KSS 5x Externer Editor

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Transcript of KSS 5x Externer Editor

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KUKA Roboter GmbHExpert Documentation

External Editor

For KUKA System Software 5.2, 5.3, 5.4, 5.5

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 © Copyright 2009

KUKA Roboter GmbHZugspitzstraße 140

D-86165 AugsburgGermany

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties withoutthe express permission of the KUKA Roboter GmbH.

Other functions not described in this documentation may be operable in the controller. The user hasno 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 softwaredescribed. Nevertheless, discrepancies cannot be precluded, for which reason we are not able toguarantee 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 operating instructions

KIM-PS5-DOC

External Editor

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Publication: Pub KSS 5.2 5.3 5.4 5.5 Externer Editor en

Book structure: KSS 5.2 5.3 5.4 5.5 Externer Editor V1.1

Label: KSS 5.2 5.3 5.4 5.5 Externer Editor V3

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Contents

1 Introduction .................................................................................................. 7

1.1 Target group .............................................................................................................. 7

1.2 Robot system documentation .................................................................................... 7

1.3 Trademarks ................................................................................................................ 7

2 Description of functions ............................................................................. 9

3 Safety ............................................................................................................ 11

3.1 General ...................................................................................................................... 11

3.1.1 Liability .................................................................................................................. 11

3.1.2 Representation of warnings and notes ................................................................. 11

3.1.3 Designated use of the robot system ..................................................................... 12

3.1.4 EC declaration of conformity and declaration of incorporation ............................. 12

3.1.5 Description of the robot system ............................................................................ 13

3.1.6 Terms used ........................................................................................................... 13

3.2 Personnel ................................................................................................................... 143.3 Safety equipment and safeguards in the robot system .............................................. 16

3.3.1 Overview of the safety equipment and safeguards ............................................... 16

3.3.2 ESC safety logic ................................................................................................... 16

3.3.3 Category for safety-related controller components ............................................... 17

3.3.4 Mode selector switch ............................................................................................ 17

3.3.5 Stop reactions ....................................................................................................... 18

3.3.6 Workspace, safety zone and danger zone ........................................................... 19

3.3.7 Operator safety ..................................................................................................... 19

3.3.8 EMERGENCY STOP device ................................................................................ 20

3.3.9 Enabling device .................................................................................................... 21

3.3.10 Connection for external enabling device ............................................................... 21

3.3.11 Jog mode .............................................................................................................. 22

3.3.12 Mechanical end stops ........................................................................................... 22

3.3.13 Software limit switches ......................................................................................... 22

3.3.14 Overview of operating modes and safety measures ............................................. 22

3.3.15 Mechanical axis range limitation (option) .............................................................. 23

3.3.16 Axis range monitoring (option) .............................................................................. 23

3.3.17 Release device (option) ........................................................................................ 23

3.3.18 KCP coupler (optional) .......................................................................................... 24

3.3.19 External safety equipment and safeguards .......................................................... 24

3.3.20 Labeling on the robot system ................................................................................ 25

3.4 Safety measures ........................................................................................................ 25

3.4.1 General safety measures ...................................................................................... 25

3.4.2 Transportation ....................................................................................................... 26

3.4.3 Start-up and recommissioning .............................................................................. 26

3.4.4 Virus protection and network security ................................................................... 28

3.4.5 Manual mode ........................................................................................................ 28

3.4.6 Simulation ............................................................................................................. 29

3.4.7 Automatic mode .................................................................................................... 29

3.4.8 Maintenance and repair ........................................................................................ 29

3.4.9 Decommissioning, storage and disposal .............................................................. 30

3.4.10 Safety measures for “single point of control” ........................................................ 31

Contents

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3.5 Applied norms and regulations .................................................................................. 32

4 Operation ...................................................................................................... 35

4.1 Opening the external editor ....................................................................................... 35

4.1.1 Opening the external editor, option 1 ................................................................... 35

4.1.2 Opening the external editor, option 2 ................................................................... 35

4.2 Permanently displaying the external editor ................................................................ 354.3 User interface of the external editor .......................................................................... 36

4.3.1 View on opening ................................................................................................... 36

4.3.2 File view ............................................................................................................... 37

4.3.3 Fold view .............................................................................................................. 38

4.3.4 Status keys ........................................................................................................... 38

4.3.5 Softkeys ................................................................................................................ 39

4.4 Search in file .............................................................................................................. 39

4.5 Selecting motion blocks ............................................................................................. 40

4.6 Printing a file .............................................................................................................. 40

4.7 Saving an SRC file as a TXT file ............................................................................... 404.7.1 Saving the SRC file as a TXT file, option 1 .......................................................... 40

4.7.2 Saving the SRC file as a TXT file, option 2 .......................................................... 40

4.8 Displaying the version of the external editor .............................................................. 41

4.9 Saving and closing a file ............................................................................................ 41

4.10 Closing the external editor ......................................................................................... 41

5 Program editing ........................................................................................... 43

5.1 Changing the parameters of motion blocks ............................................................... 43

5.2 Changing the TOOL coordinate system .................................................................... 43

5.3 Changing the BASE coordinate system .................................................................... 445.4 Duplicating motion blocks .......................................................................................... 45

5.5 Reversing the sequence of motion blocks ................................................................. 45

5.6 Mirroring points .......................................................................................................... 46

5.7 Mirroring all points of an SRC file .............................................................................. 47

5.8 Offsetting points (with numerical values) ................................................................... 48

5.9 Offsetting points (with vector) .................................................................................... 48

5.9.1 Offsetting points (with vector), option 1 ................................................................ 49

5.9.2 Offsetting points (with vector), option 2 ................................................................ 49

5.10 Offsetting and rotating points (with vector) ................................................................ 50

5.10.1 Offsetting and rotating points (with vector), option 1 ............................................ 505.10.2 Offsetting and rotating points (with vector), option 2 ............................................ 50

5.11 Online correction ....................................................................................................... 51

5.11.1 Defining limits for online correction ....................................................................... 51

5.11.2 Correcting points online ........................................................................................ 52

5.12 Offline correction ....................................................................................................... 53

5.12.1 Defining limits for offline correction ....................................................................... 53

5.12.2 Correcting points offline ........................................................................................ 54

5.13 Adapting software limit switches to the program ....................................................... 55

5.14 Deleting program lines ............................................................................................... 56

5.15 Deleting unused data from a DAT file ........................................................................ 575.16 Deleting unused master points from a DAT file ......................................................... 57

6 KUKA Service ............................................................................................... 59

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Contents

6.1 Requesting support .................................................................................................... 59

6.2 KUKA Customer Support ........................................................................................... 59

Index ............................................................................................................. 65

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1. Introduction

1 Introduction

1.1 Target group

This documentation is aimed at users with the following knowledge and skills:

Advanced knowledge of the robot controller system

Advanced KRL programming skills

1.2 Robot system documentation

The robot system documentation consists of the following parts:

Operating instructions for the robot

Operating instructions for the robot controller

Operating and programming instructions for the KUKA System Software

Documentation relating to options and accessories

Each of these sets of instructions is a separate document.

1.3 Trademarks

Windows is a trademark of Microsoft Corporation.

For optimal use of our products, we recommend that our customers take partin a course of training at KUKA College. Information about the training pro-gram can be found at www.kuka.com or can be obtained directly from oursubsidiaries.

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2. Description of functions

2 Description of functions

The external editor is a function contained within the KUKA System Software.It allows the mathematical manipulation of points in KRL programs.

Examples:

Mirroring points.

Offsetting points relative to a coordinate system.

Offsetting points using a vector.

Adapting points to a different tool or base.

etc.

Areas of application:

Offline programming of KRL programs

Online correction of KRL programs

Furthermore, the external editor also offers several other functions, such asprinting files or deleting unused data from DAT files.

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3. Safety

3 Safety

3.1 General

3.1.1 Liability

The device described in these operating instructions is an industrial robot –called “robot system” in the following text – consisting of:

Robot

Connecting cables

Robot controller

Teach pendant

Linear unit (optional)

Positioner (optional)

Two-axis positioner (optional)

Top-mounted cabinet (optional)The robot system is built using state-of-the-art technology and in accordancewith the recognized safety rules. Nevertheless, impermissible misuse of therobot system may constitute a risk to li fe and limb or cause damage to the ro-bot system and to other material property.

The robot system may only be used in perfect technical condition in accord-ance with its designated use and only by safety-conscious persons who arefully aware of the risks involved in its operation. Use of the robot system is sub-

 ject to compliance with these operating instructions and with the declaration ofincorporation supplied together with the robot system. Any functional disor-ders affecting the safety of the system must be rectified immediately.

Safety infor-

mation

Safety information cannot be held against KUKA Roboter GmbH. Even if allsafety instructions are followed, this is not a guarantee that the robot systemwill not cause personal injuries or material damage.

No modifications may be carried out to the robot system without the authori-zation of KUKA Roboter GmbH. Additional components (tools, software, etc.),not supplied by KUKA Roboter GmbH, may be integrated into the robot sys-tem. The user is liable for any damage these components may cause to therobot system or to other material property.

In addition to the Safety chapter, the operating instructions contain furthersafety instructions. These must be observed.

3.1.2 Representation of warnings and notes

Safety Warnings marked with this pictogram are relevant to safety and must be ob-served.

Danger!

This warning means that death, severe physical injury or substantial materialdamage will occur, if no precautions are taken.

Warning!

This warning means that death, severe physical injury or substantial materialdamage may occur, if no precautions are taken.

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Notes Notes marked with this pictogram contain tips to make your work easier or ref-erences to further information.

3.1.3 Designated use of the robot system

The robot system is designed exclusively for the specified applications.

Using the system for any other or additional purpose is considered impermis-

sible misuse. The manufacturer cannot be held liable for any damage resultingfrom such use. The risk lies entirely with the user.

Operating the robot system and its options within the limits of its designateduse also involves continuous observance of the operating instructions withparticular reference to the maintenance specifications.

Impermissible

misuse

Any use or application deviating from the designated use is deemed to be im-permissible misuse; examples of such misuse include:

Transportation of persons and animals

Use as a climbing aid

Operation outside the permissible operating parameters

Use in potentially explosive environments

3.1.4 EC declaration of conformity and declaration of incorporation

This robot system is a partial or incomplete machine as defined by the EC Ma-chinery Directive. The robot system may only be put into operation if the fol-lowing preconditions are met:

The robot system is integrated into an overall system.

