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SAFETY
ROBOTSYSTEMKR...WITHKRC...
General
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eCopyrightKUKARoboterGmbH
Thisdocumentationorexcerptstherefrommaynotbereproducedordisclosedtothirdpartieswithouttheexpresspermissionofthepublishers.
Otherfunctionsnotdescribedinthisdocumentationmaybeoperableinthecontroller.Theuserhasnoclaimtothesefunctions,however,in
thecaseofareplacementorservicework.
Wehavecheckedthecontentofthisdocumentationforconformitywiththehardwareandsoftwaredescribed.Nevertheless,discrepancies
cannotbeprecluded,forwhichreasonwearenotabletoguaranteetotalconformity.Theinformationinthisdocumentationischeckedona
regularbasis,however,andnecessarycorrectionswillbeincorporatedinsubsequenteditions.
Subjecttotechnicalalterationswithoutaneffectonthefunction.
PDInterleaf
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Contents
1Liability5.........................................................
2Safetysymbols7..................................................
3Safety8...........................................................
3.1Fundamentalsafetyregulations8..................................................
3.2Particularsafetymeasuresforusersandoperatingpersonnel9........................
3.3Safetyfeaturesontherobotsystem11..............................................
3.3.1Workingspacelimitation11........................................................
3.3.2Loadlimitation11.................................................................
3.3.3Counterbalancingsystem11.......................................................
3.3.4Motormonitoring11...............................................................
3.3.5Voltagemonitoring11.............................................................
3.3.6Temperaturemonitoring11.........................................................
3.3.7Jogmode(deadmanfunction)12...................................................
3.3.8Othersafetyfacilities12...........................................................
3.3.9Safetyfunctionsofthecontroller12.................................................
3.3.10Safetycategory3(validforKRC2controlcabinetonly)12.............................
3.4Releasedeviceforrobotaxes12...................................................
4Planningandconstruction14.......................................
4.1Foundationsandsubstructures14..................................................
4.2Loadratingsoftherobot14........................................................
4.3Safetyzonesandworkingzones14.................................................
4.4Operationinpotentiallyexplosiveareasofexplosionprotectionzone216................
4.4.1Industrialrobotrequirements16....................................................
4.4.2Operatingenvironmentoftheindustrialrobot16......................................
4.4.3Toolsandadditionalequipment17..................................................
4.4.4KRC...controlcabinetinstallationsite17............................................
4.4.5OperationoftheKUKAControlPanel(KCP)17.......................................
4.4.6Robotpowersupply17............................................................
4.4.7Electricalconnectingcables17.....................................................
4.4.8Workingrangemonitoring17.......................................................
4.5Collisionprotection18.............................................................
4.6Toolchange18...................................................................
4.7Safetymats18...................................................................
4.8Interfacecharacteristics18.........................................................
4.9EMERGENCYSTOPcircuit(EN418)18............................................
4.10Presettingofoutputs18...........................................................
4.11Toolingandadditionalequipment18.................................................
4.12Safetyregulations18..............................................................
5Installation,operationandotherwork19.............................
5.1Mainsconnectionconditions19.....................................................
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5.2Transportation19.................................................................
5.3ProtectionfromdirtandUVradiation19.............................................
5.4Start--up20......................................................................
5.5Software20......................................................................
5.6Operation20.....................................................................
5.7Shut--down20....................................................................
5.8Additionalremarks21.............................................................
5.9Safetyinstruction21..............................................................
6Safetylabelling22..................................................
6.1General22.......................................................................
6.2Robot22........................................................................
6.3Controlcabinet22................................................................
7ESDdirectives23...................................................
7.1General23.......................................................................
7.1.1HandlingESDmodules24.........................................................
7.1.2PackagingsuitableforESDs24....................................................
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ValidforallrobottypesKR...
robotcontrollerKRC...
TheprimarypurposeofthisDocumentationModuleisthe
safetyoftheuserandoperatingpersonnelwhenusingthe
devicedescribedbelow.
1Liability
Thedevicedescribedintheseoperatinginstructionsisanindustrialrobot--called“robot
system”inthefollowingtext--,consistingofrobot,connectingcablesandcontrolcabinet.
Therobotsystem--thesubjectmatteroftheseoperatinginstructions--hasbeenbuilt
inaccordancewithstate--of--the--artstandardsandtherecognizedsafetyrules.Nev-
ertheless,improperuseoftherobotsystemoritsemploymentforapurposeother
thantheintendedonemayconstitutearisktolifeandlimbofoperatingpersonnel
orofthirdpartiesorcausedamagetotherobotsystemandtoothermaterialproperty.
Therobotsystemmayonlybeusedintechnicallyperfectconditioninaccordance
withitsdesignateduseandonlybysafety--consciouspersonswhoarefullyaware
oftherisksinvolvedinitsoperation.Useoftherobotsystemissubjecttocompliance
withtheseoperatinginstructionsandwiththemanufacturer’sdeclarationsupplied
togetherwiththerobotsystem.Anyfunctionaldisordersaffectingthesafetyofthe
robotsystemmustberectifiedimmediately.
Thedesignandratingofthemechanicalandelectricalequipmentoftherobotsystemwas
basedontheECmachinerydirectivesthatcameintoforceon1January1993(89/392EEC
dated14June1989withamendments91/368EECdated20June1991and93/44EEC
dated14June1993)togetherwiththeirannexesandassociatedstandards.
Thefollowingharmonizedstandardsinparticularweretakenintoaccountwithregardtothe
safetyoftherobotsystem:
EN292Parts1and2(November1991)EN50081Part2
EN60204Part1(June1993)EN50082Part1
EN775EN55011
EN418EN6100--4Parts4and5
EN614Part1EN61800Part3
prEN954Part1DIN40040
Theelectricalpartoftherobotsystemadditionallyconformstothe“EClowvoltagedirective”
(73/23EECdated19February1973andEN50082--1)andthedirectiveon“Electromagnetic
compatibility”(89/336EECdated3May1989withamendments92/31EECdated28May
1992andEN55011).
Themanufacturer’sdeclarationistobefoundinthecontrolcabinet.
General
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GDesignateduse
Therobotsystemisdesignedexclusivelyfortheapplicationsspecifiedintherobot
Doc.Module“TechnicalData”(Section1).
