Displaying counters .............................................................................................. 80 4.15.9 Displaying timers .................................................................................................. 81 4.15.10 Displaying calibration data .................................................................................... 82 4.15.11 Displaying information about the robot and robot controller ................................. 83 4.15.12 Displaying/editing robot data ................................................................................ 83 5 Start-up and recommissioning ................................................................... 85 5.1 Start-up wizard ........................................................................................................... 85 5.2 Checking the machine data ....................................................................................... 85 5.3 Jogging the robot without a higher-level safety controller .......................................... 86 5.4 Checking the activation of the positionally accurate robot model .............................. 87 5.5 Mastering ................................................................................................................... 87 5.5.1 Mastering methods ............................................................................................... 88 5.5.2 Moving axes to the pre-mastering position ........................................................... 89 5.5.3 Mastering with the EMD ........................................................................................ 90 5.5.3.1 First mastering (with EMD) ................................................................................... 91 5.5.3.2 Teach offset (with EMD) ....................................................................................... 93 5.5.3.3 Check load mastering with offset (with EMD) ....................................................... 94 5.5.4 Mastering with the dial gauge ............................................................................... 95 5.5.5 Mastering external axes ........................................................................................ 97 5.5.6 Reference mastering ............................................................................................ 97 5.5.7 Mastering with the MEMD and mark ..................................................................... 98 5.5.7.1 First mastering (with MEMD) ................................................................................ 99 5.5.7.2 Teach offset (with MEMD) .................................................................................... 102 5.5.7.3 Check load mastering with offset (with MEMD) .................................................... 103 5.5.8 Manually unmastering axes .................................................................................. 105 5.6 Modifying software limit switches ............................................................................... 105 5.7 Calibration .................................................................................................................. 107 5.7.1 Tool calibration ..................................................................................................... 107 5.7.1.1 TCP calibration: XYZ 4-point method ................................................................... 109 5.7.1.2 TCP calibration: XYZ Reference method .............................................................. 111 5.7.1.3 Defining the orientation: ABC World method ........................................................ 112 5.7.1.4 Defining the orientation: ABC 2-point method ...................................................... 112 5.7.1.5 Numeric input ........................................................................................................ 114 5.7.2 Base calibration .................................................................................................... 114 5.7.2.1 3-point method ...................................................................................................... 115 5.7.2.2 Indirect method ..................................................................................................... 116 5.7.2.3 Indirect method ..................................................................................................... 117 5.7.3 Fixed tool calibration ............................................................................................. 118 5.7.3.1 Calibrating an external TCP .................................................................................. 118 5.7.3.2 Entering the external TCP 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KUKA System Software 8.3 120 121 5.7.3.3 Workpiece calibration: direct method ................................................................... 122 5.7.3.4 Workpiece calibration: indirect method ................................................................. 123 5.7.4 Renaming the tool/base ....................................................................................... 123 5.7.5 Linear unit ............................................................................................................. 124 5.7.5.1 Checking whether the linear unit needs to be calibrated ...................................... 125 5.7.5.2 Calibrating the linear unit ...................................................................................... 126 5.7.5.3 Entering the linear unit numerically ...................................................................... 126 5.7.6 Calibrating an external kinematic system ............................................................. 127 5.7.6.1 Calibrating the root point ...................................................................................... 128 5.7.6.2 Entering the root point numerically ....................................................................... 130 5.7.6.3 Workpiece base calibration .................................................................................. 130 5.7.6.4 Entering the workpiece base numerically ............................................................. 131 5.7.6.5 Calibrating an external tool ................................................................................... 132 5.7.6.6 Entering the external tool numerically .................................................................. 132 5.8 Load data ................................................................................................................... 132 5.8.1 Checking loads with KUKA.Load .......................................................................... 132 5.8.2 Calculating payloads with KUKA.LoadDataDetermination ................................... 133 5.8.3 Entering payload data .......................................................................................... 133 5.8.4 Entering supplementary load data ........................................................................ 134 5.8.5 Online load data check ......................................................................................... 136 5.9 Exporting/importing long texts ................................................................................... 136 5.10 Maintenance handbook ............................................................................................. 137 5.10.1 Logging maintenance ........................................................................................... 5.10.2 Displaying a maintenance log ............................................................................... 139 6 Program management ................................................................................. 139 140 6.1 Navigator file manager .............................................................................................. 140 6.1.1 Selecting filters ..................................................................................................... 141 6.1.2 Creating a new folder ........................................................................................... 141 6.1.3 Creating a new program ....................................................................................... 141 6.1.4 Renaming a file .................................................................................................... 142 6.2 Selecting or opening a program ................................................................................ 143 6.2.1 Selecting and deselecting a program ................................................................... 143 6.2.2 Opening a program .............................................................................................. 144 6.2.3 Toggling between the Navigator and the program ............................................... 145 6.3 Structure of a KRL program ....................................................................................... 145 6.3.1 HOME position ..................................................................................................... 145 6.4 Displaying/hiding program sections ........................................................................... 145 6.4.1 Displaying/hiding the DEF line .............................................................................. 146 6.4.2 Activating detail view ............................................................................................ 146 6.4.3 Activating/deactivating the line break function ...................................................... 146 6.5 Starting a program ..................................................................................................... 146 6.5.1 Selecting the program run mode .......................................................................... 147 6.5.2 Program run modes .............................................................................................. 147 6.5.3 Advance run ......................................................................................................... 147 6.5.4 Setting the program override (POV) ..................................................................... 148 6.5.5 Switching drives on/off .......................................................................................... 148 6.5.6 Robot interpreter status indicator ......................................................................... 6.5.7 Starting a program forwards (manual) .................................................................. 6.5.8 Starting a program forwards (automatic) 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Contents 6.5.9 Carrying out a block selection ............................................................................... 149 6.5.10 Starting a program backwards .............................................................................. 149 6.5.11 Resetting a program ............................................................................................. 150 6.5.12 Starting Automatic External mode ........................................................................ 150 6.6 Editing a program ....................................................................................................... 150 6.6.1 Inserting a comment or stamp .............................................................................. 152 6.6.2 Deleting program lines .......................................................................................... 152 6.6.3 Additional editing functions ................................................................................... 153 6.7 Printing a program ..................................................................................................... 153 6.8 Archiving and restoring data ...................................................................................... 153 6.8.1 Archiving overview ................................................................................................ 153 6.8.2 Archiving to a USB stick ....................................................................................... 155 6.8.3 Archiving on the network ...................................................................................... 155 6.8.4 Archiving the logbook ........................................................................................... 156 6.8.5 Restoring data ...................................................................................................... 156 6.8.6 Automatically compressing data for error analysis at KUKA ................................ 156 7 Basic principles of motion programming ................................................. 159 7.1 Overview of motion types ........................................................................................... 159 7.2 Motion type PTP ........................................................................................................ 159 7.3 Motion type LIN .......................................................................................................... 160 7.4 Motion type CIRC ....................................................................................................... 160 7.5 Approximate positioning ............................................................................................. 161 7.6 Orientation control LIN, CIRC .................................................................................... 162 7.7 Motion type “Spline” ................................................................................................... 163 7.7.1 Velocity profile for spline motions ......................................................................... 165 7.7.2 Block selection with spline motions ...................................................................... 166 7.7.3 Modifications to spline blocks ............................................................................... 167 7.7.4 Approximation of spline motions ........................................................................... 170 7.7.5 Replacing an approximated CP motion with a spline block .................................. 170 7.7.5.1 SLIN-SPL-SLIN transition ..................................................................................... 173 7.8 Orientation control for CP spline motions .................................................................. 174 7.8.1 Combinations of “Orientation control” and “Circle orientation control” .................. 176 7.9 Singularities ............................................................................................................... 177 8 Programming for user group “User” (inline forms) ................................. 179 8.1 Names in inline forms ................................................................................................ 179 179 8.2 Programming PTP, LIN and CIRC motions ............................................................... 179 180 8.2.1 Programming a PTP motion ................................................................................. 180 181 8.2.2 Inline form “PTP” ................................................................................................... 181 182 8.2.3 Programming a LIN motion ................................................................................... 182 183 8.2.4 Inline form “LIN” .................................................................................................... 184 184 8.2.5 Programming a CIRC motion ................................................................................ 8.2.6 Inline form “CIRC” ................................................................................................. 8.2.7 Option window “Frames” ...................................................................................... 8.2.8 Option window “Motion parameters” (LIN, CIRC, PTP) ...................................... 8.3 Programming spline motions ..................................................................................... 8.3.1 Programming tips for spline motions .................................................................... 8.3.2 Programming a spline block ................................................................................. 185 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 7 / 237