Or: The robot system, together with other machines, constitutes an overallsystem.

Or: All safety equipment and safeguards required for operation in the over-all system as defined by the EC Machinery Directive have been added tothe robot system.

The overall system complies with the EC Machinery Directive. This hasbeen confirmed by means of an assessment of conformity.

Declaration of

conformity

The system integrator must issue a declaration of conformity for the overallsystem in accordance with the Machinery Directive. The declaration of con-formity forms the basis for the CE mark for the system. The robot system mustbe operated in accordance with the applicable national laws, regulations andstandards.

The robot controller is CE certified under the EMC Directive and the Low Volt-age Directive.

Caution!

This warning means that minor physical injuries or minor material damagemay occur, if no precautions are taken.

Tips to make your work easier or references to further information.

Further information is contained in the technical data of the operating instruc-tions for the robot system and its options.

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3. Safety

Declaration of

incorporation

A declaration of incorporation is provided for the robot system. This declara-tion of incorporation contains the stipulation that the robot system must not becommissioned until it complies with the provisions of the Machinery Directive.

3.1.5 Description of the robot system

The robot system consists of the following components:

Robot

Robot controller

KCP teach pendant

Connecting cables

External axes, e.g. linear unit, two-axis positioner, positioner (optional)

Top-mounted cabinet (optional)

Software

Options, accessories

3.1.6 Terms used

Fig. 3-1: Example of a robot system

1 Linear unit 4 Connecting cables

2 Robot 5 Robot controller3 Positioner 6 Teach pendant

Term Description

Axis range Range of each axis, in degrees, within which it may move. The axisrange must be defined for each axis that is to be monitored.

Stopping distance Stopping distance = reaction distance + braking distance

The stopping distance is part of the danger zone.

The braking distance is the distance covered by the robot and anyoptional external axes after the stop function has been triggered andbefore the robot comes to a standstill.

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3.2 Personnel

The following persons or groups of persons are defined for the robot system:

User

Personnel

User The user must observe the labor laws and regulations. This includes e.g.: The user must comply with his monitoring obligations.

The user must carry out instruction at defined intervals.

Personnel Personnel must be instructed, before any work is commenced, in the type ofwork involved and what exactly it entails as well as any hazards which may ex-ist. Instruction must be repeated after particular incidents or technical modifi-cations.

Personnel includes:

System integrator

Operators, subdivided into:

Start-up, maintenance and service personnel

Operating personnel

Cleaning personnel

Workspace The robot is allowed to move within its workspace. The workspace isderived from the individual axis ranges.

Operator(User)

The user of the robot system can be the management, employer or del-egated person responsible for use of the robot system.

Danger zone The danger zone consists of the workspace and the stopping distances.

KCP The KCP (KUKA Control Panel) teach pendant has all the operator con-trol and display functions required for operating and programming therobot system.

Robot system The robot system consists of the robot controller and robot, togetherwith any options (e.g. KUKA linear unit, two-axis positioner, other posi-tioner, top-mounted cabinet).

Safety zone The safety zone is situated outside the danger zone.

Stop category 0 The drives are deactivated immediately and the brakes are applied. Therobot and any external axes (optional) perform path-oriented braking.

Note: This stop category is called STOP 0 in this document.Stop category 1 The robot and any external axes (optional) brake with path-maintaining

braking. The drives are deactivated after 1 s and the brakes are applied.Note: This stop category is called STOP 1 in this document.

Stop category 2 The drives are not deactivated and the brakes are not applied. The robotand any external axes (optional) are braked with a normal braking ramp.

Note: This stop category is called STOP 2 in this document.

System integrator(plant integrator)

System integrators are people who safely integrate the robot systeminto a plant and commission it.

T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)T2 Test mode, Manual High Velocity (> 250 mm/s permissible)

External axis Motion axis which is not part of the robot but which is controlled usingthe robot controller, e.g. KUKA linear unit, two-axis positioner, Posiflex

Term Description

All persons working with the robot system must have read and understoodthe robot system documentation, including the safety chapter.

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3. Safety

System integrator The robot system is safely integrated into a plant by the system integrator.

The system integrator is responsible for the following tasks: Installing the robot system

Connecting the robot system

Performing risk assessment

Operating the required safety equipment and safeguards

Issuing the declaration of conformity

Attaching the CE mark

Creating the operating instructions for the overall system

Operator The operator must meet the following preconditions:

The operator must be trained for the work to be carried out. Work on the robot system must only be carried out by qualified personnel.

These are people who, due to their specialist training, knowledge and ex-perience, and their familiarization with the relevant standards, are able toassess the work to be carried out and detect any potential dangers.

Example The tasks can be distributed as shown in the following table.

Installation, exchange, adjustment, operation, maintenance and repair mustbe performed only as specified in the operating instructions for the relevantcomponent of the robot system and only by personnel specially trained forthis purpose.

Tasks Operator ProgrammerSystem

integrator

Switch robot controller

on/offx x x

Start program x x x

Select program x x x

Select operating mode x x x

Calibration

(tool, base)x x

Master robot x x

Configuration x x

Programming x x

Start-up x

Maintenance x

Repair x

Shutting down x

Transportation x

Work on the electrical and mechanical equipment of the robot system mayonly be carried out by specially trained personnel.

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3.3 Safety equipment and safeguards in the robot system

3.3.1 Overview of the safety equipment and safeguards

The following safety equipment and safeguards are present in the robot sys-tem:

Mode selector switch(>>> 3.3.4 "Mode selector switch" page 17)

Operator safety (= connection for interlocking fixed guards)

(>>> 3.3.7 "Operator safety" page 19)

EMERGENCY STOP device

(>>> 3.3.8 "EMERGENCY STOP device" page 20)

Enabling device

(>>> 3.3.9 "Enabling device" page 21)

(>>> 3.3.10 "Connection for external enabling device" page 21)

Jog mode in the test modes

(>>> 3.3.11 "Jog mode" page 22) Mechanical limit stops

(>>> 3.3.12 "Mechanical end stops" page 22)

Mechanical axis range limitation (optional)

(>>> 3.3.15 "Mechanical axis range limitation (option)" page 23)

Axis range monitoring (optional)

(>>> 3.3.16 "Axis range monitoring (option)" page 23)

Release device (optional)

(>>> 3.3.17 "Release device (option)" page 23)

Labeling of danger areas in the robot system

(>>> 3.3.20 "Labeling on the robot system" page 25)

The function and triggering of the electronic safety equipment are monitoredby the ESC safety logic.

3.3.2 ESC safety logic

The ESC (Electronic Safety Circuit) safety logic is a dual-channel computer-aided safety system. It permanently monitors all connected safety-relevantcomponents. In the event of a fault or interruption in the safety circuit, the pow-er supply to the drives is shut off, thus bringing the robot system to a standstill.

The ESC safety logic triggers different stop reactions, depending on the oper-ating mode of the robot system.

The ESC safety logic monitors the following inputs:

Operator safety

Local EMERGENCY STOP (= EMERGENCY STOP button on the KCP)

External EMERGENCY STOP Enabling device

Drives OFF

Danger!

In the absence of functional safety equipment and safeguards, the robot sys-tem can cause personal injury or material damage. If safety equipment orsafeguards are dismantled or deactivated, the robot system may not be op-erated.

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3. Safety

Drives ON

Operating modes

Qualifying inputs

3.3.3 Category for safety-related controller components

Safety-related controller components include: Local EMERGENCY STOP device (= EMERGENCY STOP button on the

KCP)

External EMERGENCY STOP device

Enabling device

External enabling device

Operator safety

Qualifying inputs

Automatic mode

Test mode

These circuits conform to the requirements of category 3 according to EN 954-1.

3.3.4 Mode selector switch

The robot system can be operated in the following modes:

Manual Reduced Velocity (T1)

Manual High Velocity (T2)

Automatic (AUT)

Automatic External (AUT EXT)

The operating mode is selected using the mode selector switch on the KCP.The switch is activated by means of a key which can be removed. If the key isremoved, the switch is locked and the operating mode can no longer bechanged.

If the operating mode is changed during operation, the drives are immediatelyswitched off. The robot and any external axes (optional) are stopped with aSTOP 0.

Fig. 3-2: Mode selector switch

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3.3.5 Stop reactions

Stop reactions of the robot system are triggered in response to operator ac-tions or as a reaction to monitoring functions and error messages. The follow-ing table shows the different stop reactions according to the operating modethat has been set.

STOP 0, STOP 1 and STOP 2 are the stop definitions according to DIN EN60204-1:2006.

1 T2 (Manual High Velocity)2 AUT (Automatic)3 AUT EXT (Automatic External)

4 T1 (Manual Reduced Velocity)

Operatin

g mode

Use Velocities

T1For test operation, pro-gramming and teach-ing

Program verification:

Programmed velocity, maxi-mum 250 mm/s

Jog mode:

Jog velocity, maximum 250 mm/ s

T2 For test operation Program verification:

Programmed velocity

AUT

For robot systemswithout higher-level

controllersOnly possible with aconnected safety cir-cuit

Program mode:

Programmed velocity

Jog mode: not possible

AUT EXT

For robot systems withhigher-level control-lers, e.g. PLC

Only possible with aconnected safety cir-cuit

Program mode:

Programmed velocity

Jog mode: not possible

Trigger T1, T2 AUT, AUT EXT

Safety gate opened - STOP 1

EMERGENCY STOPpressed

STOP 0 STOP 1

Enabling withdrawn STOP 0 -Start key released STOP 2 -“Drives OFF” keypressed

STOP 0

STOP key pressed STOP 2Operating modechanged

STOP 0

Encoder error(DSE-RDC connec-

tion broken)

STOP 0

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3. Safety

3.3.6 Workspace, safety zone and danger zone

Workspaces are to be restricted to the necessary minimum size. A workspacemust be safeguarded using appropriate safeguards.

The safeguards (e.g. safety gate) must be situated inside the safety zone. If asafeguard is triggered, robot and external axes (optional) are braked andcome to a stop within the danger zone.

The danger zone consists of the workspace and the stopping distances of therobot and external axes (optional). It must be safeguarded by means of phys-ical safeguards to prevent danger to persons or the risk of material damage.