Usingtherobotsystemforanyotheroradditionalpurposeisconsideredcontrary
toitsdesignateduse.Themanufacturercannotbeheldliableforanydamageresult-
ingfromsuchmisuse.Theriskofsuchmisuseliesentirelywiththeuser.
Operatingtherobotsystemwithinthelimitsofitsdesignatedusealsoinvolves
continuousobservanceoftheseoperatinginstructionswithparticularreferenceto
themaintenancespecifications.
Thesoftwareemployedismatchedtotheapplicationsspecifiedbythecustomer/
userandhasbeenthoroughlytested.Intheeventthatthefunctionscontainedinthe
softwarearenotexecutedwithoutinterruption,theDoc.Module“ErrorMessages/
Troubleshooting”mustbeconsultedtoremedythiscondition.Thisalsoappliesto
malfunctionsoccuringduringservice,set--up,programmingandstart--upactivities.
Therobotsystemmaynotbeputintooperationuntilitisensuredthatthefunctional
machineorplantintowhichtherobotsystemhasbeenintegratedconformstothe
specificationsoftheECdirectives89/392EECdated14June1989and91/368EEC
dated20June1991.
Noliabilitycanbeacceptedifthesedirectionsaredisregarded.
Iftheuserprovidesitemsofequipmentandthelikewhichdonotconstitutepartof
theKUKAcontractandthesepartsareintegratedintotheperipheryoftherobotsys-
temonbehalfoftheuser,KUKAcannotbeheldliableforanyresultingdamage.Any
riskassociatedwiththeseparts(mechanical,pneumaticandelectrical)liesentirely
withtheuser.
Theseoperatinginstructionsconsistofthefollowingparts:?robot
?controlcabinet
?software
TheyconstituteanintegralpartoftherobotsystemsuppliedbyKUKA,whoseserial
numbersforrobotandcontrolcabinetcanbenotedfromthemanufacturer’sdeclara-
tion.
2Safetysymbols
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2Safetysymbols
Thefollowingsafetysymbolsareusedintheseoperatinginstructions:
Thissymbolisusedwherefailuretofullyandaccuratelyobserveoperatinginstruc-
tions,workinstructions,prescribedsequencesandthelikecouldresultininjury
orafatalaccident.
Thissymbolisusedwherefailuretofullyandaccuratelyobserveoperatinginstruc-
tions,workinstructions,prescribedsequencesandthelikecouldresultindamage
totherobotsystem.
Thissymbolisusedtodrawattentiontoaparticularfeature.Observanceofthenotewill
generallyresultinfacilitationoftheworkconcerned.
General
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3Safety
3.1Fundamentalsafetyregulations
Themechanicalandelectricalequipmentoftherobotsystemforwhichtheseoperating
instructions,prescribedbythemanufacturer,havebeenissuedmeetstherequirementsof
thestandardDINEN775concerningthesafetyofindustrialrobots.Thetechnicalfeatures
andpossiblemountingpositionsofthisrobotsystemarepresentedindetailintheseoper-
atinginstructionsandintherelevantspecificationsfortherobotandcontrolcabinet.
Improperuseoftherobotsystemoritsemploymentforapurposeotherthanthe
intendedonemaycause
--dangertolifeandlimb
--dangertotherobotsystemandotherassetsoftheuserand
--dangertotheefficientworkingoftherobotsystemoritsoperator.
Theassociatedoperatinginstructionsthereforecontainnumerousindicationsofdanger,
whichalsoapplytoapplicationsandtotheuseofaccessoriesandsupplementaryequipment
suppliedbyKUKA.
Everypersoninvolvedwithinstallationorexchange,adjustment,operation,maintenanceor
repairoftherobotsystemmusthavereadandunderstoodtheseoperatinginstructions,
particularlytheDoc.Module“Safety,General”,payingspecialattentiontothepassages
markedwiththesymbol,whichareofparamountimportance.
Thesepassagescontainswitch--offproceduresandothersafetyprecautionsservingto
protectoperatingpersonnel.Particularattentionmustbedevotedtothemwhenanywork
concerningforexample,transportation,installation,operation,conversionandadjustment,
adaptation,maintenanceorrepairiscarriedout.
Installation,exchange,adjustment,operation,maintenanceandrepairmustbeperformed
onlyasspecifiedintheseoperatinginstructionsandonlybypersonnelspeciallytrainedfor
thispurpose.Theuserisrecommendedtohavepersonnelassignedforthisworkcomplete
anapplication--specificKUKAtrainingcourse.
Theusershouldcheckatspecificintervalsselectedathisowndiscretionthatthepersonnel
attendtotheirworkinasafety--consciousmanner,arefullyawareoftherisksinvolvedduring
operationandobservetheseoperatinginstructions.
Theresponsibilitiesinvolvedinoperationoftherobotsystemandinallotherworkperformed
ontherobotsystemorinitsimmediatevicinitymustbeclearlydefinedandobservedbythe
userinordertopreventanyuncertaintyregardingspheresofcompetenceinmattersof
safety.
Thedangerzonesoftherobotsystem,i.e.areasinwhichtherobottogetherwithtools,
accessoriesandadditionalequipmentmoves,mustinallcasesbesafeguardedaccording
toDINEN775topreventpersonsorobjectsfromenteringthesezonesortoensurethatthe
robotsystemisimmediatelyshutdownbyanEMERGENCYSTOPsystemifapersonor
objectshouldneverthelessenteradangerzone.Thissafetyfacilityistheresponsibilityof
theuser.
TheswitchingtimesoftheEMERGENCYSTOPsystemmustbetakenintoaccount
whendeterminingthesizeofthedangerzones.
Thepaintmarkingsonthefloorandsignsindicatingthedangerzonesmustdifferclearlyin
form,colorandstylefromothermarkingswithinthemachineorplantinwhichtherobot
systemisintegrated.
3Safety(continued)
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3.2Particularsafetymeasuresforusersandoperatingpersonnel
Therobotsystemmustbeswitchedoffbeforeexchange,adjustment,maintenance
andrepairinaccordancewiththeregulationscontainedintheseoperatinginstruc-
tions,i.e.themainswitchontherobotcontrolcabinetmustbeturnedto“OFF”and
securedwithapadlocktopreventunauthorizedpersonsfromswitchingitonagain.
Voltagesinexcessof60V(upto600V)canbepresentintheKPS,the
KSDsandtheintermediate--circuitconnectingcablesupto5minutes
afterthecontrolcabinethasbeenswitchedoff!