KUKA System Software 8.3 186 187 8.3.2.1 Inline form for CP spline block .............................................................................. 187 8.3.2.2 Inline form “PTP SPLINE block” .......................................................................... 188 8.3.2.3 Option window “Frames” (CP and PTP spline block) ........................................... 189 8.3.2.4 Option window “Motion parameters” (CP spline block) ...................................... 189 8.3.2.5 Option window “Motion parameters” (PTP spline block) .................................... 189 190 8.3.3 Programming segments for a spline block ........................................................... 190 191 8.3.3.1 Programming an SPL or SLIN segment ............................................................... 192 193 8.3.3.2 Programming an SCIRC segment ........................................................................ 193 194 8.3.3.3 Inline form for CP spline segment ........................................................................ 195 198 8.3.3.4 Programming an SPTP segment .......................................................................... 199 199 8.3.3.5 Inline form for SPTP segment .............................................................................. 199 8.3.3.6 Option window “Frames” (CP and PTP spline segments) ................................... 200 8.3.3.7 Option window “Motion parameters” (CP spline segment) ................................. 201 8.3.3.8 Option window “Motion parameters” (SPTP) ...................................................... 201 8.3.3.9 Option window “Logic parameters” ..................................................................... 203 204 8.3.3.10 Teaching the shift in space for logic parameters .................................................. 204 205 8.3.4 Programming individual spline motions ................................................................ 205 207 8.3.4.1 Programming an individual SLIN motion .............................................................. 208 8.3.4.2 Inline form “SLIN” ................................................................................................. 208 8.3.4.3 Option window “Motion parameters” (SLIN) ....................................................... 209 210 8.3.4.4 Programming an individual SCIRC motion ........................................................... 210 8.3.4.5 Inline form “SCIRC” .............................................................................................. 211 8.3.4.6 Option window “Motion parameters” (SCIRC) .................................................... 211 211 8.3.4.7 Programming an individual SPTP motion ............................................................. 211 8.3.4.8 Inline form “SPTP” ................................................................................................ 212 212 8.3.5 Conditional stop .................................................................................................... 212 8.3.5.1 Inline form “Spline Stop Condition” .................................................................... 213 213 8.3.5.2 Stop condition: example and braking characteristics ........................................... 214 214 8.3.6 Constant velocity range in the CP spline block .................................................... 214 215 8.3.6.1 Block selection to the constant velocity range ...................................................... 216 216 8.3.6.2 Maximum limits ..................................................................................................... 219 8.4 Modifying motion parameters .................................................................................... 8.5 Re-teaching a point ................................................................................................... 8.6 Programming logic instructions ................................................................................. 8.6.1 Inputs/outputs ....................................................................................................... 8.6.2 Setting a digital output - OUT ............................................................................... 8.6.3 Inline form “OUT” .................................................................................................. 8.6.4 Setting a pulse output - PULSE ............................................................................ 8.6.5 Inline form “PULSE” .............................................................................................. 8.6.6 Setting an analog output - ANOUT ....................................................................... 8.6.7 Inline form “ANOUT” (static) ................................................................................. 8.6.8 Inline form “ANOUT” (dynamic) ............................................................................ 8.6.9 Programming a wait time - WAIT .......................................................................... 8.6.10 Inline form “WAIT” ................................................................................................ 8.6.11 Programming a signal-dependent wait function - WAITFOR ................................ 8.6.12 Inline form “WAITFOR” ......................................................................................... 8.6.13 Switching on the path - SYN OUT ........................................................................ 8.6.14 Inline form “SYN OUT”, option “START/END” ...................................................... 8.6.15 Inline form “SYN OUT”, option “PATH” ................................................................. 8.6.16 Setting a pulse on the path - SYN PULSE ............................................................ 221 8 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

Contents 8.6.17 Inline form “SYN PULSE” ..................................................................................... 221 8.6.18 Modifying a logic instruction .................................................................................. 222 9 Messages ..................................................................................................... 223 9.1 Automatic External error messages ........................................................................... 223 10 KUKA Service .............................................................................................. 225 10.1 Requesting support .................................................................................................... 225 10.2 KUKA Customer Support ........................................................................................... 225 Index ............................................................................................................. 233 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 9 / 237

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1 Introduction 1 Introduction 1.1 Target group This documentation is aimed at users with the following knowledge and skills:  Basic knowledge of the industrial robot For optimal use of our products, we recommend that our customers take part in a course of training at KUKA College. Information about the training program can be found at www.kuka.com or can be ob- tained directly from our subsidiaries. 1.2 Industrial robot documentation The industrial robot documentation consists of the following parts:  Documentation for the manipulator  Documentation for the robot controller  Operating and programming instructions for the KUKA System Software  Documentation relating to options and accessories  Parts catalog on storage medium Each of these sets of instructions is a separate document. 1.3 Representation of warnings and notes Safety These warnings are relevant to safety and must be observed. These warnings mean that it is certain or highly probable that death or severe injuries will occur, if no precautions are taken. These warnings mean that death or severe injuries may occur, if no precautions are taken. These warnings mean that minor injuries may occur, if no precautions are taken. These warnings mean that damage to property may oc- cur, if no precautions are taken. Notes These warnings contain references to safety-relevant information or general safety measures. These warnings do not refer to individual hazards or individual pre- cautionary measures. This warning draws attention to procedures which serve to prevent or remedy emergencies or malfunctions: Procedures marked with this warning must be followed exactly. These hints serve to make your work easier or contain references to further information. Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 11 / 237

KUKA System Software 8.3 Tip to make your work easier or reference to further information. 1.4 Trademarks Windows is a trademark of Microsoft Corporation. WordPad is a trademark of Microsoft Corporation. 12 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

2 Product description 2 Product description 2.1 Overview of the industrial robot The industrial robot consists of the following components:  Manipulator  Robot controller  Teach pendant  Connecting cables  Software  Options, accessories Fig. 2-1: Example of an industrial robot 1 Manipulator 3 Robot controller 2 Connecting cables 4 Teach pendant 2.2 Overview of KUKA System Software (KSS) Description The KUKA System Software (KSS) is responsible for all the basic operator smartHMI control functions of the industrial robot.  Path planning  I/O management  Data and file management  etc. Additional technology packages, containing application-specific instructions and configurations, can be installed. The user interface of the KUKA System Software is called KUKA smartHMI (smart Human-Machine Interface). Features:  User administration Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 13 / 237

KUKA System Software 8.3  Program editor  KRL (KUKA Robot Language)  Inline forms for programming  Message display  Configuration window  etc. (>>> 4.2 \"KUKA smartHMI user interface\" Page 47) Depending on customer-specific settings, the user interface may vary from the standard interface. 2.3 System requirements KSS 8.3 can be run on the following robot controller:  KR C4  with Windows Embedded Standard 7 V4.x  and with 2 GB RAM 2.4 Intended use of the KUKA System Software Use The KUKA System Software is intended exclusively for the operation of a Misuse KUKA industrial robot or customer-specific kinematic system. Each version of the KUKA System Software may be operated exclusively in accordance with the specified system requirements. (>>> 2.3 \"System requirements\" Page 14) Any use or application deviating from the intended use is deemed to be imper- missible misuse. The manufacturer cannot be held liable for any damage re- sulting from such use. The risk lies entirely with the user. Examples of such misuse include:  Operation of a kinematic system that is neither a KUKA industrial robot nor a customer-specific kinematic system  Operation of the KSS not in accordance with the specified system require- ments 2.5 KUKA USB sticks The following KUKA USB sticks exist for the KR C4 robot controller:  KUKA USB stick 2.0 NB 4 GB Not bootable Art. no. 00-197-266  KUKA USB stick 2.0 Recovery 4 GB Bootable Component of the product KUKA.RecoveryUSB 1.0, art. no. 00-198-642 If a task requires the use of a specific stick, this is indicated in the description of the task. 14 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

2 Product description Fig. 2-2: KUKA USB stick 2.0 NB 4 GB, not bootable (art. no. 00-197-266) Fig. 2-3: KUKA USB stick 2.0 Recovery 4 GB, bootable (art. no. 00-198- 642) Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 15 / 237

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3 Safety 3 Safety 3.1 General 3.1.1 Liability Safety infor- The device described in this document is either an industrial robot or a com- mation ponent thereof. Components of the industrial robot:  Manipulator  Robot controller  Teach pendant  Connecting cables  External axes (optional) e.g. linear unit, turn-tilt table, positioner  Software  Options, accessories The industrial robot is built using state-of-the-art technology and in accor- dance with the recognized safety rules. Nevertheless, misuse of the industrial robot may constitute a risk to life and limb or cause damage to the industrial robot and to other material property. The industrial robot may only be used in perfect technical condition in accor- dance with its designated use and only by safety-conscious persons who are fully aware of the risks involved in its operation. Use of the industrial robot is subject to compliance with this document and with the declaration of incorpo- ration supplied together with the industrial robot. Any functional disorders af- fecting safety must be rectified immediately. Safety information cannot be held against KUKA Roboter GmbH. Even if all safety instructions are followed, this is not a guarantee that the industrial robot will not cause personal injuries or material damage. No modifications may be carried out to the industrial robot without the autho- rization of KUKA Roboter GmbH. Additional components (tools, software, etc.), not supplied by KUKA Roboter GmbH, may be integrated into the indus- trial robot. The user is liable for any damage these components may cause to the industrial robot or to other material property. In addition to the Safety chapter, this document contains further safety instruc- tions. These must also be observed. 3.1.2 Intended use of the industrial robot The industrial robot is intended exclusively for the use designated in the “Pur- pose” chapter of the operating instructions or assembly instructions. Further information is contained in the “Purpose” chapter of the oper- ating instructions or assembly instructions of the industrial robot. Using the industrial robot for any other or additional purpose is considered im- permissible misuse. The manufacturer cannot be held liable for any damage resulting from such use. The risk lies entirely with the user. Operating the industrial robot and its options within the limits of its intended use also involves observance of the operating and assembly instructions for Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 17 / 237