3.3.7 Operator safety

The operator safety input is used for interlocking fixed guards. Safety equip-ment, such as safety gates, can be connected to the dual-channel input. Ifnothing is connected to this input, operation in Automatic mode is not possible.Operator safety is not active in the test modes T1 (Manual Reduced Velocity)and T2 (Manual High Velocity).

In the event of a loss of signal during Automatic operation (e.g. safety gate isopened), the drives are deactivated after 1 s and the robot and any externalaxes (optional) are stopped with a STOP 1. When the signal is applied again

Motion enable can-celed

STOP 2

Robot controllerswitched off

Power failure

STOP 0

Trigger T1, T2 AUT, AUT EXT

Fig. 3-3: Example of axis range A1

1 Workspace 3 Stopping distance2 Robot 4 Safety zone

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at the input (e.g. safety gate closed), Automatic operation can be resumedonce the corresponding message has been acknowledged.

Operator safety can be connected via the peripheral interface on the robot

controller.

3.3.8 EMERGENCY STOP device

The EMERGENCY STOP device for the robot system is the EMERGENCYSTOP button on the KCP. The button must be pressed in the event of a haz-ardous situation or emergency.

Reactions of the robot system if the EMERGENCY STOP button is pressed:

Manual Reduced Velocity (T1) and Manual High Velocity (T2) modes:

The drives are switched off immediately. The robot and any external axes

(optional) are stopped with a STOP 0. Automatic modes (AUT and AUT EXT):

The drives are switched off after 1 second. The robot and any externalaxes (optional) are stopped with a STOP 1.

Before operation can be resumed, the EMERGENCY STOP button must beturned to release it and the stop message must be acknowledged.

The operator safety must be designed in such a way that it is only possibleto acknowledge the message from outside.

Fig. 3-4: EMERGENCY STOP button on the KCP

1 EMERGENCY STOP button

Warning!

Tools and other equipment connected to the robot must be integrated into theEMERGENCY STOP circuit on the system side if they could constitute a po-tential hazard.Failure to observe this precaution may result in death, severe physical inju-ries or considerable damage to property.

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3. Safety

3.3.9 Enabling device

The enabling devices of the robot system are the enabling switches on theKCP.

There are 3 enabling switches installed on the KCP. The enabling switcheshave 3 positions:

Not pressed Center position

Panic position

In the test modes T1 (Manual Reduced Velocity) and T2 (Manual High Veloc-ity), the robot can only be moved if one of the enabling switches is held in thecentral position. If the enabling switch is released or pressed fully down (panicposition), the drives are deactivated immediately and the robot stops with aSTOP 0.

3.3.10 Connection for external enabling device

External enabling devices are required if there is more than one person in thedanger zone of the robot system. They can be connected via the peripheralinterface on the robot controller.

External enabling devices are not included in the scope of supply of the robotsystem.

Warning!

The enabling switches must not be held down by adhesive tape or othermeans or manipulated in any other way.

Death, serious physical injuries or major damage to property may result.

Fig. 3-5: Enabling switches on the KCP

1 - 3 Enabling switches

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3.3.11 Jog mode

In the operating modes T1 (Manual Reduced Velocity) and T2 (Manual HighVelocity), the robot can only execute programs in jog mode. This means thatit is necessary to hold down an enabling switch and the Start key in order toexecute a program.

If the enabling switch is released or pressed fully down (panic position), the

drives are deactivated immediately and the robot and any external axes (op-tional) stop with a STOP 0.

Releasing only the Start key causes the robot system to be stopped with aSTOP 2.

3.3.12 Mechanical end stops

The axis ranges of main axes A 1 to A 3 and wrist axis A 5 of the robot are lim-ited by means of mechanical limit stops with a buffer.

Additional mechanical limit stops can be installed on the external axes.

3.3.13 Software limit switches

The axis ranges of all robot and positioner axes are limited by means of ad- justable software limit switches. These software limit switches only serve asmachine protection and must be adjusted in such a way that the robot/posi-tioner cannot hit the mechanical limit stops.

The software limit switches are set during commissioning of a robot system.

3.3.14 Overview of operating modes and safety measures

The following table indicates the operating modes in which the safety meas-ures are active.

Danger!

If the robot or an external axis hits an obstruction or a buffer on the mechan-ical end stop or axis range limitation, this can result in material damage to therobot system. KUKA Roboter GmbH must be consulted before the robot sys-tem is put back into operation (>>> 6 "KUKA Service" page 59). The affectedbuffer must immediately be replaced with a new one. If a robot (or externalaxis) collides with a buffer at more than 250 mm/s, the robot (or external axis)must be exchanged or recommissioning must be carried out by the KUKARoboter GmbH.

Further information is contained in the operating and programming instruc-tions.

Safety measures T1 T2 AUT AUT EXT

Operator safety - - active active

EMERGENCY STOP

device

active(STOP

0)

active(STOP

0)

active(STOP

1)

active(STOP 1)

Enabling device active active - -

Reduced velocity duringprogram verification

active - - -

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3. Safety

3.3.15 Mechanical axis range limitation (option)

Most robots can be fitted with mechanical axis range limitation in axes A 1 toA 3. The adjustable axis range limitation systems restrict the working range tothe required minimum. This increases personal safety and protection of thesystem.

In the case of robots that are not designed to be fitted with mechanical axisrange limitation, the workspace must be laid out in such a way that there is nodanger to persons or material property, even in the absence of mechanicalaxis range limitation.

If this is not possible, the workspace must be limited by means of photoelectricbarriers, photoelectric curtains or obstacles on the system side. There must be

no shearing or crushing hazards at the loading and transfer areas.

3.3.16 Axis range monitoring (option)

Most robots can be fitted with dual-channel axis range monitoring systems inmain axes A 1 to A 3. The positioner axes may be fitted with additional axisrange monitoring systems. The safety zone for an axis can be adjusted andmonitored using an axis range monitoring system. This increases personal

safety and protection of the system.

3.3.17 Release device (option)

Description The release device can be used to move the robot mechanically after an acci-dent or malfunction. The release device can be used for the main axis drivemotors 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). After use of the release device, the affected motors must beexchanged.

Procedure 1. Switch off the robot controller and secure it (e.g. with a padlock) to preventunauthorized 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 toovercome the resistance of the mechanical motor brake and any otherloads acting on the axis.

Jog mode active active - -

Software limit switches active active active active

Safety measures T1 T2 AUT AUT EXT

This option can be retrofitted.

This option can be retrofitted.

Warning!

The motors reach temperatures during operation which can cause burns tothe skin. Contact should be avoided. Appropriate safety precautions must betaken, e.g. protective gloves must be worn.

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3.3.18 KCP coupler (optional)

The KCP coupler allows the KCP to be connected and disconnected with therobot controller running.

3.3.19 External safety equipment and safeguards

E-STOP There must be EMERGENCY STOP devices on every operator panel and an-ywhere else it may be necessary to trigger an EMERGENCY STOP. The sys-tem integrator is responsible for ensuring this. External EMERGENCY STOP

devices are connected to the peripheral interface of the robot.

Safeguards The access of persons to the danger zone of the robot must be prevented bymeans 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 easilycircumvented.

They are sufficiently fastened and can withstand all forces that are likelyto 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 safetyinput of the robot controller via safety gate switching devices or safetyPLC.

Switching devices, switches and the type of switching conform to category3 according to EN 954-1.

Depending on the risk situation: the safety gate is additionally safeguarded

by means of a locking mechanism that only allows the gate to be openedif the robot is safely at a standstill.

Warning!

Moving an axis with the release device can damage the motor brake. Thiscan result in personal injury and material damage. After using the release de-vice, the affected motor must be exchanged.

Further information is contained in the robot operating instructions.

Warning!

The operator must ensure that decoupled KCPs are immediately removedfrom the system and stored out of sight and reach of the robot system per-sonnel. This serves to prevent operational and non-operational EMERGEN-CY 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 robot controller operating instructions.

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3. Safety

The button for acknowledging the safety gate is located outside the spacelimited by the safeguards.

Other safety

equipment

Other safety equipment must be integrated into the system in accordance with

the corresponding standards and regulations.

3.3.20 Labeling on the robot system

All plates, labels, symbols and marks constitute safety-relevant parts of the ro-bot system. They must not be modified or removed.

Labeling on the robot system consists of:

Rating plates

Warning labels

Safety symbols

Designation labels

Cable markings

Identification plates

3.4 Safety measures

3.4.1 General safety measures

The robot system may only be used in perfect technical condition in accord-ance with its designated use and only by safety-conscious persons. Operatorerrors can result in personal injury and damage to property.

It is important to be prepared for possible movements of the robot system evenafter the robot controller has been switched off and locked. Incorrect installa-tion (e.g. overload) or mechanical defects (e.g. brake defect) can cause the ro-bot or external axes to sag. If work is to be carried out on a switched-off robotsystem, the robot and external axes must first be moved into a position inwhich they are unable to move on their own, whether the payload is mountedor not. If this is not possible, the robot and external axes must be secured by

appropriate means.

KCP If more than one KCP is used in the overall system, it must be ensured thateach KCP is unambiguously assigned to the corresponding robot system.There must be no possibility of mixing them up in an emergency situation.

Further information is contained in the corresponding standards and regula-tions. These also include DIN EN 953.

Further information can be found in the operating instructions of the robot, lin-ear unit, positioner and robot controller.

Danger!

In the absence of functional safety equipment and safeguards, the robot sys-tem can cause personal injury or material damage. If safety equipment orsafeguards are dismantled or deactivated, the robot system may not be op-erated.

Warning!

The motors reach temperatures during operation which can cause burns tothe skin. Contact should be avoided. Appropriate safety precautions must betaken, e.g. protective gloves must be worn.

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External

keyboard,

external mouse

An external keyboard and/or external mouse may only be used if the followingconditions are met:

Start-up or maintenance work is being carried out.

The drives are switched off.

There are no persons in the danger zone.

The KCP must not be used as long as an external keyboard and/or externalmouse are connected.

The external keyboard and/or external mouse must be removed as soon asthe start-up or maintenance work is completed.

Faults The following tasks must be carried out in the case of faults to the robot sys-tem:

Switch off the robot controller and secure it (e.g. with a padlock) to preventunauthorized persons from switching it on again.

Indicate the fault by means of a label with a corresponding warning (tag-out).

Keep a record of the faults.