Anymethodofworkingthatimpairsthefunctionalandoperatingsafetyoftherobotsystem
mustbeavoided.
Theuserandoperatingpersonnelmustensurethatonlyauthorizedpersonnelarepermitted
toworkontherobotsystem.Theusermustclearlysetoutwhattheresponsibilitiesofoper-
atingpersonnelactuallyentailandgivethemtheauthoritytorefusetocarryoutinstructions
fromthirdpartieswhicharecontrarytosafetyprocedures.
Donotallowpersonneltobetrainedorinstructedorpersonneltakingpartinageneraltraining
coursetoworkonorwiththerobotsystemwithoutbeingpermanentlysupervisedbyanexpe-
riencedperson.
Workontheelectricalsystemorequipmentoftherobotsystemmayonlybecarriedoutby
askilledelectricianhimselforbyspeciallyinstructedpersonnelunderthecontrolandsuper-
visionofsuchanelectricianandinaccordancewiththeapplicableelectricalengineering
rules.
Workonthehydropneumaticcounterbalancingsystem(ifpresent)mayonlybecarriedout
bypersonshavingspecialknowledgeandexperienceofhydraulicandpneumaticsystems.
Theoperatingpersonnelareobligedtoinformtheuserimmediatelyofany
changestotherobotsystemwhichimpairitssafetyorgivereasontosuspect
thatthismightbethecase.
Theusermustensurethattherobotsystemisonlyeveroperatedinfaultless
condition.
Theusermustensure,bymeansofappropriateinstructionsandchecks,thattheworkstation
andtheenvironmentoftherobotsystemarekeptincleanandorderlycondition.
Nofunctionalsafetyequipmentmaybedismantledortakenoutofoperationifthis
woulddirectlyorindirectlyaffecttherobotsystemandifexchange,adjustment,
maintenanceorrepairiscarriedoutontherobotsystem.Thiswouldcausedanger
tolifeandlimb,suchascontusions,eyeinjuries,fractures,seriousinternaland
externalinjuriesetc.
Ifitisnecessaryforsuchsafetyequipmentneverthelesstobedismantledduringtheabove--
mentionedworkontherobotsystem,themachineorplantinwhichtherobotsystemisinte-
gratedmustbeshutdownintheexactmannerspecified,withparticularattentionbeingpaid
tothetextpassagesoftheoperatinginstructionsconcernedmarkedwiththesymbol,
andmeasuresmustbetakentopreventunintentionalorunauthorizedstart--up.Immediately
aftercompletionoftheexchange,adjustment,maintenanceorrepairwork,thesafetyequip-
mentmustbereinstalledandcheckedtoensurethatitisfunctioningcorrectly.
General
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Ifitisessentialforpersonneltoentertheworkingrangeoftherobotsystemfor
conversion,adjustment,maintenanceorrepairworkonthemachineorplantin
whichtherobotsystemisintegrated,thesafetymeasuresmustalwaysbedesigned
insuchaway(e.g.enablingswitches)thattherobotsystemisswitchedoff
immediatelyshouldanunintendedsituationarise.
Aspectsrequiringspecialconsideration:
Onlytrainedpersonnelfamiliarwiththehazardsmaybeentrustedwithexchange,adjust-
ment,maintenanceandrepairworkontherobotsystem.
Whenworkiscarriedoutinthedangerzoneoftherobot,thelattermayonly,ifabso-
lutelyessential,beoperatedatmanualtraversingspeedatthemost,toallowthe
personnelenoughtimeeithertoavoiddangerousmovementsortostoptherobot.
Allpersonssituatedintheenvironmentoftherobotmustbeinformedingoodtimethatthe
robotisabouttomove.
Whereverpossible,onlyonepersonshouldworkinthedangerzoneoftherobotatanytime,
withasecondpersonremaininginvisualcontactoutsidethedangerzonewithinreachofan
EmergencyStoppushbutton.
Iftwoormorepersonsareworkinginthedangerzoneatthesametime,theymustalsoall
remaininconstantvisualcontact.Responsibilitiesforeachtypeofworkandforeachperson
mustbeclearlyandcomprehensiblydefined.
Insensor--assistedoperation,therobotisliabletoperformunexpectedmovements
andpathcorrectionsifthemainswitchonthecontrolcabinethasnotbeenturned
to“OFF”.
Ifworkistobecarriedoutwithintheworkingrangeofaswitched--offrobot,therobot
mustfirstbemovedintoapositioninwhichitisunabletomoveonitsown,whether
thepayloadismountedornot.Ifthisisnotpossible,therobotmustbesecuredby
appropriatemeans.
Components,toolingandotherobjectsmustnotbecomejammedasaresultoftherobot
motion,normusttheyleadtoshort--circuitsorbeliabletofalloff.
Anymotionoftherobotthatwouldcauseindirectdangertopersonsorobjectsmustbe
avoided.
Dueregardmustbepaidtohazardsposedbytheperipheralsystemcomponentsoftherobot
suchasgrippers,conveyors,feeddevicesorotherrobotsinamulti--robotsystem.
Anyunauthorizedconversionormodificationoftherobotsystemisnotallowed.
Nocustomer--specificequipmentmaybeinstalledinoronthecontrolcabinetwith-
outtheapprovalofthesalesrepresentativeofKUKARoboterGmbHresponsiblefor
yoursystem.
Therobotsystemincludingaccessoriesandadditionalequipmentmaynotbeequipped
oroperatedwithproductsofothermanufacturerswhoseuseisnotexpresslypermitted
intheseoperatinginstructionsorthepartscatalogoftherobotsystem.
Whenusingprescribedoperatingmediawhicharespecifiedasaggressiveortoxic,appropri-
ateprotectiveclothingmustbeworn.Warningremarksmustbeobserved.
3Safety(continued)
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Themaintenancecyclesprescribedintheseoperatinginstructionsmustbeadheredto.
Theseoperatinginstructionsmustalwaysbekeptreadytohandattheplaceofuseofthe
robotsystem(e.g.inthetoolcompartmentorinthereceptacleprovidedforthem)--whether
asamanualorCD--ROM.