KUKA System Software 8.3 Misuse the individual components, with particular reference to the maintenance spec- ifications. Any use or application deviating from the intended use is deemed to be imper- missible misuse. This includes e.g.:  Transportation of persons and animals  Use as a climbing aid  Operation outside the permissible operating parameters  Use in potentially explosive environments  Operation without additional safeguards  Outdoor operation  Underground operation 3.1.3 EC declaration of conformity and declaration of incorporation Declaration of This industrial robot constitutes partly completed machinery as defined by the conformity EC Machinery Directive. The industrial robot may only be put into operation if the following preconditions are met: Declaration of incorporation  The industrial robot is integrated into a complete system. Or: The industrial robot, together with other machinery, constitutes a com- plete system. Or: All safety functions and safeguards required for operation in the com- plete machine as defined by the EC Machinery Directive have been added to the industrial robot.  The complete system complies with the EC Machinery Directive. This has been confirmed by means of an assessment of conformity. The system integrator must issue a declaration of conformity for the complete system in accordance with the Machinery Directive. The declaration of confor- mity forms the basis for the CE mark for the system. The industrial robot must be operated in accordance with the applicable national laws, regulations and standards. The robot controller is CE certified under the EMC Directive and the Low Volt- age Directive. The industrial robot as partly completed machinery is supplied with a declara- tion of incorporation in accordance with Annex II B of the EC Machinery Direc- tive 2006/42/EC. The assembly instructions and a list of essential requirements complied with in accordance with Annex I are integral parts of this declaration of incorporation. The declaration of incorporation declares that the start-up of the partly com- pleted machinery remains impermissible until the partly completed machinery has been incorporated into machinery, or has been assembled with other parts to form machinery, and this machinery complies with the terms of the EC Ma- chinery Directive, and the EC declaration of conformity is present in accor- dance with Annex II A. The declaration of incorporation, together with its annexes, remains with the system integrator as an integral part of the technical documentation of the complete machinery. 3.1.4 Terms used STOP 0, STOP 1 and STOP 2 are the stop definitions according to EN 60204- 1:2006. 18 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

3 Safety Term Description Axis range Stopping distance Range of each axis, in degrees or millimeters, within which it may move. Workspace The axis range must be defined for each axis. Operator (User) Stopping distance = reaction distance + braking distance Danger zone Service life The stopping distance is part of the danger zone. KCP The manipulator is allowed to move within its workspace. The work- space is derived from the individual axis ranges. CRR The user of the industrial robot can be the management, employer or Manipulator delegated person responsible for use of the industrial robot. Safety zone Safe operational stop The danger zone consists of the workspace and the stopping distances. Safety STOP 0 The service life of a safety-relevant component begins at the time of delivery of the component to the customer. Safety STOP 1 The service life is not affected by whether the component is used in a robot controller or elsewhere or not, as safety-relevant components are also subject to ageing during storage. The KCP (KUKA Control Panel) teach pendant has all the operator con- trol and display functions required for operating and programming the industrial robot. The KCP variant for the KR C4 is called KUKA smartPAD. The general term “KCP”, however, is generally used in this documentation. Controlled Robot Retraction CRR is an operating mode only available when KUKA.SafeOperation or KUKA.SafeRangeMonitoring is used. If the robot has violated a monitor- ing function and been stopped by the safety controller, it can only be moved out of the violated area in CRR mode. The robot arm and the associated electrical installations The safety zone is situated outside the danger zone. The safe operational stop is a standstill monitoring function. It does not stop the robot motion, but monitors whether the robot axes are station- ary. If these are moved during the safe operational stop, a safety stop STOP 0 is triggered. The safe operational stop can also be triggered externally. When a safe operational stop is triggered, the robot controller sets an output to the field bus. The output is set even if not all the axes were sta- tionary at the time of triggering, thereby causing a safety stop STOP 0 to be triggered. A stop that is triggered and executed by the safety controller. The safety controller immediately switches off the drives and the power supply to the brakes. Note: This stop is called safety STOP 0 in this document. A stop that is triggered and monitored by the safety controller. The brak- ing process is performed by the non-safety-oriented part of the robot controller and monitored by the safety controller. As soon as the manip- ulator is at a standstill, the safety controller switches off the drives and the power supply to the brakes. When a safety STOP 1 is triggered, the robot controller sets an output to the field bus. The safety STOP 1 can also be triggered externally. Note: This stop is called safety STOP 1 in this document. Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 19 / 237

KUKA System Software 8.3 Term Description Safety STOP 2 A stop that is triggered and monitored by the safety controller. The brak- ing process is performed by the non-safety-oriented part of the robot Stop category 0 controller and monitored by the safety controller. The drives remain acti- vated and the brakes released. As soon as the manipulator is at a stand- Stop category 1 still, a safe operational stop is triggered. Stop category 2 When a safety STOP 2 is triggered, the robot controller sets an output to the field bus. System integrator (plant integrator) The safety STOP 2 can also be triggered externally. T1 T2 Note: This stop is called safety STOP 2 in this document. External axis The drives are deactivated immediately and the brakes are applied. The manipulator and any external axes (optional) perform path-oriented braking. Note: This stop category is called STOP 0 in this document. The manipulator and any external axes (optional) perform path-main- taining braking.  Operating mode T1: The drives are deactivated as soon as the robot has stopped, but no later than after 680 ms.  Operating mode T2, AUT, AUT EXT: The drives are switched off after 1.5 s. Note: This stop category is called STOP 1 in this document. The drives are not deactivated and the brakes are not applied. The manipulator and any external axes (optional) are braked with a path- maintaining braking ramp. Note: This stop category is called STOP 2 in this document. System integrators are people who safely integrate the industrial robot into a complete system and commission it. Test mode, Manual Reduced Velocity (<= 250 mm/s) Test mode, Manual High Velocity (> 250 mm/s permissible) Motion axis which is not part of the manipulator but which is controlled using the robot controller, e.g. KUKA linear unit, turn-tilt table, Posiflex. 3.2 Personnel The following persons or groups of persons are defined for the industrial robot:  User  Personnel All persons working with the industrial robot must have read and un- derstood the industrial robot documentation, including the safety chapter. User The user must observe the labor laws and regulations. This includes e.g.: Personnel  The user must comply with his monitoring obligations.  The user must carry out instructions at defined intervals. Personnel must be instructed, before any work is commenced, in the type of work involved and what exactly it entails as well as any hazards which may ex- ist. Instruction must be carried out regularly. Instruction is also required after particular incidents or technical modifications. Personnel includes:  System integrator 20 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

3 Safety  Operators, subdivided into:  Start-up, maintenance and service personnel  Operating personnel  Cleaning personnel Installation, exchange, adjustment, operation, maintenance and re- pair must be performed only as specified in the operating or assembly instructions for the relevant component of the industrial robot and only by personnel specially trained for this purpose. System integrator The industrial robot is safely integrated into a complete system by the system integrator. The system integrator is responsible for the following tasks:  Installing the industrial robot  Connecting the industrial robot  Performing risk assessment  Implementing the required safety functions and safeguards  Issuing the declaration of conformity  Attaching the CE mark  Creating the operating instructions for the complete system Operator The operator must meet the following preconditions:  The operator must be trained for the work to be carried out.  Work on the industrial robot must only be carried out by qualified person- nel. These are people who, due to their specialist training, knowledge and experience, and their familiarization with the relevant standards, are able to assess the work to be carried out and detect any potential hazards. Example The tasks can be distributed as shown in the following table. Tasks Operator Programmer System inte- grator Switch robot controller x x on/off x x Start program x x Select program x x x Select operating mode x x Calibration x (tool, base) x Master the manipulator x Configuration x Programming x x Start-up x x Maintenance x Repair x Decommissioning x Transportation x x x Work on the electrical and mechanical equipment of the industrial ro- bot may only be carried out by specially trained personnel. Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 21 / 237

KUKA System Software 8.3 3.3 Workspace, safety zone and danger zone Workspaces are to be restricted to the necessary minimum size. A workspace must be safeguarded using appropriate safeguards. The safeguards (e.g. safety gate) must be situated inside the safety zone. In the case of a stop, the manipulator and external axes (optional) are braked and come to a stop within the danger zone. The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). It must be safeguarded by means of physical safeguards to prevent danger to persons or the risk of material dam- age. Fig. 3-1: Example of axis range A1 3 Stopping distance 4 Safety zone 1 Workspace 2 Manipulator 3.4 Triggers for stop reactions Stop reactions of the industrial robot are triggered in response to operator ac- tions or as a reaction to monitoring functions and error messages. The follow- ing tables show the different stop reactions according to the operating mode that has been set. Trigger T1, T2, CRR AUT, AUT EXT Start key released STOP 2 - STOP key pressed STOP 2 Drives OFF STOP 1 “Motion enable” input drops out STOP 2 Robot controller switched STOP 0 off (power failure) STOP 0 or STOP 1 Internal error in non- (dependent on the cause of the error) safety-oriented part of the robot controller 22 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