Eliminate the fault and carry out a function test.

Modifications After modifications to the robot system, checks must be carried out to ensure

the required safety level. The valid national or regional work safety regulationsmust be observed for this check. The correct functioning of all safety circuitsmust also be tested.

3.4.2 Transportation

Robot The prescribed transport position of the robot must be observed. Transporta-tion must be carried out in accordance with the robot operating instructions.

Robot controller The robot controller must be transported and installed in an upright position.Avoid vibrations and impacts during transportation in order to prevent damageto the robot controller.

Transportation must be carried out in accordance with the operating instruc-tions for the robot controller.

External axis

(optional)

The prescribed transport position of the external axis (e.g. KUKA linear unit,two-axis positioner, etc.) must be observed. Transportation must be carriedout in accordance with the operating instructions for the external axis.

3.4.3 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 thischeck. The correct functioning of all safety circuits must also be tested.

Warning!

The operator must ensure that decoupled KCPs are immediately removedfrom the system and stored out of sight and reach of the robot system per-sonnel. This serves to prevent operational and non-operational EMERGEN-CY STOP facilities from becoming interchanged.Failure to observe this precaution may result in death, severe physical inju-ries or considerable damage to property.

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3. Safety

Function test The following tests must be carried out before start-up and recommissioning:

General test

It must be ensured that:

The robot system is correctly installed and fastened in accordance with thespecifications in the documentation.

There are no foreign bodies or loose parts on the robot system.

All required safety equipment is correctly installed and operational.

The power supply ratings of the robot system correspond to the local sup-ply voltage and mains type.

The ground conductor and the equipotential bonding cable are sufficientlyrated and correctly connected.

The connecting cables are correctly connected and the connectors arelocked.

Test of safety-oriented circuits

A function test must be carried out for the following safety-oriented circuits toensure that they are functioning correctly:

Local EMERGENCY STOP device (= EMERGENCY STOP button on theKCP)

External EMERGENCY STOP device (input and output)

Enabling device (in the test modes)

Operator safety (in the automatic modes)

Qualifying inputs (if connected)

Test of reduced velocity control

This test is to be carried out as follows:

1. Program a straight path with the maximum possible velocity.

2. Calculate the length of the path.

3. Execute the path in T1 mode with the override set to 100% and time themotion with a stopwatch.

4. Calculate the velocity from the length of the path and the time measuredfor execution of the motion.

The velocity thus calculated must not exceed 250 mm/s.

Machine data It must be ensured that the rating plate on the robot controller has the samemachine data as those entered in the declaration of incorporation. The ma-

The passwords for logging onto the KUKA System Software as “Expert” and“Administrator” must be changed before start-up and must only be communi-cated to authorized personnel.

Danger!

The robot controller is preconfigured for the specific robot system. If cablesare interchanged, the robot and the external axes (optional) may receive in-

correct data and can thus cause personal injury or material damage. If a sys-tem consists of more than one robot, always connect the connecting cablesto the robots and their corresponding robot controllers.

Caution!

If the internal cabinet temperature of the robot controller differs greatly fromthe ambient temperature, condensation can form, which may cause damageto the electrical components. Do not put the robot controller into operation un-til the internal temperature of the cabinet has adjusted to the ambient temper-ature.

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chine data on the rating plate of the robot and the external axes (optional) mustbe entered during start-up.

3.4.4 Virus protection and network security

The user of the robot system is responsible for ensuring that the software isalways safeguarded with the latest virus protection. If the robot controller is in-tegrated into a network that is connected to the company network or to the In-ternet, it is advisable to protect this robot network against external risks bymeans of a firewall.

3.4.5 Manual mode

Manual mode is the mode for setup work. Setup work is all the tasks that haveto be carried out on the robot system to enable automatic operation. Setupwork includes:

Jog mode

Teaching

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 robot

or the external axes (optional) from being moved unintentionally.

New or modified programs must always be tested first in Manual ReducedVelocity mode (T1).

The robot, tooling or external axes (optional) must never touch or projectbeyond the safety fence.

Components, tooling and other objects must not become jammed due tothe motion of the robot system, nor must they lead to short-circuits or beliable to fall off.

All setup work must be carried out, where possible, from outside the safe-

guarded area.

If the setup work has to be carried out inside the safeguarded area, the follow-ing must be taken into consideration:

In Manual Reduced Velocity mode (T1):

If it can be avoided, there must be no other persons inside the safeguard-ed area.

If it is necessary for there to be several persons inside the safeguarded ar-ea, the following must be observed:

Each person must have an enabling device.

All persons must have an unimpeded view of the robot system.

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.

Warning!

The robot must not be moved if incorrect machine data are loaded. Death,severe physical injuries or considerable damage to property may otherwiseresult. The correct machine data must be loaded.

For optimal use of our products, we recommend that our customers carry outa regular virus scan. Information about security updates can be found atwww.kuka.com.

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3. Safety

In Manual High Velocity mode (T2):

This mode may only be used if the application requires a test at a velocityhigher than Manual Reduced Velocity.

Teaching and programming are not permissible in this operating mode.

Before commencing the test, the operator must ensure that the enablingdevices 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.

3.4.6 Simulation

Simulation programs do not correspond exactly to reality. Robot programs cre-ated in simulation programs must be tested in the system in Manual ReducedVelocity mode (SSTEP T1). It may be necessary to modify the program.

3.4.7 Automatic mode

Automatic mode is only permissible in compliance with the following safetymeasures:

All safety equipment and safeguards are present and operational.

There are no persons in the production line.

The defined working procedures are adhered to.

If the robot or an external axis (optional) comes to a standstill for no apparentreason, the danger zone must not be entered until an EMERGENCY STOPhas been triggered.

3.4.8 Maintenance and repair

After maintenance and repair work, checks must be carried out to ensure therequired safety level. The valid national or regional work safety regulationsmust be observed for this check. The correct functioning of all safety circuitsmust also be tested.

The purpose of maintenance and repair work is to ensure that the system iskept 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 repairitself.

The following safety measures must be carried out when working on the robot

system:

Carry out work outside the danger zone. If work inside the danger zone isnecessary, the user must define additional safety measures to ensure thesafe protection of personnel.

Switch off the robot controller and secure it (e.g. with a padlock) to preventunauthorized persons from switching it on again. If it is necessary to carryout work with the robot controller switched on, the user must define addi-tional safety measures to ensure the safe protection of personnel.

If it is necessary to carry out work with the robot controller switched on, thismay 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.

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The EMERGENCY STOP systems must remain active. If safety equip-ment or safeguards are deactivated during maintenance or repair work,they must be reactivated immediately after the work is completed.

Faulty components must be replaced using new components with the samearticle numbers or equivalent components approved by KUKA Roboter GmbHfor this purpose.

Cleaning and preventive maintenance work is to be carried out in accordancewith the operating instructions.

Robot controller Even when the robot controller is switched off, parts connected to peripheraldevices may still carry voltage. The external power sources must therefore beswitched off if work is to be carried out on the robot controller.

The ESD regulations must be adhered to when working on components in therobot controller.

Voltages in excess of 50 V (up to 600 V) can be present in the KPS 600 (KUKAPower Supply), the KSDs (KUKA Servo Drives) and the intermediate-circuitconnecting cables several minutes after the robot controller has beenswitched off. To prevent life-threatening injuries, no work may be carried out

on the robot system in this time.

Water and dust must be prevented from entering the robot controller.

Counterbal-

ancing system

Some robot variants are equipped with a hydropneumatic, spring or gas cylin-der counterbalancing system.

The hydropneumatic and gas cylinder counterbalancing systems are pressureequipment and, as such, are subject to obligatory equipment monitoring. De-pending on the robot variant, the counterbalancing systems correspond to cat-egory II or III, fluid group 2, of the Pressure Equipment Directive.

The user must comply with the applicable national laws, regulations andstandards 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 robot assemblies supported by the counterbalancing systems mustbe secured.

Work on the counterbalancing systems must only be carried out by quali-fied personnel.

Hazardoussubstances

The following safety measures must be carried out when handling hazardoussubstances:

Avoid prolonged and repeated intensive contact with the skin.

Avoid breathing in oil spray or vapors.

Clean skin and apply skin cream.

3.4.9 Decommissioning, storage and disposal

The robot system must be decommissioned, stored and disposed of in accord-ance with the applicable national laws, regulations and standards.

To ensure safe use of our products, we recommend that our customers reg-ularly request up-to-date safety data sheets from the manufacturers of haz-ardous substances.

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3. Safety

3.4.10 Safety measures for “single point of control”

Overview If certain components in the robot system are operated, safety measures mustbe taken to ensure complete implementation of the principle of “single point ofcontrol”.

Components:

Submit interpreter PLC

OPC server

Remote control tools

External keyboard/mouse

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.

Submit inter-

preter, PLC

If motions, (e.g. drives or grippers) are controlled with the Submit interpreteror the PLC via the I/O system, and if they are not safeguarded by other means,then this control will take effect even in T1 and T2 modes or while an EMER-GENCY STOP is active.

If variables that affect the robot motion (e.g. override) are modified with theSubmit interpreter or the PLC, this takes effect even in T1 and T2 modes orwhile an EMERGENCY STOP is active.

Safety measures:

Do not modify safety-relevant signals and variables (e.g. operating mode,

EMERGENCY STOP, safety gate contact) via the Submit interpreter orPLC.

If modifications are nonetheless required, all safety-relevant signals andvariables 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,

remote control

tools

These components can be used with write access to modify programs, outputsor other parameters of the robot controller, without this being noticed by anypersons 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 bemodified using these components.

External

keyboard/mouse

These components can be used to modify programs, outputs or other param-eters of the robot controller, without this being noticed by any persons locatedinside the system.

Safety measures:

Only use one operator console at each robot controller.

If the KCP is being used for work inside the system, remove any keyboardand mouse from the robot controller beforehand.

The implementation of additional safety measures may be required. Thismust be clarified for each specific application; this is the responsibility of thesystem integrator, programmer or user of the system.

