Safety circuit

check manuals download section

Hi Casius.
1. On version Retrofit VKRC 8.2.20 You can unplug SmartHmi after pushing disconnect button (white button on top of panel), then You have to wait 20 sec and there is ability to unplug panel without any problems with E-stop.
2. You have wire-up two channels external E-Stop (on the BMS side You have to prepare Pilz applications (Open door Pilz, second for robots and other devices E-stop safety buttons, third for cell E-stop safety buttons), Then You have to use next one Pilz to check all of rearmed PILZ safety relays, manual resetting). When You prepare safety for cell You can use contacts on last global Safety Pilz Relay to cut robot safety. I can not upload example application for pilz but this is easy to find on Pilz web page.
Of course safety circuits must to be build in acoordance to IEC 61508 is an international standard of rules applied in industry. It is titled Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems (E/E/PE, or E/E/PES).
http://en.wikipedia.org/wiki/IEC_61508.

Casius

Do your controllers have X11 interface? What is the KSS version?

If they do have X11, you can see sample wiring for KRC4 X11 in the manuals section. As markopo already stated, safety I/O are redundant and there are standards to be met. If some of inputs are not used (for example external enabling switch or safe stop2), you still must close the circuit and use jumpers.

If they do not have X11 then you must have robot safety over network with some safety PLC. This requires having safetyPLC of course (S7 or AB) and on the robot suitable software (paid option), either ProfiNet Device/Controller (when using S7 and ProfiSafe) or EthernetIP (when using AB and CIP Safety).