3 Safety Trigger T1, T2, CRR AUT, AUT EXT Operating mode changed Safety stop 2 during operation - Safety stop 1 Safety gate opened (oper- ator safety) Safety stop 2 - Releasing the enabling Safety stop 1 - switch Safety stop 1 Enabling switch pressed Safety stop 0 fully down or error E-STOP pressed Error in safety controller or periphery of the safety controller 3.5 Safety functions 3.5.1 Overview of the safety functions The following safety functions are present in the industrial robot:  Mode selection  Operator safety (= connection for the guard interlock)  EMERGENCY STOP device  Enabling device  External safe operational stop  External safety stop 1 (not for the controller variant “KR C4 compact”)  External safety stop 2  Velocity monitoring in T1 The safety functions of the industrial robot meet the following requirements:  Category 3 and Performance Level d in accordance with EN ISO 13849- 1:2008  SIL 2 according to EN 62061 The requirements are only met on the following condition, however:  The EMERGENCY STOP device is pressed at least once every 6 months. The following components are involved in the safety functions:  Safety controller in the control PC  KUKA Control Panel (KUKA smartPAD)  Cabinet Control Unit (CCU)  Resolver Digital Converter (RDC)  KUKA Power Pack (KPP)  KUKA Servo Pack (KSP)  Safety Interface Board (SIB) (if used) There are also interfaces to components outside the industrial robot and to other robot controllers. In the absence of operational safety functions and safe- guards, the industrial robot can cause personal injury or material damage. If safety functions or safeguards are dismantled or deacti- vated, the industrial robot may not be operated. Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 23 / 237

KUKA System Software 8.3 During system planning, the safety functions of the overall system must also be planned and designed. The industrial robot must be in- tegrated into this safety system of the overall system. 3.5.2 Safety controller The safety controller is a unit inside the control PC. It links safety-relevant sig- nals and safety-relevant monitoring functions. Safety controller tasks:  Switching off the drives; applying the brakes  Monitoring the braking ramp  Standstill monitoring (after the stop)  Velocity monitoring in T1  Evaluation of safety-relevant signals  Setting of safety-oriented outputs 3.5.3 Mode selection The industrial robot can be operated in the following modes:  Manual Reduced Velocity (T1) (โหมดควบคุมความเร็วจากัดไมเ่ กนิ 250 mm/s ไดท้ ัง้ ควบคมุ แบบ เขยี นโปรแกรม และ Jog Mode )  Manual High Velocity (T2) (โหมดควบคุมความเรว็ แบบจากัด ใชท้ ดสอบควบคมุ แบบเขยี นโปรแกรม เท่านน้ั และไม่สามารถ Jog Mode ได้ )  Automatic (AUT) (โหมดควบคมุ อตั โนมัติ โดยใชต้ วั ควบคุมการทางานของ KUKA เท่าน้นั และไม่สามารถ Jog Mode ได้ )  Automatic External (AUT EXT) (โหมดควบคมุ อตั โนมตั ิ โดยใชต้ ัวควบคมุ การทางานร่วมกับ PLC และไม่ สามารถ Jog Mode ได้ )  CRR Do not change the operating mode while a program is running. If the operating mode is changed during program execution, the industrial robot is stopped with a safety stop 2. Operat- Use Velocities ing mode  Program verification: T1 For test operation, pro- Programmed velocity, maxi- T2 AUT gramming and teach- mum 250 mm/s ing  Jog mode: Jog velocity, maximum 250 mm/ s  Program verification: For test operation Programmed velocity  Jog mode: Not possible For industrial robots  Program mode: without higher-level Programmed velocity controllers  Jog mode: Not possible 24 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

3 Safety Operat- Use Velocities ing mode AUT EXT For industrial robots  Program mode: with higher-level con- Programmed velocity CRR trollers, e.g. PLC  Jog mode: Not possible CRR is only available if KUKA.SafeOperation or KUKA.Saf- eRangeMonitoring is used. If the robot has violated a monitoring function and been stopped by the safety controller, it can only be moved out of the violated area in CRR mode. Speeds similar to T1 3.5.4 Operator safety The operator safety signal is used for interlocking physical safeguards, e.g. safety gates. Automatic operation is not possible without this signal. In the event of a loss of signal during automatic operation (e.g. safety gate is opened), the manipulator stops with a safety stop 1. Operator safety is not active in the modes T1 (Manual Reduced Velocity), T2 (Manual High Velocity) and CRR. Following a loss of signal, automatic operation must not be resumed merely by closing the safeguard; it must first additionally be acknowledged. It is the responsibility of the system integrator to ensure this. This is to prevent automatic operation from being resumed in- advertently while there are still persons in the danger zone, e.g. due to the safety gate closing accidentally. The acknowledgement must be designed in such a way that an actual check of the danger zone can be carried out first. Acknowledgement functions that do not allow this (e.g. because they are automatically trig- gered by closure of the safeguard) are not permissible. Failure to observe this may result in death to persons, severe injuries or considerable damage to property. 3.5.5 EMERGENCY STOP device The EMERGENCY STOP device for the industrial robot is the EMERGENCY STOP device on the KCP. The device must be pressed in the event of a haz- ardous situation or emergency. Reactions of the industrial robot if the EMERGENCY STOP device is pressed:  The manipulator and any external axes (optional) are stopped with a safe- ty stop 1. Before operation can be resumed, the EMERGENCY STOP device must be turned to release it. Tools and other equipment connected to the manipulator must be integrated into the EMERGENCY STOP circuit on the system side if they could constitute a potential hazard. Failure to observe this precaution may result in death, severe injuries or con- siderable damage to property. There must always be at least one external EMERGENCY STOP device in- stalled. This ensures that an EMERGENCY STOP device is available even when the KCP is disconnected. Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 25 / 237

KUKA System Software 8.3 (>>> 3.5.7 \"External EMERGENCY STOP device\" Page 26) 3.5.6 Logging off from the higher-level safety controller If the robot controller is connected to a higher-level safety controller, this con- nection will inevitably be terminated in the following cases:  Switching off of the robot controller via the main switch or due to a power failure In this case, it does not matter whether the Cold start or Hibernate start type has been selected.  Shutdown of the robot controller via the smartHMI  Activation of a WorkVisual project in WorkVisual or directly on the robot controller  Changes to Start-up > Network configuration  Changes to Configuration > Safety configuration  I/O drivers > Reconfigure  Restoration of an archive Effect of the interruption:  If the X11 interface is used, this triggers an EMERGENCY STOP for the overall system.  If the Ethernet interface is used, the KUKA safety controller generates a signal that prevents the higher-level controller from triggering an EMER- GENCY STOP for the overall system. If the Ethernet safety interface is used: In his risk assess- ment, the system integrator must take into consideration whether the fact that switching off the robot controller does not trigger an EMERGENCY STOP of the overall system could constitute a hazard and, if so, how this hazard can be countered. Failure to take this into consideration may result in death to persons, severe injuries or considerable damage to property. If a robot controller is switched off, the E-STOP device on the KCP is no longer functional. The user is responsible for ensuring that the KCP is either covered or removed from the system. This serves to prevent operational and non-operational EMERGENCY STOP de- vices from becoming interchanged. Failure to observe this precaution may result in death to persons, severe in- juries or considerable damage to property. 3.5.7 External EMERGENCY STOP device There must be EMERGENCY STOP devices available at every operator sta- tion that can initiate a robot motion or other potentially hazardous situation. The system integrator is responsible for ensuring this. There must always be at least one external EMERGENCY STOP device in- stalled. This ensures that an EMERGENCY STOP device is available even when the KCP is disconnected. External EMERGENCY STOP devices are connected via the customer inter- face. External EMERGENCY STOP devices are not included in the scope of supply of the industrial robot. 26 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

3.5.8 3 Safety Enabling device The enabling devices of the industrial robot are the enabling switches on the KCP. There are 3 enabling switches installed on the KCP. The enabling switches have 3 positions:  Not pressed  Center position  Panic position In the test modes and in CRR, the manipulator can only be moved if one of the enabling switches is held in the central position.  Releasing the enabling switch triggers a safety stop 2.  Pressing the enabling switch down fully (panic position) triggers a safety stop 1.  It is possible, for a short time, to hold 2 enabling switches in the center po- sition simultaneously. This makes it possible to adjust grip from one en- abling switch to another one. If 2 enabling switches are held simultaneously in the center position for a longer period of time, this trig- gers a safety stop after several seconds. If an enabling switch malfunctions (jams), the industrial robot can be stopped using the following methods:  Press the enabling switch down fully  Actuate the EMERGENCY STOP system  Release the Start key The enabling switches must not be held down by adhe- sive tape or other means or manipulated in any other way. Death, injuries or damage to property may result. 3.5.9 External enabling device External enabling devices are required if it is necessary for more than one per- son to be in the danger zone of the industrial robot. They are connected to the robot controller via an interface. Which interface can be used for connecting external enabling devices is described in the “Planning” chapter of the robot controller operating instructions and assembly instructions. External enabling devices are not included in the scope of supply of the indus- trial robot. 3.5.10 External safe operational stop The safe operational stop can be triggered via an input on the customer inter- face. The state is maintained as long as the external signal is FALSE. If the external signal is TRUE, the manipulator can be moved again. No acknowl- edgement is required. 3.5.11 External safety stop 1 and external safety stop 2 Safety stop 1 and safety stop 2 can be triggered via an input on the customer interface. The state is maintained as long as the external signal is FALSE. If Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 27 / 237