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3.5 Applied norms and regulations

Name Definition Edition

2006/95/EC Low Voltage Directive:

Directive of the European Parliamentand the Council of 12 December 2006

on the harmonization of the laws ofMember States relating to electricalequipment designed for use within cer-tain voltage limits

2006

89/336/EEC EMC Directive:

Council Directive of 3 May 1989 on theapproximation of the laws of the MemberStates relating to electromagnetic com-patibility

1993

97/23/EC Pressure Equipment Directive:

Directive of the European Parliament

and of the Council of 29 May 1997 onthe approximation of the laws of theMember States concerning pressureequipment

1997

98/37/EC Machinery Directive:

Directive of the European Parliamentand of the Council of 22 June 1998 onthe approximation of the laws of theMember States relating to machinery

1998

EN ISO 13850 Safety of machinery:

E-STOP - Principles for design

2007

EN ISO 13732-1 Ergonomics of thermal environment:

Methods for the assessment of humanresponses to contact with surfaces - Part1: Hot surfaces

2006

EN 614-1 Safety of machinery:

Ergonomic design principles – Part 1:Terms and general principles

2006

EN 954-1 Safety of machinery:

Safety-related parts of control systems -Part 1: General principles for design

1997

EN 60204-1 Safety of machinery:Electrical equipment of machines - Part1: General requirements

2007

EN 61000-6-2 Electromagnetic compatibility (EMC):

Part 6-2: Generic standards; Immunityfor industrial environments

2002

EN 61000-6-4 Electromagnetic compatibility (EMC):

Part 6-4: Generic standards; Emissionstandard for industrial environments

2002

EN ISO 10218-1 Industrial robots:

Safety

2006

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3. Safety

EN ISO 12100-1 Safety of machinery:

Basic concepts, general principles fordesign - Part 1: Basic terminology, meth-odology

2004

EN ISO 12100-2 Safety of machinery:

Basic concepts, general principles fordesign - Part 2: Technical principles

2004

Name Definition Edition

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4. Operation

4 Operation

4.1 Opening the external editor

Overview Only SRC files that have a corresponding DAT file can be opened in the ex-ternal editor.

The are 2 ways of opening the external editor, depending on whether or notthere is a program selected in the Navigator.

4.1.1 Opening the external editor, option 1

Precondition User group “Expert”

No program is selected in the Navigator.

Procedure 1. Select the menu sequence Setup > Service > External Editor.

The external editor is opened. The Select files window is displayed.

2. Select the desired file. Press the OK softkey. The file is opened.

4.1.2 Opening the external editor, option 2

Precondition User group "Expert" Program is selected.

Procedure 1. Select the menu sequence Edit > Correct > Point. The external editoropens and the Select files window is displayed.

2. Select the SRC file of the selected program and press the OK softkey. Thefile is opened.

4.2 Permanently displaying the external editor

Description In certain cases, the external editor is automatically hidden and the KUKA.HMIis displayed in the foreground. This occurs, for example, i f new messages aredisplayed in the message window of the KUKA.HMI. The Stay on top com-mand can be used to prevent the external editor from being hidden. The KU-KA.HMI is then no longer displayed in the foreground until the external editor

is closed.

Procedure Select the menu sequence Help > Stay on top.

If you wish to close the Select files window without opening a file, pressthe ESC key.

The Select files window can be reopened by selecting the menu se-quence File > Open.

You can return from the external editor to the KUKA.HMI by pressing thewindow selection key on the KCP. To return to the external editor, selectthe same menu sequence as for opening a file.

If you wish to close the Select files window without opening a file, pressthe ESC key.

The Select files window can be reopened by selecting the menu se-quence File > Open.

You can return from the external editor to the KUKA.HMI by pressing thewindow selection key on the KCP. To return to the external editor, selectthe same menu sequence as for opening a file.

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External Editor

4.3 User interface of the external editor

4.3.1 View on opening

This functionality is not available in KUKA System Software 5.5.

Fig. 4-1: View on opening

1 Select files window

2 Message window

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4. Operation

4.3.2 File view

Fig. 4-2: File view

1 File opened in external editor

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External Editor

4.3.3 Fold view

4.3.4 Status keys

Fig. 4-3: Fold view

1 Point Fold

2 Point data

Status key Name Description

Open Shifts the highlight towards the start of theprogram.

Down Shifts the highlight towards the end of theprogram.

Plus Opens the Fold of the selected line and dis-plays the point data.

Minus Hides the Fold and the point data onceagain.

Delete Deletes all messages from the messagewindow.

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4. Operation

4.3.5 Softkeys

4.4 Search in file

Precondition The SRC file is opened in the external editor.

Procedure 1. Select the menu sequence HotEdit > Search. The Search window isopened.

2. Enter the search string. No distinction is made between uppercase andlowercase letters.

3. Press Enter. The line containing the specified character string is displayed

red.To find more cells containing the search string, press the Enter key again.

4. To close the Search window, press ESC.

Softkey Name Description

OK Opens the selected file or confirms a selec-tion or entry.

Close Closes the open file.

Cancel Cancels an action. Changes are not saved.

Back Undo last step.

Next To the next step.

Set This softkey is only relevant with the func-tion Limit set:

The minimum and maximum values of theaxis positions are applied as software limitswitches.

Reset This softkey is only relevant with the func-

tion Limit set:Resets the software limit switches to thevalues they had before they were adaptedin the external editor.

Select file This softkey is only relevant with the func-tion File - Shift:

Opens a window in which the reference filefor the offset can be selected.

Teach file This softkey is only relevant with the func-tion File - Shift:

Creates a reference file and opens it. Thereference points for the offset can then betaught in this file.

Transfer This softkey is only relevant for online andoffline correction.

The offset is taken into consideration fromthe next program cycle onwards. It can thenbe undone with Undo or applied perma-nently with OK.

Undo This softkey is only relevant for online andoffline correction.

An offset enabled with Transfer is undone.

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External Editor

4.5 Selecting motion blocks

Precondition The SRC file is opened in the external editor.

Procedure 1. Position the cursor in the motion block that is to be selected. If multiple mo-tion blocks are to be selected, position the cursor in the uppermost motionblock.

2. Press SHIFT and press the Down status key once to select the motionblock. If multiple motion blocks are to be selected, press the Down statuskey repeatedly until all desired motion blocks are selected.

Only consecutive motion blocks can be selected.

3. To cancel a selection, press ESC.

If you wish to select not individual motion blocks, but the entire file, this can bedone using the menu sequence Edit > Select all.

4.6 Printing a file

Description The file is printed without Folds.

Procedure 1. Select the menu sequence Option > Output setting > Printer.

2. Select the menu sequence File > Output > actual program. The SRC fileopened in the external editor is printed.

File > Output > All user programs prints all SRC files. It is irrelevantwhether or not a file is open in the external editor.

4.7 Saving an SRC file as a TXT file

Overview This function saves an SRC file as a TXT file. The file is saved without Folds.There are 2 possible ways of performing the operation:

The first option is to open the SRC file as a TXT file and then save it.

(>>> 4.7.1 "Saving the SRC file as a TXT file, option 1" page 40)

In the second option, the file is saved without opening it. If required, allavailable files can be saved at once.

(>>> 4.7.2 "Saving the SRC file as a TXT file, option 2" page 40)

4.7.1 Saving the SRC file as a TXT file, option 1

Precondition The SRC file is opened in the external editor.

Procedure 1. Select the menu sequence Option > Output setting > Editor.

2. Select the menu sequence File > Output > actual program.

The file is opened as a TXT file. The file can be saved. Default directory:C:\DOCUMENTS AND SETTINGS\Administrator\Templates\USER-PROG.

4.7.2 Saving the SRC file as a TXT file, option 2

Precondition The SRC file is opened in the external editor.

The cursor can be moved using the Up / Down status keys or the arrow keys.The cursor cannot be moved in the external editor using the mouse.

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4. Operation

Procedure 1. Select the menu sequence Option > Output setting > set Path. A targetdirectory can be defined here.

If no target directory is defined, the file is saved in the following default di-rectory: C:\DOCUMENTS AND SETTINGS\Administrator\Tem-plates\USERPROG.

2. Select the menu sequence Option > Output setting > File.

3. Select the menu sequence File > Output > actual program. The file issaved as a TXT file.File > Output > All user programs saves all available SRC files as TXTfiles.

4.8 Displaying the version of the external editor

Procedure Select the menu sequence Help > Version.

The version of the external editor is displayed in the message window.

4.9 Saving and closing a file

Precondition The SRC file is opened in the external editor.

Procedure 1. Select the menu sequence File > Save. The changes are saved in theKUKA System Software.

2. Select the menu sequence File > Close.

4.10 Closing the external editor

Procedure Select the menu sequence File > Exit.

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External Editor

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5. Program editing

5 Program editing

5.1 Changing the parameters of motion blocks

Description This function can be used to change the following parameters:

Velocity

Acceleration

Approximate positioning TRUE/FALSE

TOOL coordinate system

BASE coordinate system

The HOME position parameters cannot be changed.

Precondition The SRC file is opened in the external editor.

Procedure 1. Select the motion blocks to be modified.

2. Select the menu sequence Util > Block change. A window opens.

3. Enter changes and confirm with the Change softkey.

5.2 Changing the TOOL coordinate system

Description This function can be used to replace one TOOL coordinate system with anoth-er TOOL coordinate system in some or all programs.

Precondition A freely selected SRC file is open in the external editor.

Procedure 1. Select the menu sequence Util > TCP Adjust.

2. In the Source TCP Data box, select the TOOL coordinate system that isto be replaced.

3. In the Target TCP Data box, select the new TOOL coordinate system.

4. In the program list in the top right-hand corner, select the programs inwhich the TOOL coordinate system is to be replaced. By default, all pro-grams in which the TOOL coordinate system selected under Source TCP

Data is used are selected.

Multiple motion blocks with different parameters can be selected. In the sec-tion Old data XP[...], however, only the name and parameters of the upper-most motion block are ever displayed.

Fig. 5-1: Modifying parameters

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External Editor

5. Press the OK softkey.

6. If the adaptation would last longer than about 1 minute, a query appears,asking whether the procedure should be carried out. Answer the querywith Yes.

7. Once the process has been successfully completed, the message “ok, suc- 

cess ” is displayed.

5.3 Changing the BASE coordinate system

Description This function can be used to replace one BASE coordinate system with anoth-er BASE coordinate system in some or all programs.

Precondition A freely selected SRC file is open in the external editor.

Procedure 1. Select the menu sequence Util > Frame Adjust.