3.3Safetyfeaturesontherobotsystem
3.3.1Workingspacelimitation
Themeansoflimitingtheworkingspaceoftherobotcompriseadjustablesoftwarelimit
switchesforallaxesandforsomeaxesmechanicallimitstopswithabufferfunction,which
asthe“workingrangelimitation”accessoryarealsoadjustable(seealsorobotspecification).
Theworkingspaceoftherobotcanberestrictedtotherequiredminimumbythetravel
limitingdevicesoftherobotaxes.
Iftherobotcollideswithanobstacleorhitsthestopsofabufferedaxisata
speedgreaterthanmanualtraversingspeed,thebufferconcernedmustbe
exchangedimmediately.
AlwaysconsultKUKAbeforetherobotisputbackintooperation!
Withwall--mountedrobots,itisnecessarytoexchangetherotatingcolumninall
suchcases.
3.3.2Loadlimitation
Allrobotaxesaresafeguardedbyoverloadprotectiondevices,whichautomaticallyswitch
offtherobotifthepermissiblepowerinputisexceeded(overloadprotectionofthedrive
units).Anoverloadcanbecausedbyanexcessiveweightorbyahardwarefaultoftheasso-
ciatedservopowermodule.
3.3.3Counterbalancingsystem
Somerobottypesareequippedwithahydropneumaticormechanicalcounterbalancing
system.
Ifworkistobecarriedoutonthecounterbalancingsystems,thepartsoftherobot
assistedbythesesystemsmustbesecuredsothattheyareunabletomoveineither
the(+)or(--)direction.
3.3.4Motormonitoring
Themotorsareprotectedagainstoverloadbymeansoftemperaturesensorsinthemotor
windings.
3.3.5Voltagemonitoring
Thepowersupplyunitisswitchedoffifthevoltageistoohighfortheservodrivemodules.
Ifthevoltageistoolow,theservodriveunitscannotbereleased.
3.3.6Temperaturemonitoring
Thetemperaturesinsidethecontrolcabinet(internaltemperature)aremonitored.Therobot
isstoppedifdefinedlimitsareexceeded.
General
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3.3.7Jogmode(deadmanfunction)
Allprogramscanbeexecutedmanuallyinthetestmodesatreducedvelocity.However,
programexecutionisonlypossibleaslongasthe“Start”keyishelddown.Assoonasitis
released,therobotstops.Theprogramiscontinuedonlywhenthe“Start”keyispressed
again.
3.3.8Othersafetyfacilities
--EnablingswitchontheKUKAControlPanel(KCP)
--Operatormodeselectionbymeansofhardware
--Connectionforexternalsafetyequipment
--Keyswitch
3.3.9Safetyfunctionsofthecontroller
Thesesafetyfunctionsconcern:
--Motionvariables
--Path,position
--Workingzonelimits
--Controllerhardware
--Peripheraldevicesandassociateddatatransmission
--OperatoractionsontheKCP
--Programming,programorganization,programexecution
--Admissibilityofmachineanduserdata
--ImplementationofDINEN775
Moredetaileddescriptionsofthefunctionalareasmentionedabovemaybefoundinthese
operatinginstructions.
3.3.10Safetycategory3(validforKRC2controlcabinetonly)
Thissafetyfunctionappliesto:
--ImplementationofEN954--1
i.e.amalfunctioningcomponent(e.g.arelaythatisweldedclosed)isdetectedatthe
nextactuationof“DRIVESON”/“DRIVESOFF”.Thefunction“DRIVESON”isthen
disabledandthecomponentconcernedisindicated.
3.4Releasedeviceforrobotaxes
Thisdevicecanbeusedtomovetherobotmechanicallyafteramalfunctionviathemainaxis
drivemotorsand,dependingonthetypeofrobot,alsoviathewristaxisdrivemotorsinsome
instances.Itisonlyforuseinexceptionalcircumstancesandemergencies(e.g.forfreeing
personnel).
Thereleasedevicemayonlybeusedifthemainswitchonthecontrolcabinetof
therobotisturnedto“OFF”andsecuredwithapadlocktopreventunauthorized
personsfromswitchingitonagain.
Ifarobotaxishasbeenmovedbythereleasedevice,allrobotaxesmustbe
remastered.Themotorconcernedmustbeexchanged.
TherobotmayonlybemovedmanuallyusingthereleasedevicesuppliedbyKUKA.Byfitting
thereleasedeviceontothemotorshaft(removeprotectivecover!),theshaftcanbeturned
3Safety(continued)
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manually.Theresistanceofthemechanicalmotorbrakeandanyadditionalaxisloadshave
tobeovercomewhendoingso.Theprotectivecapmustbeputbackonaftertheoperation.
Themotorsreachtemperaturesduringoperationwhichcancauseburnstothe
skin.Appropriatesafetymeasuresmustbetaken.
General
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4Planningandconstruction
Thefollowingsafetymeasuresmustbeimplementedduringtheplanningandconstruction
ofaroboticinstallation.
4.1Foundationsandsubstructures
ItmustbeensuredthatthedimensionsandqualitiesspecifiedbyKUKAforthefoundations,
substructureortheceilingconstructionhavebeenadheredto.Deviationsfromthese
dimensionsorqualityrequirementsarenotpermitted.
4.2Loadratingsoftherobot
Itmustbecheckedthatthetorques,acceleration,weightsandothermechanicalandenviron-
mentalconditionstobeexpectedinoperationoftherobotsystemliewithinthepermissible
rangefortherobot.
4.3Safetyzonesandworkingzones
Workingzonesaretoberestrictedtothenecessaryminimumsize.Inadditiontosoftware
limitation,theycanalsobesafeguardedwithadjustablemechanicalstops(“workingrange
limitation”accessory).Theworkingzonesmustmeetthesafetyrequirements,i.e.onno
accountmaypersonsorequipmentbeexposedtoanydanger.
Dangerzones,i.e.areasinwhichrobotsmove,mustbesafeguardedbymeansofprotective
barriers.Thesecantaketheformofsafetyfences,lightbarriers,lightcurtainsorzonescan-
ners,forexample.
Fixedsafetydevices(safetyfencing)mustbedesignedtowithstandallforcesthatarelikely
tooccurinthecourseofoperation,whetherfrominsideoroutsidetheenclosure.