KUKA System Software 8.3 the external signal is TRUE, the manipulator can be moved again. No ac- knowledgement is required. No external safety stop 1 is available for the controller variant “KR C4 compact”. 3.5.12 Velocity monitoring in T1 and CRR The velocity at the TCP is monitored in the T1 and CRR modes. If, due to an error, the velocity exceeds 250 mm/s, a safety stop 0 is triggered. 3.6 Additional protective equipment 3.6.1 Jog mode In the operating modes T1 (Manual Reduced Velocity), T2 (Manual High Ve- locity) and CRR, the robot controller can only execute programs in jog mode. This means that it is necessary to hold down an enabling switch and the Start key in order to execute a program.  Releasing the enabling switch triggers a safety stop 2.  Pressing the enabling switch down fully (panic position) triggers a safety stop 1.  Releasing the Start key triggers a STOP 2. 3.6.2 Software limit switches The axis ranges of all manipulator and positioner axes are limited by means of adjustable software limit switches. These software limit switches only serve as machine protection and must be adjusted in such a way that the manipulator/ positioner cannot hit the mechanical end stops. The software limit switches are set during commissioning of an industrial ro- bot. Further information is contained in the operating and programming in- structions. 3.6.3 Mechanical end stops Depending on the robot variant, the axis ranges of the main and wrist axes of the manipulator are partially limited by mechanical end stops. Additional mechanical end stops can be installed on the external axes. If the manipulator or an external axis hits an obstruction or a mechanical end stop or axis range limitation, this can result in material damage to the industrial robot. The manipulator must be taken out of operation and KUKA Roboter GmbH must be consulted be- fore it is put back into operation (>>> 10 \"KUKA Service\" Page 225). 3.6.4 Mechanical axis range limitation (optional) Some manipulators can be fitted with mechanical axis range limitation in axes A1 to A3. The adjustable axis range limitation systems restrict the working 28 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

3 Safety range to the required minimum. This increases personal safety and protection of the system. In the case of manipulators that are not designed to be fitted with mechanical axis range limitation, the workspace must be laid out in such a way that there is no danger to persons or material property, even in the absence of mechan- ical axis range limitation. If this is not possible, the workspace must be limited by means of photoelectric barriers, photoelectric curtains or obstacles on the system side. There must be no shearing or crushing hazards at the loading and transfer areas. This option is not available for all robot models. Information on spe- cific robot models can be obtained from KUKA Roboter GmbH. 3.6.5 Axis range monitoring (optional) Some manipulators can be fitted with dual-channel axis range monitoring sys- tems in main axes A1 to A3. The positioner axes may be fitted with additional axis range monitoring systems. The safety zone for an axis can be adjusted and monitored using an axis range monitoring system. This increases person- al safety and protection of the system. This option is not available for all robot models. Information on spe- cific robot models can be obtained from KUKA Roboter GmbH. 3.6.6 Devices for moving the manipulator without the robot controller (options) Description The following devices are available for moving the manipulator after an acci- dent or malfunction:  Release device The release device can be used for the main axis drive motors and, de- pending on the robot variant, also for the wrist axis drive motors.  Brake release device The brake release device is designed for robot variants whose motors are not freely accessible. The devices are only for use in exceptional circumstances and emergencies, e.g. for freeing people. These options are not available for all robot models. Information on specific robot models can be obtained from KUKA Roboter GmbH. Procedure The motors reach temperatures during operation which can cause burns to the skin. Contact must be avoided. Appropriate safety precautions must be taken, e.g. protective gloves must be worn. Moving the manipulator with the release device: The following procedure must be followed exactly! 1. Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again. 2. Remove the protective cap from the motor. Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 29 / 237

KUKA System Software 8.3 3. Push the release device onto the corresponding motor and move the axis in the desired direction. The directions are indicated with arrows on the motors. It is necessary to overcome the resistance of the mechanical motor brake and any other loads acting on the axis. Moving an axis with the release device can damage the motor brake. This can result in personal injury and mate- rial damage. After using the release device, the motor must be exchanged. Procedure If a robot axis has been moved by the release device, all robot axes must be remastered. Serious infuries or dam- age to property may otherwise result. Moving the manipulator with the brake release device: Use of the brake release device may result in unexpect- ed robot motions, especially sagging of the axes. During use of the brake release device, attention must be paid to motion of this kind in order to be able to prevent physical injuries or damage to property. Stand- ing under moving axes is not permitted. The following procedure must be followed exactly! 1. Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again. 2. Connect the brake release device to the base frame of the robot: Unplug connector X30 from interface A1. Plug connector X20 of the brake release device into interface A1. 3. Select the brakes to be released (main axes, wrist axes) via the selection switch on the brake release device. 4. Press the button on the hand-held device. The brakes of the main axes or wrist axes are released and the robot can be moved manually. Further information about the brake release device can be found in the documentation for the brake release device. 3.6.7 Labeling on the industrial robot All plates, labels, symbols and marks constitute safety-relevant parts of the in- dustrial robot. They must not be modified or removed. Labeling on the industrial robot consists of:  Identification plates  Warning labels  Safety symbols  Designation labels  Cable markings  Rating plates Further information is contained in the technical data of the operating instructions or assembly instructions of the components of the indus- trial robot. 30 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

3.6.8 3 Safety External safeguards The access of persons to the danger zone of the industrial robot must be pre- vented by means of safeguards. It is the responsibility of the system integrator to ensure this. Physical safeguards must meet the following requirements:  They meet the requirements of EN 953.  They prevent access of persons to the danger zone and cannot be easily circumvented.  They are sufficiently fastened and can withstand all forces that are likely to occur in the course of operation, whether from inside or outside the en- closure.  They do not, themselves, represent a hazard or potential hazard.  The prescribed minimum clearance from the danger zone is maintained. Safety gates (maintenance gates) must meet the following requirements:  They are reduced to an absolute minimum.  The interlocks (e.g. safety gate switches) are linked to the operator safety input of the robot controller via safety gate switching devices or safety PLC.  Switching devices, switches and the type of switching conform to the re- quirements of Performance Level d and category 3 according to EN ISO 13849-1.  Depending on the risk situation: the safety gate is additionally safeguarded by means of a locking mechanism that only allows the gate to be opened if the manipulator is safely at a standstill.  The button for acknowledging the safety gate is located outside the space limited by the safeguards. Further information is contained in the corresponding standards and regulations. These also include EN 953. Other safety Other safety equipment must be integrated into the system in accordance with equipment the corresponding standards and regulations. 3.7 Overview of operating modes and safety functions The following table indicates the operating modes in which the safety functions are active. Safety functions T1, T2 AUT AUT EXT CRR Operator safety - active active EMERGENCY STOP device - active active active Enabling device active active Reduced velocity during pro- active - - gram verification - Jog mode active - - Software limit switches active active active - - active active active Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 31 / 237

KUKA System Software 8.3 3.8 Safety measures 3.8.1 General safety measures The industrial robot may only be used in perfect technical condition in accor- dance with its intended use and only by safety-conscious persons. Operator errors can result in personal injury and damage to property. It is important to be prepared for possible movements of the industrial robot even after the robot controller has been switched off and locked. Incorrect in- stallation (e.g. overload) or mechanical defects (e.g. brake defect) can cause the manipulator or external axes to sag. If work is to be carried out on a switched-off industrial robot, the manipulator and external axes must first be moved into a position in which they are unable to move on their own, whether the payload is mounted or not. If this is not possible, the manipulator and ex- ternal axes must be secured by appropriate means. In the absence of operational safety functions and safe- guards, the industrial robot can cause personal injury or material damage. If safety functions or safeguards are dismantled or deacti- vated, the industrial robot may not be operated. Standing underneath the robot arm can cause death or serious injuries. For this reason, standing underneath the robot arm is prohibited! KCP The motors reach temperatures during operation which Faults can cause burns to the skin. Contact must be avoided. Modifications Appropriate safety precautions must be taken, e.g. protective gloves must be worn. The user must ensure that the industrial robot is only operated with the KCP by authorized persons. If more than one KCP is used in the overall system, it must be ensured that each KCP is unambiguously assigned to the corresponding industrial robot. They must not be interchanged. The operator must ensure that decoupled KCPs are im- mediately removed from the system and stored out of sight and reach of personnel working on the industrial robot. This serves to prevent operational and non-operational EMERGENCY STOP devices from becoming interchanged. Failure to observe this precaution may result in death, severe injuries or con- siderable damage to property. The following tasks must be carried out in the case of faults in the industrial robot:  Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again.  Indicate the fault by means of a label with a corresponding warning (tag- out).  Keep a record of the faults.  Eliminate the fault and carry out a function test. After modifications to the industrial robot, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations 32 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

3 Safety must be observed for this check. The correct functioning of all safety circuits must also be tested. New or modified programs must always be tested first in Manual Reduced Ve- locity mode (T1). After modifications to the industrial robot, existing programs must always be tested first in Manual Reduced Velocity mode (T1). This applies to all compo- nents of the industrial robot and includes modifications to the software and configuration settings. 3.8.2 Transportation Manipulator The prescribed transport position of the manipulator must be observed. Trans- Robot controller portation must be carried out in accordance with the operating instructions or assembly instructions of the robot. External axis (optional) The prescribed transport position of the robot controller must be observed. Transportation must be carried out in accordance with the operating instruc- tions or assembly instructions of the robot controller. Avoid vibrations and impacts during transportation in order to prevent damage to the robot controller. The prescribed transport position of the external axis (e.g. KUKA linear unit, turn-tilt table, positioner) must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the external axis. 3.8.3 Start-up and recommissioning Before starting up systems and devices for the first time, a check must be car- ried out to ensure that the systems and devices are complete and operational, that they can be operated safely and that any damage is detected. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety circuits must also be tested. The passwords for the user groups must be changed in the KUKA System Software before start-up. The passwords must only be com- municated to authorized personnel. The robot controller is preconfigured for the specific in- dustrial robot. If cables are interchanged, the manipula- tor and the external axes (optional) may receive incorrect data and can thus cause personal injury or material damage. If a system consists of more than one manipulator, always connect the connecting cables to the manipulators and their corresponding robot controllers. If additional components (e.g. cables), which are not part of the scope of supply of KUKA Roboter GmbH, are integrated into the industrial robot, the user is responsible for ensuring that these components do not adversely affect or disable safety functions. If the internal cabinet temperature of the robot controller differs greatly from the ambient temperature, condensa- tion can form, which may cause damage to the electrical components. Do not put the robot controller into operation until the internal temperature of the cabinet has adjusted to the ambient temperature. Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 33 / 237