2. In the Source Frame Data box, select the BASE coordinate system thatis to be replaced.

3. In the Target Frame Data box, select the new BASE coordinate system.

4. In the program list in the top right-hand corner, select the programs inwhich the BASE coordinate system is to be replaced. By default, all pro-grams in which the BASE coordinate system selected under Source

Frame Data is used are selected.

5. Press the OK softkey.

6. If the adaptation would last longer than about 1 minute, a query appears,asking whether the procedure should be carried out. Answer the querywith Yes.

Fig. 5-2: Changing the TOOL coordinate system

Item Description

1 TOOL coordinate system that is replaced2 New TOOL coordinate system3 Data of the new TOOL coordinate system. These can be modified

as required.

Warning! If these data are modified, this affects all programs inwhich this TOOL coordinate system is used.

4 Program list. All programs in which the TOOL coordinate systemselected under Source TCP Data is used are indicated here.

5 All points affected by the adaptation are indicated here.

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5. Program editing

7. Once the process has been successfully completed, the message “ok, suc- 

cess ” is displayed.

5.4 Duplicating motion blocks

Precondition The SRC file is opened in the external editor.

Procedure 1. Select the motion blocks to be duplicated. (Only consecutive motionblocks can be duplicated in one go.)

2. Select the menu sequence Edit > Copy.

3. Position the cursor in the line after which the copied motion blocks are tobe inserted.

4. Select the menu sequence Edit > Paste as > original path.The system automatically assigns point names to the inserted motionblocks. They start with C0 .

5.5 Reversing the sequence of motion blocks

Precondition The SRC file is opened in the external editor.

Procedure 1. Select the motion blocks for which the sequence is to be modified.

2. Either cut or copy the motion blocks. To do so, select the menu sequenceEdit > Cut or Copy.

3. Position the cursor in the line after which the reversed section is to be in-serted.

4. Select the menu sequence Edit > Paste as > reverse path.

Fig. 5-3: Changing the BASE coordinate system

Item Description

1 BASE coordinate system that is replaced2 New BASE coordinate system3 Data of the new frame (base). These can be modified as required.

Warning! If these data are modified, this affects all programs inwhich this BASE coordinate system is used.

4 Program list. All programs in which the BASE coordinate systemselected under Source Frame Data is used are indicated here.

5 All points affected by the adaptation are indicated here.

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External Editor

The motion blocks are inserted. The system automatically assigns pointnames. They start with R0 .

5.6 Mirroring points

Description This function is used to mirror points along the XZ plane of the ROBROOT co-ordinate system.

When mirroring is carried out, a new SRC file is created (with a correspondingDAT file). The original file remains unchanged. The HOME position cannot bemirrored.

Precondition The SRC file is opened in the external editor.

The points that are mirrored all have the 0 frame (= $NULLFRAME).

If the motion blocks are inserted immediately after the last copied point, thecopy of this point is not inserted, as there would otherwise be 2 consecutivepoints with identical Cartesian coordinates.In this case, one point fewer is inserted than was copied.

Fig. 5-4: Mirroring

Only points with the 0 frame (= $NULLFRAME) may be mirrored!If points created using a different frame (base) have to be mirrored, proceedas follows:

1. Replace the other base with the 0 frame.

(>>> 5.3 "Changing the BASE coordinate system" page 44)

2. Mirror.

3. In the original file and in the mirrored file, replace the 0 frame with theoriginal base.

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5. Program editing

Procedure 1. Select the motion blocks to be mirrored.

2. Select the menu sequence Util > Mirror.

3. The File mirroring window is opened. Enter the name under which thenew file is to be saved. By default, the name [Original_file ]_MIRROR isspecified. The new file is saved in the directory in which the original file islocated.

4. Press the Start button. Once the process has been successfully complet-ed, the message “Mirror file created.” is displayed.

If the new file is not displayed in the Navigator, select a higher-level folder andthen return to the folder with the file. This refreshes the display.

5.7 Mirroring all points of an SRC file

Description This function is used to mirror the points of an SRC file along the XZ plane of

the ROBROOT coordinate system.When mirroring is carried out, a new SRC file is created (with a correspondingDAT file). The original file remains unchanged. The HOME position cannot bemirrored. It remains unchanged.

Precondition No file is open in the external editor. The points that are mirrored all have the 0 frame (= $NULLFRAME).

If a file of this name already exists in the same directory, it is overwritten bythe new file without a request for confirmation!

Fig. 5-5: Mirroring

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External Editor

Procedure 1. Select the menu sequence Ext.Util > File - Mirror.

2. Select the file that is to be mirrored.

3. Press the Next softkey. The Destination box is displayed. Enter the nameunder which the new file is to be saved. By default, the name[Original_file ]_MIRROR is specified. The new file is saved in the directoryin which the original file is located.

4. Press the Next softkey. The Comment box is displayed. If required, acomment can be entered for the new file.

The comment will subsequently be displayed in the Comment column inthe Navigator.

5. Press the Next softkey to mirror the file. Once the process has been suc-cessfully completed, the message “Mirror file created.” is displayed.

If the new file is not displayed in the Navigator, select a higher-level folder andthen return to the folder with the file. This refreshes the display.

5.8 Offsetting points (with numerical values)

Description This function can be used to offset points. The following menu items are avail-able:

Base: The offset refers to the current BASE coordinate system.

TCP: The offset refers to the current TOOL coordinate system.

World: The offset is relative to the WORLD coordinate system.

Joint: The offset is axis-specific.

There are no limits for the offset. The HOME position cannot be offset.

Precondition The SRC file is opened in the external editor.

Procedure 1. Select the motion blocks to be modified.

2. Select the menu sequence Util > Manual entry and then select the de-sired reference system: Base, TCP, World or Joint.

3. A window opens. Enter values for the offset and press the OK softkey.

5.9 Offsetting points (with vector)

Overview This function offsets points in an SRC file using a specified vector. The vectoris defined in a different file. The points are offset with reference to the file con-taining the vector.

The SRC file is not copied during this operation; instead, the original file ismodified. The HOME position is not changed.

Only points with the 0 frame (= $NULLFRAME) may be mirrored!If points created using a different frame (base) have to be mirrored, proceedas follows:

1. Replace the other base with the 0 frame.

(>>> 5.3 "Changing the BASE coordinate system" page 44)

2. Mirror.

3. In the original file and in the mirrored file, replace the 0 frame with theoriginal base.

If a file of this name already exists in the same directory, it is overwritten bythe new file without a request for confirmation!

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5. Program editing

There are 2 possible ways of performing the operation:

In the first option, the file with the vector is created first. The offset is thencarried out.

(>>> 5.9.1 "Offsetting points (with vector), option 1" page 49)

In the second option, the file with the vector is created during the offset op-eration.

(>>> 5.9.2 "Offsetting points (with vector), option 2" page 49)

5.9.1 Offsetting points (with vector), option 1

Preparation Create a file (SRC or DAT file, any name) in the Navigator. Teach 2 pointsin this file. The points define the vector.

Precondition No file is open in the external editor.

Procedure 1. Select the menu sequence Ext.Util > File - Shift > 2 Point.

2. Press the Select file softkey. Select the file with the vector. Press the Next 

softkey.3. Select the file in which points are to be offset. Press the Next softkey.

4. The file is opened in the external editor. Select the motion blocks to be off-set.

5. Press the Next softkey to offset the motion blocks. Once the process hasbeen successfully completed, a message is displayed, indicating thatpoints XP[x] to XP[n] have been offset.

6. Press the Close softkey. Respond to the request for confirmation askingwhether the changes should be saved by pressing Yes.

If you do not wish to save the changes: press the Back softkey. Answerthe request for confirmation with No.

5.9.2 Offsetting points (with vector), option 2

Precondition No file is open in the external editor.

Procedure 1. Select the menu sequence Ext.Util > File - Shift > 2 Point.

2. Press the Teach file softkey. The file REF_2POINT is created automati-cally.

3. Switch to the user interface of the KSS using the window selection key.The file REF_2POINT is selected. Teach 2 points The points define thevector.

4. Select the menu sequence Edit > Correct > Point to return to the externaleditor.

5. Select the file in which points are to be offset. Press the Next softkey.

6. The file is opened in the external editor. Select the motion blocks to be off-set.

7. Press the Next softkey to offset the motion blocks. Once the process hasbeen successfully completed, a message is displayed, indicating thatpoints XP[x] to XP[n] have been offset.

8. Press the Close softkey. Respond to the request for confirmation askingwhether the changes should be saved by pressing Yes.

If a file of this name already exists, it is overwritten without a request for con-firmation when the new file is created!

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External Editor

If you do not wish to save the changes: press the Back softkey. Answerthe request for confirmation with No.

5.10 Offsetting and rotating points (with vector)

Overview This function offsets points in an SRC file using a specified vector and also ro-tates them. The values for the offset and rotation are defined in a different filewhich is referenced.

The SRC file is not copied; instead, the original file is modified. The HOME po-sition is not changed.

There are 2 possible ways of performing the operation:

In the first option, the file with the values for the offset and rotation is cre-ated first. The offset and rotation are then carried out.

(>>> 5.10.1 "Offsetting and rotating points (with vector), option 1"page 50)

In the second option, the file with the values for the offset and rotation iscreated during the operation itself.

(>>> 5.10.2 "Offsetting and rotating points (with vector), option 2"page 50)

5.10.1 Offsetting and rotating points (with vector), option 1

Preparation Create a file (SRC or DAT file, any name) in the Navigator. Teach 6 pointsin this file: the first 3 points define the source base, the second 3 define thedestination base.

The offset and rotation between the source and destination bases are thevalues for the offset and rotation of the selected points.

Precondition No file is open in the external editor.

Procedure 1. Select the menu sequence Ext.Util > File - Shift > 6 Point.

2. Press the Select file softkey. Select the reference file. Press the Next softkey.

3. Select the file in which points are to be offset. Press the Next softkey.

4. The file is opened in the external editor. Select the motion blocks to be off-set.

5. Press the Next softkey to offset the motion blocks. Once the process hasbeen successfully completed, a message is displayed, indicating thatpoints XP[x] to XP[n] have been offset.

6. Press the Close softkey. Respond to the request for confirmation askingwhether the changes should be saved by pressing Yes.

If you do not wish to save the changes: press the Back softkey. Answerthe request for confirmation with No.

5.10.2 Offsetting and rotating points (with vector), option 2

Precondition No file is open in the external editor.