Ifsafetyfencesareused,theymusthaveameshsizeasspecifiedinDINEN294,DINEN
349andDINEN811.Theymustalsobehighenoughtopreventanybodyfromreachingover
them.Thesizeofthefencesectionsmustbeselectedinaccordancewiththestrengthofthe
fencing;designmeasuresmustbetakentopreventthemfrombending.Thenumberof
entrances(gates)inthefencingmustbekepttoaminimum.Thereshouldpreferablybeonly
onegate.Allentrancesmustbeconnectedtothesafetydevicesincorporatedintherobot
andtotheoverallEMERGENCYSTOPsystem.
Shownbelowisanexampleillustratingtheconnectionofgatepositionswitchesincombina-
tionwithapushbuttonforenablingoperationwhenthesafetygateisclosed.
4Planningandconstruction(continued)
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hereX11forexample
Peripheralconnector
782526
KRC...
13142324
X1
X2
S23
S24
S12
S11
A1(+)
A2(--)
U
e
L+
L--
Safetygatemonitor
e.g.PST3,manuf.:Pilz
=safetygateopen
=safetygateclosed
=actuatedelement
Gatepositionswitches
Pushbuttonforenable
withsafetygateclosed
Thispushbuttonmustbelocated
outsidethespacelimitedbythe
safeguards.
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Lightbarriers,lightcurtainsorzonescannersmustbeinstalledinadditiontoorinstead
ofsafetyfences.TheymustbeconnectedtotheoverallEMERGENCYSTOPsystem.
Irrespectiveofthesesafeguardingmeasures,thedangerzoneistobeindicatedbymeans
ofpaintmarkingsonthefloor.Thesemarkingsmustdifferdistinctlyinform,colorandstyle
fromothermarkingswithinthemachineorplantinwhichtherobotsystemisintegrated.
General
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4.4Operationinpotentiallyexplosiveareasofexplosionprotectionzone2
(incompliancewithEN60079--10)
Whenoperatingan“explosionprotectionzone2”--classKUKAindustrialrobotinpotentially
explosiveareasofprotectionzone2,thefollowingpreconditionsmustbemet.
Protectionzone2coversareasinwhichthereisonlyanoccasionalandshort--termrisk
ofdangerous,potentiallyexplosiveatmospheresforming.
Operationisnotpermittedinareasatriskfromflammabledust.
4.4.1Industrialrobotrequirements
Theindustrialrobot,connectingcablesandaccessoriesmustbeexplicitlyreleasedbyKUKA
RoboterGmbHforoperationinexplosionprotectionzone2inaccordancewiththedirectives
andregulationsinforce.
Theoperationofrobotsofnormaldesignisnotpermittedinpotentially
explosiveareas.
4.4.2Operatingenvironmentoftheindustrialrobot
Theoperatingenvironmentoftheindustrialrobotmustbedefinedandsetupbytheuseras
anexplosionprotectionzone2,inaccordancewithDINVDE0165/DINEN60079--14
(Part1).
Thefollowingrequirementsapplyhere:
GEquipmentwhich,duringnormaloperation,doesnotproducesparks,arcsorimpermis-
sibletemperatures,maybeused.(“Normaloperation”heremeanstheundisrupted
operationofapieceofequipmentwithindefinedlimitvalues,e.g.temperature.)
GAtemperatureequaltoorgreaterthantheignitiontemperatureoftheflammable
materialinquestionisnotpermissible.
GOnlysubstanceswhichcomplywithtemperatureclassT3arepermissibleinexplosion
protectionzone2.
TemperatureclassT3isdefinedasfollows:
--maximumpermissiblesurfacetemperatureoftheequipment200?C
--ignitiontemperatureofflammablematerials>200?C
Thesafetycharacteristicsofthepotentiallyexplosiveatmosphereswhichcouldarisemust
becheckedbythepersonresponsibleforthesystem.Thefollowingcharacteristicsarelaid
downinEN1127--1/VDE0165:
--Ignitiontemperature
--Flashpoint
--Explosionclass
--Lowerexplosivelimit(LEL)
--Upperexplosivelimit(UEL)
--Temperatureclass
4Planningandconstruction(continued)
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4.4.3Toolsandadditionalequipment
Toolsandadditionalequipmentusedintheprotectionzonemustbereleasedbythesupplier
and/orsystembuilderforoperationinprotectionzone2incompliancewiththeregulations
inforce.
Thefollowingstandards,amongothers,mustbeobserved:
--VDE165/EN50021
--VDE0100(Part540)
Responsibilityforthefitting,adaptationandoperationoftoolsliesentirelywiththesuppliers
and/orsystembuildersconcerned.
4.4.4KRC...controlcabinetinstallationsite
TheKRC...controlcabinetmustbeinstalledandoperatedoutsidethepotentiallyexplosive
area.
4.4.5OperationoftheKUKAControlPanel(KCP)
TheKUKAControlPanel(KCP)mayonlybeusedoutsidetheprotectionzone.
Exceptionsareonlypermissibleduringprogramming.
4.4.6Robotpowersupply
Thecustomermustfuse--protecttherobotpowersupplyusingaground--faultcircuitinter-
rupterwitha300mAtrippingcurrent.TypeF374,ABBStotzGmbH.
4.4.7Electricalconnectingcables
TheelectricalconnectingcablesbetweentheKRC...controlcabinetandtherobotconsist
ofmotorandcontrolcables.
Thesystemuserisresponsiblefortheproperlayingofthecables,cableinletsandthe
necessarysafetymeasures(e.g.cableducts)incompliancewiththerelevantregulations
andstandards.
Cablerequirements:
StandardCablewithPVCsheath,flame--retardantinaccordancewith
VDE0472(Part804B)
Specialversion,onlyifrequired:
CablewithPURsheath,flame--retardantaccordingtoVDE0472(Part804B)
Temperaturerangeforfixedinstallation:80?C.
Cablediameter:motorcableapprox.25mm
Datacable:datacableapprox.11mm
4.4.8Workingrangemonitoring
Workingrangemonitoringmustbecarriedoutwithproximityswitchesusingaredundant
(dual--channel)design.
Ifmechanicallimitswitchesareused,verificationoftherestrictedbreathing
enclosureisrequired.
Allequipmentintheworkingrangemonitoringsystemmustbesuitableforthe
protectionzoneconcerned.
General
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4.5Collisionprotection
Therobotcanbeequippedwithacollisionprotectiondevice(additionalequipment).This
mustinallcasesbeconnectedtotheEMERGENCYSTOPcircuitoftherobotsystemand
higher--levelcontroller.