KUKA System Software 8.3 Function test The following tests must be carried out before start-up and recommissioning: General test: It must be ensured that:  The industrial robot is correctly installed and fastened in accordance with the specifications in the documentation.  There are no foreign bodies or loose parts on the industrial robot.  All required safety equipment is correctly installed and operational.  The power supply ratings of the industrial robot correspond to the local supply voltage and mains type.  The ground conductor and the equipotential bonding cable are sufficiently rated and correctly connected.  The connecting cables are correctly connected and the connectors are locked. Test of the safety functions: A function test must be carried out for the following safety functions to ensure that they are functioning correctly:  Local EMERGENCY STOP device  External EMERGENCY STOP device (input and output)  Enabling device (in the test modes)  Operator safety  All other safety-relevant inputs and outputs used  Other external safety functions 3.8.3.1 Checking machine data and safety-relevant control configuration The industrial robot must not be moved if incorrect ma- chine data are loaded. Death, severe injuries or consid- erable damage to property may otherwise result. The correct machine data must be loaded.  It must be ensured that the rating plate on the robot controller has the same machine data as those entered in the declaration of incorporation. The machine data on the rating plate of the manipulator and the external axes (optional) must be entered during start-up.  The practical tests for the machine data must be carried out within the scope of the start-up procedure.  Following modifications to the machine data, the safety configuration must always be checked.  If changes are made to the machine data when checking the safety con- figuration (regardless of the reason for the safety configuration check), the practical tests for the machine data must be carried out. Information about checking the safety configuration is contained in the Operating and Programming Instructions for System Integrators. General practical If the practical tests are not successfully completed in the initial start-up, KUKA test Roboter GmbH must be contacted. If the practical test is not successfully completed during a different procedure, the machine data must be checked and corrected. If practical tests are required for the machine data, this test must always be carried out. The following methods are available for performing the practical test: 34 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

3 Safety Practical test for  TCP calibration with the XYZ 4-point method axes that are not The practical test is passed if the TCP has been successfully calibrated. mathematically coupled Or: Practical test for 1. Align the TCP with a freely selected point. couplable axes The point serves as a reference point. It must be located so that reorien- tation is possible. 2. Move the TCP manually at least 45° once in each of the A, B and C direc- tions. The movements do not have to be accumulative, i.e. after motion in one direction it is possible to return to the original position before moving in the next direction. The practical test is passed if the TCP does not deviate from the reference point by more than 2 cm in total. If practical tests are required for the machine data, this test must be carried out when axes are present that are not mathematically coupled. 1. Mark the starting position of the axis that is not mathematically coupled. 2. Move the axis manually by a freely selected path length. Determine the path length from the display Actual position on the smartHMI.  Move linear axes a specific distance.  Move rotational axes through a specific angle. 3. Measure the length of the path covered and compare it with the value dis- played on the smartHMI. The practical test is passed if the values differ by no more than 10%. 4. Repeat the test for each axis that is not mathematically coupled. If practical tests are required for the machine data, this test must be carried out when axes are present that can be physically coupled and uncoupled, e.g. a servo gun. 1. Physically uncouple the couplable axis. 2. Move all the remaining axes individually. The practical test is passed if it has been possible to move all the remain- ing axes. 3.8.3.2 Start-up mode Description The industrial robot can be set to Start-up mode via the smartHMI user inter- Hazards face. In this mode, the manipulator can be moved in T1 or CRR mode in the absence of the safety periphery.  If the X11 interface is used: Start-up mode is always possible if all input signals have the state “logic zero”. If this is not the case, the robot controller prevents or terminates Start-up mode.  If the Ethernet safety interface is used: If a connection to a higher-level safety system exists or is established, the robot controller prevents or terminates Start-up mode. Possible hazards and risks involved in using Start-up mode:  A person walks into the manipulator’s danger zone.  An unauthorized person moves the manipulator.  In a hazardous situation, a disabled external EMERGENCY STOP device is actuated and the manipulator is not shut down. Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 35 / 237

KUKA System Software 8.3 Additional measures for avoiding risks in Start-up mode:  Cover disabled EMERGENCY STOP devices or attach a warning sign in- dicating that the EMERGENCY STOP device is out of operation.  If there is no safety fence, other measures must be taken to prevent per- sons from entering the manipulator’s danger zone, e.g. use of warning tape.  Use of Start-up mode must be minimized – and avoided where possible – by means of organizational measures. Use Intended use of Start-up mode:  Only service personnel who have received safety instruction may use Start-up mode.  Start-up in T1 mode or CRR mode when the external safeguards have not yet been installed or put into operation. The danger zone must be delimit- ed at least by means of warning tape.  Fault localization (periphery fault). Use of Start-up mode disables all external safeguards. The service personnel are responsible for ensuring that there is no-one in or near the danger zone of the manipulator as long as the safeguards are disabled. Failure to observe this may result in death to persons, injuries or damage to property. Misuse Any use or application deviating from the designated use is deemed to be im- permissible misuse. This includes, for example, use by any other personnel. KUKA Roboter GmbH accepts no liability for damage or injury caused thereby. The risk lies entirely with the user. 3.8.4 Manual mode Manual mode is the mode for setup work. Setup work is all the tasks that have to be carried out on the industrial robot to enable automatic operation. Setup work includes:  Jog mode  Teach  Programming  Program verification The following must be taken into consideration in manual mode:  If the drives are not required, they must be switched off to prevent the ma- nipulator or the external axes (optional) from being moved unintentionally. New or modified programs must always be tested first in Manual Reduced Velocity mode (T1).  The manipulator, tooling or external axes (optional) must never touch or project beyond the safety fence.  Workpieces, tooling and other objects must not become jammed as a re- sult of the industrial robot motion, nor must they lead to short-circuits or be liable to fall off.  All setup work must be carried out, where possible, from outside the safe- guarded area. If the setup work has to be carried out inside the safeguarded area, the follow- ing must be taken into consideration: 36 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

3 Safety In Manual Reduced Velocity mode (T1):  If it can be avoided, there must be no other persons inside the safeguard- ed area. If it is necessary for there to be several persons inside the safeguarded ar- ea, the following must be observed:  Each person must have an enabling device.  All persons must have an unimpeded view of the industrial robot.  Eye-contact between all persons must be possible at all times.  The operator must be so positioned that he can see into the danger area and get out of harm’s way. In Manual High Velocity mode (T2):  This mode may only be used if the application requires a test at a velocity higher than Manual Reduced Velocity.  Teaching and programming are not permissible in this operating mode.  Before commencing the test, the operator must ensure that the enabling devices are operational.  The operator must be positioned outside the danger zone.  There must be no other persons inside the safeguarded area. It is the re- sponsibility of the operator to ensure this. 3.8.5 Simulation Simulation programs do not correspond exactly to reality. Robot programs cre- ated in simulation programs must be tested in the system in Manual Reduced Velocity mode (T1). It may be necessary to modify the program. 3.8.6 Automatic mode Automatic mode is only permissible in compliance with the following safety measures:  All safety equipment and safeguards are present and operational.  There are no persons in the system.  The defined working procedures are adhered to. If the manipulator or an external axis (optional) comes to a standstill for no ap- parent reason, the danger zone must not be entered until an EMERGENCY STOP has been triggered. 3.8.7 Maintenance and repair After maintenance and repair work, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety circuits must also be tested. The purpose of maintenance and repair work is to ensure that the system is kept operational or, in the event of a fault, to return the system to an operation- al state. Repair work includes troubleshooting in addition to the actual repair itself. The following safety measures must be carried out when working on the indus- trial robot:  Carry out work outside the danger zone. If work inside the danger zone is necessary, the user must define additional safety measures to ensure the safe protection of personnel. Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 37 / 237

KUKA System Software 8.3  Switch off the industrial robot and secure it (e.g. with a padlock) to prevent it from being switched on again. If it is necessary to carry out work with the robot controller switched on, the user must define additional safety mea- sures to ensure the safe protection of personnel.  If it is necessary to carry out work with the robot controller switched on, this may only be done in operating mode T1.  Label the system with a sign indicating that work is in progress. This sign must remain in place, even during temporary interruptions to the work.  The EMERGENCY STOP systems must remain active. If safety functions or safeguards are deactivated during maintenance or repair work, they must be reactivated immediately after the work is completed. Before work is commenced on live parts of the robot sys- tem, the main switch must be turned off and secured against being switched on again. The system must then be checked to en- sure that it is deenergized. It is not sufficient, before commencing work on live parts, to execute an EMERGENCY STOP or a safety stop, or to switch off the drives, as this does not disconnect the robot system from the mains power supply in the case of the drives of the new generation. Parts remain energized. Death or severe injuries may result. Faulty components must be replaced using new components with the same article numbers or equivalent components approved by KUKA Roboter GmbH for this purpose. Cleaning and preventive maintenance work is to be carried out in accordance with the operating instructions. Robot controller Even when the robot controller is switched off, parts connected to peripheral devices may still carry voltage. The external power sources must therefore be switched off if work is to be carried out on the robot controller. The ESD regulations must be adhered to when working on components in the robot controller. Voltages in excess of 50 V (up to 780 V) can be present in various components for several minutes after the robot controller has been switched off! To prevent life-threatening injuries, no work may be carried out on the industrial robot in this time. Water and dust must be prevented from entering the robot controller. Counterbal- Some robot variants are equipped with a hydropneumatic, spring or gas cylin- ancing system der counterbalancing system. The hydropneumatic and gas cylinder counterbalancing systems are pressure equipment and, as such, are subject to obligatory equipment monitoring. De- pending on the robot variant, the counterbalancing systems correspond to cat- egory 0, II or III, fluid group 2, of the Pressure Equipment Directive. The user must comply with the applicable national laws, regulations and stan- dards pertaining to pressure equipment. Inspection intervals in Germany in accordance with Industrial Safety Order, Sections 14 and 15. Inspection by the user before commissioning at the instal- lation site. The following safety measures must be carried out when working on the coun- terbalancing system:  The manipulator assemblies supported by the counterbalancing systems must be secured.  Work on the counterbalancing systems must only be carried out by quali- fied personnel. 38 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