Procedure 1. Select the menu sequence Ext.Util > File - Shift > 6 Point.

2. Press the Teach file softkey. The file REF_6POINT is created automati-

cally.

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5. Program editing

3. Switch to the user interface of the KSS using the window selection key.The file REF_6POINT is selected. Teach 6 points in this file: the first 3points define the source base, the second 3 define the destination base.

The offset and rotation between the source and destination bases are thevalues for the offset and rotation of the selected points.

4. Select the menu sequence Edit > Correct > Point to return to the externaleditor.

5. Select the file to be offset. Press the Next softkey.

6. The file is opened in the external editor. Select the motion blocks to be off-set.

7. Press the Next softkey to offset the motion blocks. Once the process hasbeen successfully completed, a message is displayed, indicating thatpoints XP[x] to XP[n] have been offset.

8. Press the Close softkey. Respond to the request for confirmation askingwhether the changes should be saved by pressing Yes.

If you do not wish to save the changes: press the Back softkey. Answerthe request for confirmation with No.

5.11 Online correction

5.11.1 Defining limits for online correction

Precondition A freely selected SRC file is open in the external editor.

Procedure 1. Select the menu HotEdit > Online > Limits: Base / World. 2 windows are

displayed.

2. In the HotEdit-Online window, enter the desired limits and press the OK softkey twice.

If a file of this name already exists, it is overwritten without a request for con-firmation when the new file is created!

Depending on the technology packages that have been installed, limits canalso be defined for the “tool-based technological system TTS” (tool-basedmoving frame). In this case, select the menu HotEdit > Online > Limits:

TTS.

Fig. 5-6: Limits for online correction

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External Editor

5.11.2 Correcting points online

Description This function can be used to offset points during operation. The correction istaken into consideration from the next program cycle onwards and can be

checked in this way. It can then be permanently applied or undone.

The correction can refer to the BASE or WORLD coordinate system. Depend-ing on the technology packages that have been installed, the correction canalso refer to the “tool-based technological system TTS” (tool-based movingframe).

Precondition The limit values for the online correction have been defined.

(>>> 5.11.1 "Defining limits for online correction" page 51)

User group “Expert”

A program is selected in the Navigator.

T1, T2 or AUT mode

Procedure 1. Select the menu sequence Edit > Correct > Point. The external editoropens and the Select files window is displayed.

2. Select the SRC file of the selected program and press the OK softkey. Thefile is opened.

3. Select the motion blocks to be modified. (For TTS, a motion block must beselected from the technology package.)

4. Select the menu sequence HotEdit > Base, World or TTS.

5. In the HotEdit-Online window, enter the desired correction and press theOK softkey. Then press the Transfer softkey.

6. If the program is already running, the corrected point will be addressed

from the next program cycle onwards.If the program is not yet running, it is possible to switch to the KUKA.HMIusing the window selection key and start the program from there. The cor-rected point is then addressed during program execution.

Select the menu sequence Edit > Correct > Point to return to the externaleditor.

7. To apply the correction permanently, press the OK softkey.

To undo the correction permanently, press the Undo softkey. Then exit theHotEdit-Online window by pressing the OK or Cancel softkey.

Item Description

1 Maximum permissible values for items 4 and 5.

(Limit values specified by the system for the user-defined limit val-ues.)

2 The current user-defined limit values for the correction3 This display is irrelevant for the definition of limits.

4 Here the user can define the limit values for the offset along the X,Y and Z axes. Each value is valid as both a positive value (maxi-mum value) and a negative value (minimum value).

5 Here the user can define the limit values for the rotation in the A, Band C directions. Each value is valid as both a positive value(maximum value) and a negative value (minimum value).

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5. Program editing

5.12 Offline correction

5.12.1 Defining limits for offline correction

Precondition A freely selected SRC file is open in the external editor.

Procedure 1. Select the menu HotEdit > Offline > Limits: Base / World / Tcp. 2 win-dows are displayed.

2. In the HotEdit-Offline window, enter the desired limits and press the OK softkey twice.

Fig. 5-7: Online correction

Item Description

1 This display is irrelevant for the online correction.2 Limit value for the correction. Each value is valid as both a posi-

tive value (maximum value) and a negative value (minimumvalue).

3 If a point is corrected more than once, the values of the last cor-rection are displayed here. The values are deleted when theexternal editor is closed.

4 Offset along the X, Y and Z axes5 Rotation in the A, B and C directions

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External Editor

The same limits apply for offline offsets with the “tool-based technological sys-tem TTS” (tool-based moving frame) as for online offsets.

5.12.2 Correcting points offline

Description This function can be used to correct points. The following menu items areavailable:

Base: The correction refers to the current BASE coordinate system.

TCP: The correction refers to the current TOOL coordinate system.

World: The correction refers to the WORLD coordinate system.

TTS: Depending on the technology packages that have been installed, thecorrection can also refer to the “tool-based technological system TTS”(tool-based moving frame).

Precondition The limit values for the offline correction have been defined.

(>>> 5.12.1 "Defining limits for offline correction" page 53)

User group “Expert” The SRC file is opened in the external editor.

Fig. 5-8: Limits for offline correction

Item Description

1 Maximum permissible values for items 4 and 5.

(Limit values specified by the system for the user-defined limit val-ues.)

2 The current user-defined limit values for the correction3 This display is irrelevant for the definition of limits.4 Here the user can define the limit values for the offset along the X,

Y and Z axes. Each value is valid as both a positive value (maxi-mum value) and a negative value (minimum value).

5 Here the user can define the limit values for the rotation in the A, Band C directions. Each value is valid as both a positive value(maximum value) and a negative value (minimum value).

Depending on the technology packages that have been installed, limits canalso be defined for the “tool-based technological system TTS” (tool-basedmoving frame). In this case, select the menu HotEdit > Online > Limits:

TTS.

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5. Program editing

Procedure 1. Select the motion blocks to be modified. (For TTS, a motion block must beselected from the technology package.)

2. Select the menu sequence HotEdit > Base, TCP, World or TTS.

3. In the HotEdit-Offline window, enter the desired correction and press theOK softkey. Then press the Transfer softkey.

4. Switch to the KUKA.HMI using the window selection key and start the pro-gram there. The corrected point is then addressed during program execu-tion.Select the menu sequence Edit > Correct > Point to return to the externaleditor.

5. To apply the correction permanently, press the OK softkey.

To undo the correction permanently, press the Undo softkey. Then exit theHotEdit-Offline window by pressing the OK or Cancel softkey.

5.13 Adapting software limit switches to the program

Description The software limit switches of the individual axes can be adapted to one ormore programs using this function. The function determines the minimum andmaximum axis positions of the programs. The values thus calculated can beset as software limit switches.

A buffer of -5° is added to the calculated minimum values. A buffer of +5° isadded to the calculated maximum values.

Precondition No file is open in the external editor.

Procedure 1. Select the menu sequence Ext.Util > Limit set. The axis values of the cur-rent robot position are displayed.

Fig. 5-9: Offline correction

Item Description

1 This display is irrelevant for the offline correction.2 Limit value for the correction. Each value is valid as both a posi-

tive value (maximum value) and a negative value (minimumvalue).

3 If a point is corrected more than once, the values of the last cor-rection are displayed here. The values are deleted when theexternal editor is closed.

4 Offset along the X, Y and Z axes5 Rotation in the A, B and C directions

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External Editor

2. Switch to the KUKA.HMI using the window selection key. Start the pro-gram to which the software limit switches are to be adapted.

3. Once the program has been completely executed, start another programif required.

4. Once the last program has been completely executed, select the menu se-quence Edit > Correct > Point to return to the external editor.

5. The maximum and minimum values of the axis positions are displayed.Deactivate the check box for the axes whose values are not to be appliedas software limit switches.

6. Press the SET softkey. Answer the request for confirmation with Yes. Thevalues are saved.

5.14 Deleting program lines

Precondition The SRC file is opened in the external editor.

Procedure 1. Select the program lines.

2. Select the menu sequence Edit > Delete.

By pressing the Reset softkey, the software limit switches can be reset at anytime to the values they had before they were adapted in the external editor.

Fig. 5-10: Setting the limit switches

Item Description

1 Check box activated: if the Set softkey is pressed, the values ofthis axis are applied as softkey limit switches.

A buffer of -5° is added to the minimum values. A buffer of +5° isadded to the maximum values.

2 Minimum value calculated for this axis during program execution.3 Current position of this axis

4 Maximum value calculated for this axis during program execution.

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5. Program editing

5.15 Deleting unused data from a DAT file

Description This function is used to delete all position data (XP) in the DAT file for whichno points exist any longer in the corresponding SRC file.

Only in KUKA System Software 5.5: This function is also used to delete allmaster points (MP) in the DAT file for which no points exist any longer in thecorresponding SRC file.

Precondition The SRC file is opened in the external editor.

Procedure

Select the menu sequence Util > Clean file list. Once the process hasbeen successfully completed, the message “Data file cleaned! ” is displayed.

5.16 Deleting unused master points from a DAT file

Description This function is only available in KUKA System Software 5.5.

This function is used to delete all master points (MP) in the DAT file for whichno points exist any longer in the corresponding SRC file.

Precondition The SRC file is opened in the external editor.

Procedure

Select the menu sequence Util > Delete Masterpoints.Once the process has been successfully completed, a message is dis-played.

The Delete command cannot be undone. If program lines are deleted inad-vertently, proceed as follows:

1. Select the menu sequence File > Close.

Respond to the query asking whether the changes should be saved bypressing No.

2. Select the menu sequence File > Open and reopen the file.

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External Editor

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6. KUKA Service

6 KUKA Service

6.1 Requesting support

Introduction The KUKA Roboter GmbH documentation offers information on operation andprovides assistance with troubleshooting. For further assistance, please con-

tact your local KUKA subsidiary.

Information The following information is required for processing a support request:

Model and serial number of the robot

Model and serial number of the controller

Model and serial number of the linear unit (if applicable)

Version of the KUKA System Software

Optional software or modifications Archive of the software

Application used

Any external axes used

Description of the problem, duration and frequency of the fault

6.2 KUKA Customer Support

Availability KUKA Customer Support is available in many countries. Please do not hesi-tate to contact us if you have any questions.