Inthecaseofconveyoroperation,additionalprecautionsarerequiredtoensurethatthe
conveyorcannotcollidewiththerobotwhentheEMERGENCYSTOPfunctionistriggered.
Appropriatemeasuresmustbetakentopreventtheconveyorfromcontinuingtomovein
areaswhereacollisionispossibleafteranEMERGENCYSTOP,e.g.bymeansofshort
systemswithtransferstations.
4.6Toolchange
Removalandinstallationstationsmustbeprovidedtoallowtoolstobechanged.These
stationsmustbeaccessibletotheoperatoroutsidethedangerzoneandtherobotmustbe
abletomovetothembymeansofaspecialprogramstep.
4.7Safetymats
Ifthepresenceofoperatingpersonnelintheworkenvelopeoftherobotisunavoidable(e.g.
forloadingcomponents),thedangerzoneistobeisolatedbymeansofasafetymatorlight
curtain.Thiscanbeaccomplishedbyconnectingthesafetymatorlightcurtaintorangelimit
switches(“workingrangemonitoring”accessory)oralimitswitchfortherobot’shomeposi-
tionandtotheEMERGENCYSTOPcircuit.
4.8Interfacecharacteristics
Thevoltageandoutputloadcapacityvaluesofallsignalscorrespondingwiththerobot
controllermustliewithinthepermissiblelimitsforthecontroller.
4.9EMERGENCYSTOPcircuit(EN418)
Iftherobotsystemisoperatedinconjunctionwithahigher--levelcontroller,thetwo
EMERGENCYSTOPcircuitsmustbeinterconnected.Boththesecircuitsmustbeoffailsafe
design(dualEMERGENCYSTOPcontactorswithreciprocalmonitoring).Inaddition,every
operatorstationmustbeprovidedwithanEMERGENCYSTOPdevice.Thismaytakethe
formofapullcordoramushroom--headpushbuttonwithalockingmechanism.Itis
particularlyimportantthataregularcheckismadetoensurethatthattheEMERGENCY
STOPdevicesarefunctioningcorrectly.
4.10Presettingofoutputs
Outputsaretobepresetinaccordancewiththemainprojectfile,i.e.signalsforholdfunctions
mustnotberesetwhentherobotcontrollerisswitchedoffifpersonnelorequipmentwould
beendangeredasaresult.
4.11Toolingandadditionalequipment
IftheyhavenotbeensuppliedbyKUKA,toolingandadditionalequipmentfortherobotmust
bedesignedtothesamestandardofsafetyastherobotsystem.Thespecificationsvalidfor
themachineorplantintowhichtherobotsystemisintegratedmustbeappliedanalogously
tothetoolingandequipment(e.g.fusesfortheprimarycircuitofweldingtransformers).
4.12Safetyregulations
Themachineorplantintowhichtherobotsystemisintegratedmustbecheckedbeforethe
robotsystemisinstalledtoensurethattheuser’ssafetyregulations,generalaccident
preventionrulesandtradeassociationregulationshavebeenobserved.Pleaseobserve
Section5.9.
5Installation,operationandotherwork
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5Installation,operationandotherwork
Personalprotection:
Allpersonsworkingwithinthedangerzoneoftherobotsystemmustwear
protectiveclothing.Ofparticularimportancearesafetyhelmets,safetyfootwear
andcloselyfittingclothing.Inaddition,thesafetyregulationsoftherelevant
tradeassociationsaretobeobserved.
Themotorunits,thehydropneumaticcounterbalancingsystemandtherobotwrist
areliabletoreachoperatingtemperatureswhichmayresultinburns.Workmust
notbecarriedoutonthesecomponentsuntiltheyhavecooleddownsufficiently.
5.1Mainsconnectionconditions
ThemainsconnectionconditionsspecifiedbyKUKAinrespectofconductorcross--sections,
fuses,voltageandfrequencymustbeadheredto.Thepertinentregulationsofthepower
utilitiesconcernedmustbeobserved.
5.2Transportation
Theprescribedtransportpositionsfortherobotmustbeobserved.Allanglespecifications
arereferredtothemechanicalzerooftherobotaxisconcerned.
Iftherobotistransportedbyforklifttruck,theforksmustbeplacedintheslotsin
thebaseframe.Itisforbiddentopickuptherobotinanyotherwayusingaforklift
truck!
Whenbeingexchanged,individualpartsandlargerassembliesaretobefastenedwithcare
totheliftinggearandsecuredsothattheydonotconstituteahazard.Onlysuitableand
technicallyfaultlessliftinggearandload--bearingequipmentwithanadequatecarrying
capacitymaybeused.
Donotworkorstandundersuspendedloads!
Thefasteningofloadsandtheinstructingofcraneoperatorsshouldbeentrustedtoexperi-
encedpersonsonly.Themarshallergivingtheinstructionsmustbewithinsightorsoundof
theoperator.
5.3ProtectionfromdirtandUVradiation
Noweldingmaybecarriedoutintheimmediatevicinityoftheopencontrolcabinet
dueto,amongstotherfactors,theriskofEPROMsbeingerasedbyUVradiation.
Foreignmatter(e.g.swarf,water,dust)mustbepreventedfromenteringthecontrol
cabinet.Ifaparticularlylargeamountofdirtordustiscreatedduringtheinstallation
phase,thecontrolcabinetandrobotmustbecovered.
General
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5.4Start--up
Itmustbeensuredthatallsafetydevices,limitswitchesandotherprotectivemeasuresare
installedcompletelyandfunctioningcorrectlybeforetherobotsystemisstartedup.The
systemelementsoftherobotandthecontrolcabinetmustbecheckedforforeignbodies.
Nopersonsorobjectsmaybeinthedangerzone(workenvelopeoftherobot)duringthe
start--upprocedure.Itmustbeensuredthatthecorrectmachinedatahavebeenloaded
beforethesystemisputintooperationforthefirsttime.
InordertocomplywithprotectionclassificationIP54,thecontrolcabinetmustonlybe
operatedwithalloftheprovidedcoverplatesfordevicesandoptionswhicharenotpresent
(e.g.connectors,converters,diskdrives).
5.5Software
Specialsoftwarehasbeendevelopedforthecontrolcomputer.Thesoftware
detectsmostincorrectentriesandoperatorerrors.Forfurtherinformationreferto
therelevantpartsoftheseoperatinginstructions.