Hazardous 3 Safety substances The following safety measures must be carried out when handling hazardous substances:  Avoid prolonged and repeated intensive contact with the skin.  Avoid breathing in oil spray or vapors.  Clean skin and apply skin cream. To ensure safe use of our products, we recommend that our custom- ers regularly request up-to-date safety data sheets from the manufac- turers of hazardous substances. 3.8.8 Decommissioning, storage and disposal The industrial robot must be decommissioned, stored and disposed of in ac- cordance with the applicable national laws, regulations and standards. 3.8.9 Safety measures for “single point of control” Overview If certain components in the industrial robot are operated, safety measures T1, T2, CRR must be taken to ensure complete implementation of the principle of “single point of control” (SPOC). Components:  Submit interpreter  PLC  OPC Server  Remote control tools  Tools for configuration of bus systems with online functionality  KUKA.RobotSensorInterface The implementation of additional safety measures may be required. This must be clarified for each specific application; this is the respon- sibility of the system integrator, programmer or user of the system. Since only the system integrator knows the safe states of actuators in the pe- riphery of the robot controller, it is his task to set these actuators to a safe state, e.g. in the event of an EMERGENCY STOP. In the test modes T1, T2 and CRR, the components referred to above may only access the industrial robot if the following signals have the following states: Signal State required for SPOC $USER_SAF TRUE $SPOC_MOTION_ENABLE TRUE Submit inter- If motions, (e.g. drives or grippers) are controlled with the submit interpreter or preter, PLC the PLC via the I/O system, and if they are not safeguarded by other means, then this control will take effect even in T1, T2 and CRR modes or while an EMERGENCY STOP is active. If variables that affect the robot motion (e.g. override) are modified with the submit interpreter or the PLC, this takes effect even in T1, T2 and CRR modes or while an EMERGENCY STOP is active. Safety measures:  In T1, T2 and CRR, the system variable $OV_PRO must not be written to by the submit interpreter or the PLC. Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 39 / 237

KUKA System Software 8.3  Do not modify safety-relevant signals and variables (e.g. operating mode, EMERGENCY STOP, safety gate contact) via the submit interpreter or PLC. If modifications are nonetheless required, all safety-relevant signals and variables must be linked in such a way that they cannot be set to a dan- gerous state by the submit interpreter or PLC. OPC server, These components can be used with write access to modify programs, outputs remote control or other parameters of the robot controller, without this being noticed by any tools persons located inside the system. Safety measures:  KUKA stipulates that these components are to be used exclusively for di- agnosis and visualization. Programs, outputs or other parameters of the robot controller must not be modified using these components.  If these components are used, outputs that could cause a hazard must be determined in a risk assessment. These outputs must be designed in such a way that they cannot be set without being enabled. This can be done us- ing an external enabling device, for example. Tools for configu- If these components have an online functionality, they can be used with write ration of bus access to modify programs, outputs or other parameters of the robot control- systems ler, without this being noticed by any persons located inside the system.  WorkVisual from KUKA  Tools from other manufacturers Safety measures:  In the test modes, programs, outputs or other parameters of the robot con- troller must not be modified using these components. 3.9 Applied norms and regulations Name Definition Edition 2006/42/EC Machinery Directive: 2006 2004/108/EC 2004 Directive 2006/42/EC of the European Parliament and of 97/23/EC the Council of 17 May 2006 on machinery, and amending 1997 Directive 95/16/EC (recast) EN ISO 13850 EMC Directive: 2008 EN ISO 13849-1 2008 Directive 2004/108/EC of the European Parliament and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC Pressure Equipment Directive: Directive 97/23/EC of the European Parliament and of the Council of 29 May 1997 on the approximation of the laws of the Member States concerning pressure equipment (Only applicable for robots with hydropneumatic counter- balancing system.) Safety of machinery: Emergency stop - Principles for design Safety of machinery: Safety-related parts of control systems - Part 1: General principles of design 40 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

3 Safety Name Definition Edition EN ISO 13849-2 Safety of machinery: 2008 EN ISO 12100 2010 Safety-related parts of control systems - Part 2: Validation EN ISO 10218-1 Safety of machinery: 2011 EN 614-1 2006 General principles of design, risk assessment and risk EN 61000-6-2 reduction 2005 Industrial robots: EN 61000-6-4 2007 Safety EN 60204-1 Safety of machinery: 2006 Ergonomic design principles - Part 1: Terms and general principles Electromagnetic compatibility (EMC): Part 6-2: Generic standards; Immunity for industrial envi- ronments Electromagnetic compatibility (EMC): Part 6-4: Generic standards; Emission standard for indus- trial environments Safety of machinery: Electrical equipment of machines - Part 1: General requirements Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 41 / 237

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4 Operation 4 Operation 4.1 KUKA smartPAD teach pendant 4.1.1 Front view Function The smartPAD is the teach pendant for the industrial robot. The smartPAD has all the operator control and display functions required for operating and pro- gramming the industrial robot. The smartPAD has a touch screen: the smartHMI can be operated with a fin- ger or stylus. An external mouse or external keyboard is not necessary. The general term “KCP” (KUKA Control Panel) is often used in this documentation for the smartPAD. Overview Fig. 4-1: KUKA smartPAD, front view 43 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

KUKA System Software 8.3 Item Description 1 Button for disconnecting the smartPAD(ใชก้ รณที ต่ี ้องการถอดตัว smartPAD ออกจากตู้ควบคมุ โดยกดแลว้ หนา้ จอจะแสดงผลตวั เลขนบั ถอยหลงั 25 วินาที ให้ถอดสายออก ในเวลาทก่ี าหนด ส่วนการต่อสายกลับเข้าท่ีเดิมสามารถทาได้ทนั ทีไมต่ ้องปดิ เคร่อื งเพยี งแต่รอ ระบบ boot สกั คร่เู พ่อื smartPAD กลบั มาทางานปกติ) (>>> 4.1.3 \"Disconnecting and connecting the smartPAD\" Page 46) 2 Keyswitch for calling the connection manager. The switch can only be turned if the key is inserted. The operating mode can be changed by using the connection man- ager. (ใชเ้ พ่ือปรับโหมดการใชง้ านควบคมุ T1 T2 AUT EXT ) (>>> 4.10 \"Changing operating mode\" Page 59) 3 EMERGENCY STOP button. Stops the robot in hazardous situa- tions. The EMERGENCY STOP button locks itself in place when it is pressed. (ใชเ้ พื่อสาหรบั หยุดหุ่นยนต์ฉกุ เฉิน ) 4 Space Mouse: For moving the robot manually. ( 6D Mouse ใชเ้ พอ่ื ควบคมุ หนุ่ ยนต์ ) (>>> 4.12 \"Jogging the robot\" Page 61) 5 Jog keys: For moving the robot manually. (Jog keys ใชเ้ พื่อควบคมุ หนุ่ ยนต์ ) (>>> 4.12 \"Jogging the robot\" Page 61) 6 Key for setting the program override(Jog keys ใชเ้ พอื่ ควบคุมความเรว็ ของ หนุ่ ยนตใ์ หก้ บั โปรแกรมควบคุมอตั โนมตั ิ POV ) 7 Key for setting the jog override(Jog keys ใชเ้ พอ่ื ควบคุมความเรว็ ของหุน่ ยนต์ ให้กบั การควบคมุ แบบ Manual HOV ) 8 Main menu key: Shows the menu items on the smartHMI(Short cut สาหรับเรยี ก main menu มาใชง้ าน ) (>>> 4.4 \"Calling the main menu\" Page 50) 9 Status keys. The status keys are used primarily for setting param- eters in technology packages. Their exact function depends on the technology packages installed. (External input/output สาหรับควบคุมต่างๆ เช่น gripper ) 10 Start key: The Start key is used to start a program. . (ปุ่ม run โปรแกรม ไปข้างหน้าท่ลี ะ step ) 11 Start backwards key: The Start backwards key is used to start a program backwards. The program is executed step by step. (ป่มุ run โปรแกรม ถอยหลงั ทีล่ ะ step ) 12 STOP key: The STOP key is used to stop a program that is run- ning. (สาหรบั สงั่ หยดุ run โปรแกรม (หยุดชวั่ คราว)) 13 Keyboard key Displays the keyboard. It is generally not necessary to press this key to display the keyboard, as the smartHMI detects when key- board input is required and displays the keyboard automatically. (สาหรับเรียกใช้คียบ์ อร์ด (สาหรบั พิมพต์ วั อักษร และการป้อนตวั เลขตา่ งๆ)) (>>> 4.2.3 \"Keypad\" Page 50) 44 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

