External Safety Stop 1 is typically a safety device used in industrial automation, such as robotics, to provide a physical means of stopping a machine or process immediately in the event of an emergency or hazardous situation.

The "External Safety Stop 1" message on a KUKA robot indicates that an external safety circuit or device has triggered a safety stop. This is part of the robot's safety system designed to protect the operator, the robot, and the environment in case of an unsafe condition. "Stop 1" typically refers to a safe stop that does not immediately cut off power to the robot but brings it to a controlled stop.

Steps to Troubleshoot and Resolve:

1. Check Safety Devices:

   • Inspect all connected safety devices (e.g., emergency stop buttons, safety gates, light curtains) to see if any have been triggered. Reset any activated safety devices if it is safe to do so.
   • Ensure that no one is in the robot’s working area before resetting the safety devices.

2. Verify Safety Circuit:

   • Check the wiring and connections in the external safety circuit. Look for loose connections, damaged wires, or faulty components.
   • Use a multimeter to verify continuity in the safety circuit, ensuring that all connections are intact.

3. Check Safety PLC or External Safety Systems:

   • If the robot is integrated with an external safety PLC or system, check the status of this equipment. Look for error messages or indicators that might suggest a problem.
   • Ensure that the robot and the safety system are properly communicating.

4. Review Safety Configuration in the Robot Controller:

   • Access the safety configuration settings on the KUKA robot controller (this is usually done via the KUKA SmartPad or WorkVisual).
   • Verify that the safety inputs and outputs are correctly configured according to your system’s design.

5. Fieldbus Communication Check:

   • If safety devices are connected via a fieldbus, ensure that the communication with these devices is stable and that there are no error messages related to fieldbus communication.
   • Restart the fieldbus communication or reinitialize the connection if necessary.

6. Clear the Safety Stop:

   • Once the issue is identified and resolved, clear the safety stop condition on the KUKA SmartPad by acknowledging the safety message.
   • The robot may need to be reset or rebooted after clearing the safety stop.