Thehardwareandsoftwaresuppliedhavebeencheckedforviruses.Itistheuser’sresponsi-
bilitytomakesurethatthelatestvirusscannerisalwaysused.Relevantdetailscanbefound
intheChapter“RunningUp/ShuttingDowntheController”.
5.6Operation
Allsafetyregulationsmustbeadheredtowhiletherobotsystemisinoperation.Nochanges
maybemadetosafetymeasuresorequipment.Intheeventofamalfunction,therobotmust
beswitchedoffimmediately.Untilthefaulthasbeeneliminated,measuresmustbetaken
topreventunauthorizedstart--upandtoprecludeanydangertopersonsorobjects.
Appropriaterecordsaretobekeptofmalfunctions,theircausesandtheremedialaction
taken.
Checktherobotsystematleastonceperworkingshiftforobviousdamageanddefects.
Reportanychanges,includingchangesintherobotsystem’sworkingbehaviortothe
competentdepartmentorpersonimmediately.Ifnecessary,stoptherobotimmediatelyand
lockit!
5.7Shut--down
Beforeanyexchange,adjustment,maintenanceorrepairworkiscarriedout,therobot
systemmustbeshutdownasspecifiedintheseoperatinginstructionsandprecautionsmust
betakentopreventunauthorizedstart--up(e.g.padlock,keyswitch).Ifitisabsolutely
essentialfortherobottobemovedduringcertainactivities,specialattentionmustbepaid
totherelevantremarksinSection3.2.
Itisimportanttobepreparedforpossiblemovementsoftherobotevenafterthecontroller
hasbeenswitchedoffandlocked.
5Installation,operationandotherwork(continued)
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5.8Additionalremarks
Alwaystightenanyscrewedconnectionsthathavebeenloosenedduringmaintenanceand
repairasspecified.
Whencarryingoutoverheadworkalwaysusesafety--orientedladdersandworkingplat-
forms.Neverusetherobotorthecontrolcabinetasaclimbingaid.
Ensurethatallconsumables,auxiliarysubstancesandreplacedpartsaredisposedofsafely
andwithminimumenvironmentalimpact!
5.9Safetyinstruction
Thepersonnelresponsibleforinstallation,exchange,adjustment,operation,maintenance
andrepairmustbeinstructedbeforeanyworkiscommencedinthetypeofworkinvolved
andwhatexactlyitentailsaswellasanyhazardswhichmayexist.Recordsaretobekept
ofthecontentandextentoftheinstruction.
Theabove--mentionedpersonnelmustbeinstructedorallyeverysixmonthsandinwriting
everytwoyearswithregardtotheobservanceofsafetyregulationsandprecautions.The
instructionmaybecarriedoutbysafetyofficersoftheuserand/orwithintheframeworkof
theKUKAtrainingprogram.Instructionisalsorequiredafterparticularincidentsortechnical
modifications.
General
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6Safetylabelling
6.1General
Identificationplates,warninglabelsandsafetysymbolsareattachedtotherobotandtothe
insideandoutsideofthecontrolcabinet.Theconnectingcablesbetweentherobotandthe
controlcabinetaswellaselectriccablesandotherlinesbothinandontherobotandcontrol
cabinetareprovidedwithdesignationlabels,manyalsowithpositionmarks.
Alloftheseplates,labels,symbolsandmarksconstitutesafety--relevantpartsoftherobot
system.Theymustremainattachedtotherobotorcontrolcabinetconcernedforthewhole
oftheirservicelivesintheirspecified,clearlyvisiblepositions.
Itisforbidden
toremove,cover,obliterate,paintoveroralterinanyotherwaydetractingfrom
theirclearvisibility
--identificationplates,
--warninglabels,
--safetysymbols,
--designationlabelsand
--cablemarks.
6.2Robot
SeerobotDoc.Module“TechnicalData”.
6.3Controlcabinet
SeecontrolcabinetDoc.Module“Maintenance/Repair”.
7ESDdirectives
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7ESDdirectives
7.1General
TheESDregulations(ESD:electrostaticsensitivedevices)mustbeobservedatalltimes
whenhandlingmodulesforuseintheKRC....Thesemodulesarefittedwithhigh--quality
componentsandareverysensitivetoelectrostaticdischarges(e.s.d.).
Partlythroughfriction(triboelectricity)andpartlythroughelectrostaticinduction,itisnotrare
forobjects,orevenpeopleundercertainenvironmentalconditions,tobecomechargedto
veryhighvoltages,uptoseveralthousandvolts.
Themostcommonkindofelectrostaticchargingiscausedbyfriction.Thiseffectis
particularlyencouragedbythecombinationofsyntheticfibersanddryairandoccursasa
resultoftwofabricswithdifferentdielectricconstantsrubbingtogether.Thischargesthe
materials,i.e.onematerialgiveselectronstotheother,resultinginanaccumulationof
chargecarriersofoneparticularpolarity.Thesameeffectcanalsooccurinpeople.Moving
inadryatmospherewithwell--insulatedshoesonasyntheticcarpet,youcanbuildupa
chargeofuptoapproximately15kV.
Evenafractionofthisvoltage(althoughimperceptibletoaperson)isenoughtodestroy
ESDs.Itispossibletoseefromthefollowingtablethatthevoltageenduranceofmodern
semiconductorcomponents,comparedwiththevoltageswhicharisethroughelectrostatic
charging,isalarminglylow.
ElementVoltage
MOSFET
EPROM
JFET
OPamplifiers
CMOS
Schottkydiodes
Bipolartransistors
SchottkyTTL
Thick/thin--filmcircuits
U/kV
b)e.s.d.vulnerabilityofsemiconductor
elements
a)averagevaluesforelectricalvoltages
towhichapersoncanbecharged
e.g.officeswithouthumidityregulation
(inwinter)
synthetic
wool
anti--static
Relativeairhumidity
Fig.1Electrostaticchargesinpeopleande.s.d.vulnerabilityofsemiconductors
Furthermore,aswellascausingcompletefailureofcomponents,e.s.d.canalsoberesponsi-
bleforpartialdamagetoanICorcomponent,whichinturnreducesservicelifeorleadsto
sporadicfaultsofpartswhicharestill,forthetimebeing,abletofunction.
Forthesereasons,notonlynewmodules,butalsodefectivemodules,
mustbehandledverycarefullyinawaysuitableforESDs.