4 Operation 4.1.2 Rear view Overview Fig. 4-2: KUKA smartPAD, rear view USB connection Enabling switch Enabling switch Identification plate Start key (green) Enabling switch Description Element Description Identification plate Identification plate Start key The Start key is used to start a program. (ป่มุ run โปรแกรม Enabling ไปขา้ งหน้าทลี่ ะ step ) switch The enabling switch has 3 positions:  Not pressed  Center position (ใชก้ ับโหมด T1 และ T2 เพ่อื อนุญาตใิ หห้ ุ่นยนต์ ทางาน )  Panic position The enabling switch must be held in the center position in operating modes T1 and T2 in order to be able to jog the manipulator. In the operating modes Automatic and Automatic Exter- nal, the enabling switch has no function. Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 45 / 237

KUKA System Software 8.3 The USB connection is used, for example, for archiving and restoring data. USB connec- tion Only for FAT32-formatted USB sticks. 46 / 237 Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

4 Operation 4.1.3 Disconnecting and connecting the smartPAD Description The smartPAD can be disconnected while the robot controller is running. If the smartPAD is disconnected, the system can no lon- ger be switched off by means of the EMERGENCY STOP device on the smartPAD. For this reason, an external EMERGENCY STOP must be connected to the robot controller. The user is responsible for ensuring that the smartPAD is immediately re- moved from the system when it has been disconnected. The smartPAD must be stored out of sight and reach of personnel working on the industrial robot. This prevents operational and non-operational EMERGENCY STOP devices from becoming interchanged. Failure to observe these precautions may result in death to persons, severe injuries or considerable damage to property. Procedure Disconnection: 1. Press the disconnect button on the smartPAD. A message and a counter are displayed on the smartHMI. The counter runs for 30 s. During this time, the smartPAD can be disconnected from the robot controller. If the smartPAD is disconnected without the counter running, this trig- gers an EMERGENCY STOP. The EMERGENCY STOP can only be canceled by plugging the smartPAD back in. 2. Disconnect the smartPAD from the robot controller. If the counter expires without the smartPAD having been disconnected, this has no effect. The disconnect button can be pressed again at any time to display the counter again. Connection:  Connect the smartPAD to the robot controller. A smartPAD can be connected at any time. Precondition: Same smartPAD variant as the disconnected device. The EMERGENCY STOP and enabling switches are operational again 30 s after connection. The smartHMI is auto- matically displayed again. (This may take longer than 30 s.) The connected smartPAD assumes the current operating mode of the robot controller. The current operating mode is not, in all cases, the same as that be- fore the smartPAD was disconnected: if the robot controller is part of a RoboTeam, the operating mode may have been changed after dis- connection, e.g. by the master. The user connecting a smartPAD to the robot controller must subsequently stay with the smartPAD for at least 30 s, i.e. until the EMERGENCY STOP and enabling switches are operation- al once again. This prevents another user from trying to activate a non-oper- ational EMERGENCY STOP in an emergency situation, for example. Failure to observe this may result in death to persons, injuries or damage to property. Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 47 / 237

KUKA System Software 8.3 4.2 KUKA smartHMI user interface 48 / 237 Fig. 4-3: KUKA smartHMI user interface Item Description 1 Status bar (>>> 4.2.1 \"Status bar\" Page 48) (แถบแสดงสถานะกระทางาน) 2 Message counter(แถบแสดงจานวนข้อความเตอื นตา่ งๆ) The message counter indicates how many messages of each mes- sage type are active. Touching the message counter enlarges the display. 3 Message window(แถบแสดงจานวนรายละเอยี ดข้อความเตือนตา่ งๆ) By default, only the last message is displayed. Touching the mes- sage window expands it so that all active messages are displayed. An acknowledgeable message can be acknowledged with OK. All acknowledgeable messages can be acknowledged at once with All OK. 4 Space Mouse status indicator(แถบแสดงรูปแบบการควบคุมในโหมดตา่ งๆ ของ 6D Mouse เชน่ World ,Tool ,Axis ,Base) This indicator shows the current coordinate system for jogging with the Space Mouse. Touching the indicator displays all coordinate systems, allowing a different one to be selected. Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)

4 Operation Item Description 5 Space Mouse alignment indicator (แถบปรับตาแหนง่ การยืนควบคมุ หุ่นยนต์ เชน่ ด้านหน้า ,ด้านขา้ ง ,ด้านหลงั ) Touching this indicator opens a window in which the current align- ment of the Space Mouse is indicated and can be changed. (>>> 4.12.8 \"Defining the alignment of the Space Mouse\" Page 69) 6 Jog keys status indicator (แถบแสดงรปู แบบการควบคมุ ในโหมดต่างๆ ของ Jog Key เช่น World ,Tool ,Axis ,Base) This indicator shows the current coordinate system for jogging with the jog keys. Touching the indicator displays all coordinate sys- tems, allowing a different one to be selected. 7 Jog key labels (แถบควบคุมหุน่ ยนต์ แบบ Jog Key ในแกนต่างๆ ) If axis-specific jogging is selected, the axis numbers are displayed here (A1, A2, etc.). If Cartesian jogging is selected, the coordinate system axes are displayed here (X, Y, Z, A, B, C). Touching the label causes the selected kinematics group to be dis- played. 8 Program override (แถบควบคุมความเร็วหุ่นยนต์ โหมดโปรแกรม ) (>>> 6.5.4 \"Setting the program override (POV)\" Page 147) 9 Jog override (แถบควบคุมความเร็วหุ่นยนต์ โหมด Manual ) (>>> 4.12.3 \"Setting the jog override (HOV)\" Page 66) 10 Button bar. The buttons change dynamically and always refer to the window that is currently active in the smartHMI. (แถบแสดง รูปแบบการควบคมุ โดยปุม และจะเปลย่ี นหน้าทีไ่ ปตามหน้าจอแตล่ ะหน้าจอ) At the right-hand end is the Edit button. This can be used to call numerous commands relating to the Navigator. 11 Clock (แถบแสดงนาฬกิ าของระบบ) The clock displays the system time. Touching the clock displays the system time in digital format, together with the current date. 12 WorkVisual icon If no project can be opened, the icon has a small red X in the bot- tom left-hand corner. This is the case, for example, if the files be- longing to the project are missing. In such a case, the system is only partially available, e.g. the safety configuration cannot be opened. Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF) 49 / 237

KUKA System Software 8.3 4.2.1 Status bar Overview The status bar indicates the status of certain central settings of the industrial robot. In most cases, touching the display opens a window in which the set- tings can be modified. 50 / 237 Fig. 4-4: KUKA smartHMI status bar Item Description 1 Main menu key. Shows the menu items on the smartHMI. (ปุม่ เรียก Menu ควบคมุ หลกั ) (>>> 4.4 \"Calling the main menu\" Page 50) 2 Robot name. The robot name can be changed. (แถบแสดงชื่อหนุ่ ยนต์) (>>> 4.15.12 \"Displaying/editing robot data\" Page 83) 3 If a program has been selected, the name is displayed here. (แถบ แสดงช่ือโปรแกรม) 4 Submit interpreter status indicator (>>> 4.2.2 \"“Submit interpreter” status indicator\" Page 49) 5 Drives status indicator. The drives can be switched on or off here. (แถบแสดงและควบคมุ สถานะการทางานของหุ่นยนต)์ (>>> 6.5.5 \"Switching drives on/off\" Page 147) 6 Robot interpreter status indicator. Programs can be reset or can- celed here. (แถบควบคุมสถานะการทางานของโปรแกรม เช่น Reset , Cancel ) (>>> 6.5.6 \"Robot interpreter status indicator\" Page 148) (>>> 6.2.1 \"Selecting and deselecting a program\" Page 142) (>>> 6.5.11 \"Resetting a program\" Page 150) 7 Current operating mode (แถบแสดงสถานะของโหมดการควบคุม เชน่ T1 ,T2 ,AUT ,EXT AUT ) (>>> 4.10 \"Changing operating mode\" Page 59) 8 POV/HOV status indicator. Indicates the current program override and the current jog override. mode (แถบแสดงสถานะของความเร็วในการ ควบคุม ทัง้ โปรแกรมโหมดและ Jog โหมด ) (>>> 6.5.4 \"Setting the program override (POV)\" Page 147) (>>> 4.12.3 \"Setting the jog override (HOV)\" Page 66) 9 Program run mode status indicator. Indicates the current program run mode. (แถบแสดงสถานะและควบคมุ การใช้งานโหมดการ Run โปรแกรมในแบบตา่ งๆ เชน่ ทางานแบบตอ่ เนื่อง ,ทางานทีละคาสัง่ etc. ) (>>> 6.5.2 \"Program run modes\" Page 146) 10 Tool/base status indicator. Indicates the current tool and base. (แถบแสดงสถานะและควบคมุ การใช้งาน Tool และ Base ตา่ งๆ ) (>>> 4.12.4 \"Selecting the tool and base\" Page 66) 11 Incremental jogging status indicator. (>>> 4.12.10 \"Incremental jogging\" Page 71) Issued: 22.01.2013 Version: KSS 8.3 END V1 en (PDF)