Argentina Ruben Costantini S.A. (Agency)Luis Angel Huergo 13 20

Parque Industrial2400 San Francisco (CBA)Argentina

Tel. +54 3564 421033Fax +54 3564 [email protected]

Australia Marand Precision Engineering Pty. Ltd. (Agency)

153 Keys RoadMoorabbinVictoria 31 89Australia

Tel. +61 3 8552-0600Fax +61 3 [email protected]

Faults leading to production downtime should be reported to the local KUKAsubsidiary within one hour of their occurrence.

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External Editor

Belgium KUKA Automatisering + Robots N.V.Centrum Zuid 1031

3530 HouthalenBelgiumTel. +32 11 516160

Fax +32 11 526794

[email protected]

Brazil KUKA Roboter do Brasil Ltda.Avenida Franz Liszt, 80

Parque Novo MundoJd. GuançãCEP 02151 900 São Paulo

SP BrazilTel. +55 11 69844900Fax +55 11 62017883

[email protected]

Chile Robotec S.A. (Agency)

Santiago de ChileChileTel. +56 2 331-5951

Fax +56 2 [email protected]

China KUKA Flexible Manufacturing Equipment (Shanghai) Co., Ltd.Shanghai Qingpu Industrial Zone

No. 502 Tianying Rd.201712 ShanghaiP.R. China

Tel. +86 21 5922-8652Fax +86 21 [email protected]

www.kuka.cn

Germany KUKA Roboter GmbH

Zugspitzstr. 14086165 AugsburgGermany

Tel. +49 821 797-4000Fax +49 821 [email protected]

www.kuka-roboter.de

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6. KUKA Service

France KUKA Automatisme + Robotique SASTechvallée

6, Avenue du Parc91140 Villebon S/YvetteFrance

Tel. +33 1 6931660-0

Fax +33 1 [email protected]

www.kuka.fr

India KUKA Robotics, Private Limited

621 Galleria TowersDLF Phase IV122 002 Gurgaon

HaryanaIndiaTel. +91 124 4148574

[email protected]

Italy KUKA Roboter Italia S.p.A.Via Pavia 9/a - int.610098 Rivoli (TO)

ItalyTel. +39 011 959-5013Fax +39 011 959-5141

[email protected]

www.kuka.it

Japan KUKA Robotics Japan K.K.Ogikubo TM Building 7F5-26-13 Ogikubo, Suginami-ku

Tokio167-0051Japan

Tel. +81 353 47-9831Fax +81 353 47-9835

kuka.co.jp

Korea KUKA Robot Automation Korea Co. Ltd.4 Ba 806 Sihwa Ind. Complex

Sung-Gok Dong, Ansan CityKyunggi Do425-110

KoreaTel. +82 31 496-9937 or -9938Fax +82 31 496-9939

[email protected]

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External Editor

Malaysia KUKA Robot Automation Sdn BhdSouth East Asia Regional Office

No. 24, Jalan TPP 1/10Taman Industri Puchong47100 Puchong

Selangor

MalaysiaTel. +60 3 8061-0613 or -0614

Fax +60 3 [email protected]

Mexico KUKA de Mexico S. de R.L. de C.V.Rio San Joaquin #339, Local 5Colonia Pensil Sur

C.P. 11490 Mexico D.F.MexicoTel. +52 55 5203-8407

Fax +52 55 [email protected]

Norway KUKA Sveiseanlegg + RoboterBryggeveien 92821 Gjövik

NorwayTel. +47 61 133422Fax +47 61 186200

[email protected]

Austria KUKA Roboter Austria GmbH

Vertriebsbüro ÖsterreichRegensburger Strasse 9/14020 Linz

AustriaTel. +43 732 784752Fax +43 732 793880

[email protected]

Portugal KUKA Sistemas de Automatización S.A.Rua do Alto da Guerra n° 50Armazém 04

2910 011 SetúbalPortugalTel. +351 265 729780

Fax +351 265 [email protected]

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6. KUKA Service

Russia OOO KUKA Robotics RusWebnaja ul. 8A

107143 MoskauRussiaTel. +7 495 781-31-20

Fax +7 495 781-31-19

kuka-robotics.ru

Sweden KUKA Svetsanläggningar + Robotar ABA. Odhners gata 15421 30 Västra Frölunda

SwedenTel. +46 31 7266-200Fax +46 31 7266-201

[email protected]

Switzerland KUKA Roboter Schweiz AGRiedstr. 78953 DietikonSwitzerland

Tel. +41 44 74490-90Fax +41 44 [email protected]

www.kuka-roboter.ch

Spain KUKA Sistemas de Automatización S.A.

Pol. IndustrialTorrent de la PasteraCarrer del Bages s/n

08800 Vilanova i la Geltrú (Barcelona)SpainTel. +34 93 814-2353

Fax +34 93 [email protected]

South Africa Jendamark Automation LTD (Agency)76a York Road

North End6000 Port ElizabethSouth Africa

Tel. +27 41 391 4700Fax +27 41 373 3869www.jendamark.co.za

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External Editor

Taiwan KUKA Robot Automation Taiwan Co. Ltd.136, Section 2, Huanjung E. Road

Jungli City, TaoyuanTaiwan 320Tel. +886 3 4371902

Fax +886 3 2830023

[email protected]

Thailand KUKA Robot Automation (M)SdnBhdThailand Office

c/o Maccall System Co. Ltd.49/9-10 Soi Kingkaew 30 Kingkaew RoadTt. Rachatheva, A. Bangpli

Samutprakarn10540 ThailandTel. +66 2 7502737

Fax +66 2 [email protected]

Hungary KUKA Robotics Hungaria Kft.Fö út 140

2335 TaksonyHungaryTel. +36 24 501609

Fax +36 24 477031

[email protected]

USA KUKA Robotics Corp.22500 Key DriveClinton Township

48036 MichiganUSATel. +1 866 8735852

Fax +1 586 [email protected]

www.kukarobotics.com

UK KUKA Automation + RoboticsHereward Rise

HalesowenB62 8ANUK

Tel. +44 121 585-0800Fax +44 121 [email protected]

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Index

Index

Numbers

2006/95/EC 3289/336/EEC 3297/23/EC 3298/37/EC 32

A

Accessories 13Applied norms and regulations 32AUT 18AUT EXT 18Automatic 18Automatic External 18Automatic mode 29Axis range 13Axis range limitation 23Axis range monitoring 23

B

BASE coordinate system, changing 43, 44Brake defect 25Braking distance 13

C

CE mark 12Cleaning work 30Closing the external editor 41Closing, SRC file 41Connecting cables 13Counterbalancing system 30

D

Danger zone 14DAT file, deleting unused data 57Declaration of conformity 12Declaration of incorporation 11, 12, 13Decommissioning 30Deleting program lines 56Deleting unused data in DAT file 57Deleting unused master points 57Description of functions 9Designated use 12

Disposal 30Documentation, robot system 7Drives OFF 16Drives ON 17Duplicating motion blocks 45

E

EC declaration of conformity 12EMC Directive 12, 32EMERGENCY STOP 18EMERGENCY STOP button 16, 17, 20, 27EMERGENCY STOP device 16, 20, 22, 24EMERGENCY STOP, external 16, 17, 24, 27EMERGENCY STOP, local 16, 17, 27EN 60204-1 32EN 61000-6-2 32

EN 61000-6-4 32EN 614-1 32EN 954-1 32EN ISO 10218-1 32EN ISO 12100-1 33

EN ISO 12100-2 33EN ISO 13732-1 32EN ISO 13850 32Enabling device 16, 21, 22Enabling device, external 21Enabling switches 21ESC 16External axes 13, 14

F

Faults 26Firewall 28

Function test 27

G

General safety measures 25Guard interlock 19

H

Hazardous substances 30

I

Introduction 7

J

Jog mode 22, 23

K

KCP 13, 14, 25KCP coupler 24Keyboard, external 26KUKA Customer Support 59

L

Labeling 25Liability 11Limits, offline correction 53

Limits, online correction 51Linear unit 13Low Voltage Directive 12, 32

M

Machine data 27Machinery Directive 12, 32Maintenance 29Manual High Velocity 18Manual mode 28Manual Reduced Velocity 18Master points, deleting unused 57Mechanical axis range limitation 23Mechanical end stops 22Mirroring all points of an SRC file 47Mirroring individual points 46

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External Editor

Mode selector switch 17Motion blocks, changing parameters 43Mouse, external 26

N

Network security 28

OOffline correction 54Offline correction, defining limits 53Offsetting points (numerical) 48Offsetting points (with vector) 48, 50Online correction 52Online correction, defining limits 51Opening the external editor 35Operating modes 17Operation 35Operator 14, 15Operator safety 16, 19, 22Options 13

Overload 25

P

Panic position 21Personnel 14Plant integrator 14Positioner 13Pressure Equipment Directive 30, 32Preventive maintenance work 30Printing 40Program editing 43

QQualifying inputs 17, 27

R

Reaction distance 13Recommissioning 26Release device 23Repair 29Reversing the sequence of motion blocks 45Robot 13, 19Robot controller 13, 28Robot system 11, 13, 14Rotating points (with vector) 50

S

Safeguards, external 24Safeguards, overview 16Safety 11Safety equipment, external 24Safety equipment, overview 16Safety instructions 11Safety logic 16Safety measures 22Safety zone 14, 19Safety, general 11

Saving an SRC file as a TXT file 40Saving, SRC file 41Search 39Selecting motion blocks 40

Service, KUKA Roboter 59Simulation 29Single point of control 31Softkeys 39Software 13Software limit switches 22, 23Software limit switches, adapting to program 55

Start-up 26Status keys 38STOP 0 14, 18STOP 1 14, 18STOP 2 14, 18Stop category 0 14Stop category 1 14Stop category 2 14Stop reactions 18Stopping distance 13, 19Storage 30Support request 59System integrator 12, 14, 15

T

T1 14, 18T2 14, 18Teach pendant 13Terms used, safety 13TOOL coordinate system, changing 43Tool-based technological system (TTS) 51, 52,54Top-mounted cabinet 13Trademarks 7Training program 7

Transport position 26Transportation 26Two-axis positioner 13TXT file 40

U

Use, contrary to designated use 11Use, improper 11User 14User interface 36User interface, external editor always in fore-ground 35

V

Version, external editor 41Virus protection 28

W

Warnings 11Working range limitation 23Workspace 14, 19

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External Editor