General
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7.1.1HandlingESDmodules
GComponentsshouldonlybeunpackedandtouchedif
--youarewearingESDshoesorESDshoegroundingstrips,or
--youareconstantlygroundedbymeansofanESDarmbandthrougha1MΩprotective
resistor
GBeforetouchinganelectronicmoduleyoushoulddischargethevoltagefromyourown
body(bytouchingagrounded,electroconductiveobject)
GSurroundings:antistatictablesurfaces,conductivefloorcoverings,highrelativeair
humidity,groundedtablesandchairs(through1MΩprotectiveresistor)
GElectronicmodulesmustnotbebroughtnearVDUs,monitorsortelevisionsets
GModulesmayonlybemeasuredif
--themeasuringinstrumentisgrounded(e.g.bymeansofaprotectiveconductor)or
--beforemeasuringwithapotential--freemeasuringinstrument,themeasuringheadis
brieflydischarged(e.g.touchedagainstanuncoatedmetallicsectionofthecontroller
casing).
GOnlyunpackandtouchelectroniccomponentsifitisabsolutelynecessary.
Thebestprotectionagainsttheeffectsofelectrostaticdischargesisnotlettingthesecharges
buildupinthefirstplace.Forthisreason,thegroundingofallpossibleelectricpotential
carriersisabsolutelyvitalfortheoptimalhandlingofESDs(seediagram).
Module
Worksurface
(conductive)
Person
Module
packaging
Instruments,
tools
R:protectiveresistor1MOhm
Fig.2HandlingESDmodules
7.1.2PackagingsuitableforESDs
WhenpackagingESDmodulesandcomponents,careshouldalwaysbetakentouseonly
conductiveandantistaticpackagingmaterials,e.g.metallizedorgraphite--containingpack-
aging,antistaticplasticbags,etc.
1
Index
Index--i
A
Acceleration,14
Accessories,10
Adaptation,8,17
Additionalequipment,10,17
Adjustment,8
Adjustmentwork,20
Auxiliarysubstances,21
B
Buffer,11
C
Carryingcapacity,19
Clothing,19
Collisionprotection,18
Connectingcables,5,17,22
Connectionconditions,19
Connectionofgateposition,14
Construction,14
Controlcabinet,5
Conversion,10
Conveyor,10,18
Counterbalancingsystem,9,11,19
Cross--sections,19
D
Damagetotherobotsystem,7
Danger,8
Dangerzones,8
Deadmanfunction,12
Defects,20
Designateduse,6
Designationlabels,22
E
EClowvoltagedirective,5
ECmachinerydirectives,5
Electromagneticcompatibility,5
EMERGENCYSTOP,8,14,18
EMERGENCYSTOPcircuit,18
Employmentforapurposeotherthanthe
intendedone,5
Enablingswitch,12
EPROMs,19
ESDdirectives,23
Exchange,8
Exchangework,20
Explosionclass,16
Explosionprotectionzone2,16
Externalsafetyequipment,12
F
Fatalaccident,7
Feeddevices,10
Fixedsafetydevices,14
Flashpoint,16
Foreignbodies,20
Foreignmatter,19
Foundations,14
Frequency,19
Fuses,19
G
Generalaccidentpreventionrules,18
Gripper,10
I
Identificationplates,22
Ignitiontemperature,16
Improperuse,5
Indicationsofdanger,8
Industrialrobot,5
Injury,7
Installation,8,19
Installationsite,17
Interfacecharacteristics,18
J
Jogmode,12
K
Keyswitch,12
L
LEL,16
Liability,5
Lifttruck,19
Liftinggear,19
Lightbarriers,14
Lightcurtain,18
Lightcurtains,14
Index
Index--ii
Lightzonescanners,14
Limitstops,11
Loadlimitation,11
Loadratings,14
M
Mainswitch,9
Maintenance,8
Maintenancecycles,11
Maintenancespecifications,6
Maintenancework,20
Manualtraversingspeed,10,11
Manufacturer’sdeclaration,5,6
Mechanicallimitstops,11
Modification,10
Motormonitoring,11
O
Observance,7
Operatingenvironment,16
Operatinginstructions,5
Operatingmedia,10
Operation,8,17,19,20
Operationinpotentiallyexplosiveareas,16
Operatormodeselection,12
P
Padlock,9
Paintmarkings,8
Particularsafetymeasures,9
Partscatalog,10
Payload,10
Personalprotection,19
Planningandconstruction,14
Plates,22
Positionmarks,22
Potentiallyexplosiveareas,16
Powersupply,17
Presettingofoutputs,18
Protectionfromdirt,19
ProtectionfromdirtandUVradiation,19
Protectionzone2,16
Protectivebarriers,14
Protectiveclothing,19
Puttingrobotbackintooperation,11
R
Rangelimitswitches,18
Regulations,18
Releasedeviceforrobotaxes,12
Repairwork,20
Replacedparts,21
Requirementsconcerningthesafetyof
industrialrobots,8
Responsibilityforthefitting,17
Risktolifeandlimb,5
Robot,5
Robotsystem,5
Rotatingcolumn,11
S
Safety,8
Safetycategory3,12
Safetyequipment,9,20
Safetyfeatures,11
Safetyfences,14
Safetyfootwear,19
Safetyinstruction,21
Safetylabelling,22
Safetymats,18
Safetymeasures,9,20
Safetyregulations,8,18,20
Safetysymbols,7,22
Safetyzones,14
Safety--oriented,21
Screwedconnections,21
Sensor--assistedoperation,10
Serialnumbers,6
Shut--down,20
Signs,8
Skilledelectrician,9
Software,20
Start--up,6,20
Substructures,14
Suspendedloads,19
T
T3,16
TechnicalData,6
Temperatureclass,16
Temperaturemonitoring,11
Toolchange,18
Torques,14
Tradeassociations,19
Index
Index--iii
Transportpositions,19
Transportation,19
Travellimitingdevices,11
U
UEL,16
V
Viruses,20
Visualcontact,10
Voltage,19
Voltagemonitoring,11
Voltagetoohigh,11
W
Wall--mountedrobots,11
Warninglabels,22
Warningremarks,10
Weights,14
Workingplatforms,21
Workingrangelimitation,14
Workingrangemonitoring,17
Workingspacelimitation,11
Workingzones,14
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