4.6.1 Jog mode
In the operating modes T1 (Manual Reduced Velocity) and T2 (Manual High Velocity), the robot controller can only execute programs in jog mode. This means that it is necessary to hold down an enabling switch and the Start key in order to execute a program.
If the enabling switch is released or pressed fully down (panic position), the drives are deactivated immediately and the manipulator and any external axes (optional) stop with a STOP 0.
Releasing only the Start key causes the industrial robot to be stopped with a STOP 2.
4.6.2 Software limit switches
The axis ranges of all manipulator and positioner axes are limited by means of adjustable software limit switches. These software limit switches only serve as machine protection and must be adjusted in such a way that the manipulator/
positioner cannot hit the mechanical end stops.
Fig. 4-4: Enabling switches on the KCP
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The software limit switches are set during commissioning of an industrial ro-bot.
4.6.3 Mechanical end stops
The axis ranges of main axes A1 to A3 and wrist axis A5 of the manipulator are limited by means of mechanical end stops with buffers.
Additional mechanical end stops can be installed on the external axes.
4.6.4 Mechanical axis range limitation (optional)
Some manipulators can be fitted with mechanical axis range limitation in axes A1 to A3. The adjustable axis range limitation systems restrict the working range to the required minimum. This increases personal safety and protection of the system.
In the case of manipulators that are not designed to be fitted with mechanical axis range limitation, the workspace must be laid out in such a way that there is no danger to persons or material property, even in the absence of mechan-ical axis range limitation.
If this is not possible, the workspace must be limited by means of photoelectric barriers, photoelectric curtains or obstacles on the system side. There must be no shearing or crushing hazards at the loading and transfer areas.
4.6.5 Axis range monitoring (optional)
Some manipulators can be fitted with dual-channel axis range monitoring sys-tems in main axes A1 to A3. The positioner axes may be fitted with additional axis range monitoring systems. The safety zone for an axis can be adjusted and monitored using an axis range monitoring system. This increases person-al safety and protection of the system.
Further information is contained in the operating and programming in-structions.
If the manipulator or an external axis hits an obstruction or a buffer on the mechanical end stop or axis range lim-itation, this can result in material damage to the industrial robot. KUKA Ro-boter GmbH must be consulted before the industrial robot is put back into operation. (>>> 11 "KUKA Service" Page 103)
The affected buffer must be replaced with a new one before operation of the industrial robot is resumed. If a manipulator (or external axis) collides with a buffer at more than 250 mm/s, the manipulator (or external axis) must be ex-changed or recommissioning must be carried out by KUKA Roboter GmbH.
This option is not available for all robot models. Information on spe-cific robot models can be obtained from KUKA Roboter GmbH.
This option is not available for all robot models. Information on spe-cific robot models can be obtained from KUKA Roboter GmbH.
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4.6.6 Release device (optional)
Description The release device can be used to move the manipulator manually after an ac-cident or malfunction. The release device can be used for the main axis drive motors and, depending on the robot variant, also for the wrist axis drive mo-tors. It is only for use in exceptional circumstances and emergencies (e.g. for freeing people).
Procedure 1. Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again.
2. Remove the protective cap from the motor.
3. Push the release device onto the corresponding motor and move the axis in the desired direction.
The directions are indicated with arrows on the motors. It is necessary to overcome the resistance of the mechanical motor brake and any other loads acting on the axis.
4.6.7 KCP coupler (optional)
The KCP coupler allows the KCP to be connected and disconnected with the robot controller running.
4.6.8 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
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 an axis with the release device can damage the motor brake. This can result in personal injury and mate-rial damage. After using the release device, the affected motor must be ex-changed.
The operator must ensure that decoupled KCPs are im-mediately removed from the system and stored out of sight and reach of personnel working on the industrial robot. This serves to prevent operational and non-operational EMERGENCY STOP facilities from becoming interchanged.
Failure to observe this precaution may result in death, severe physical inju-ries or considerable damage to property.
Further information is contained in the assembly or operating instruc-tions for the robot controller.
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4.6.9 External safeguards
Safeguards The access of persons to the danger zone of the manipulator must be prevent-ed by means of safeguards.
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.
Other safety equipment
Other safety equipment must be integrated into the system in accordance with the corresponding standards and regulations.