TX60 Manual

Arm - TX series 60 family
Instruction manual
D28082804C – 20/01/2015
Translation of the original manual
TX60 © Stäubli 2015
You can find added elements and "errata" in the "readme.pdf" document supplied with the
robot's CD-ROM.
2 / 116 © Stäubli 2015 – D28082804C TX60

TABLE OF CONTENTS
1 - INTRODUCTION ............................................................................................................. 7
1.1. Foreword ............................................................................................................................. 9
1.1.1. Objective of this manual .......................................................................................... 9
1.1.2. Special messages concerning warnings, alerts, and information............................ 9
1.2. Definition of the elements around the machine ................................................................. 10
1.3. Safety ................................................................................................................................ 11
1.3.1. Reminder concerning the safety standards........................................................... 11
1.3.2. Safety directives concerning to the work environment .......................................... 14
1.3.3. Safety directives concerning to staff protection..................................................... 16
1.3.4. Safety directives concerning to protection of the equipment................................. 18
1.3.5. Arm safety devices ................................................................................................ 22
2 - DESCRIPTION .............................................................................................................. 23
2.1. Identification ...................................................................................................................... 25
2.2. General presentation......................................................................................................... 26
2.3. Designation of robots of the TX series 60 family............................................................... 31
2.4. General characteristics...................................................................................................... 32
2.4.1. Dimensions............................................................................................................ 32
2.4.2. Work environment ................................................................................................. 32
2.4.3. Weight ................................................................................................................... 33
2.4.4. Cleaning and disinfecting recommendations......................................................... 34
2.5. Performance...................................................................................................................... 39
2.5.1. Range, speed and resolution ................................................................................ 39
2.6. Load capacity – Mechanical interface ............................................................................... 41
2.6.1. Load capacity ........................................................................................................ 41
2.6.2. Torque limits.......................................................................................................... 44
2.6.3. Attachment of additional load on forearm.............................................................. 44
2.6.4. Additional load diagrams ....................................................................................... 44
2.6.5. Fixing the auxiliary harness on the arm casing ..................................................... 49
2.7. User circuit ........................................................................................................................ 53
2.8. Pneumatic circuits (using compressed air) and electric circuits with standard robot
equipment (or clean room as an optional extra) ................................................................ 57
2.8.1. Pneumatic circuit ................................................................................................... 57
2.8.2. Electric circuit ........................................................................................................ 58
2.9. Pneumatic circuits (using vacuum) and electric circuits with clean room robot
equipment (or standard equipment as an option).............................................................. 61
2.9.1. Pneumatic circuit ................................................................................................... 61
2.9.2. Electric circuit ........................................................................................................ 61
2.10. Pressurization unit............................................................................................................. 63
2.10.1. Purpose ................................................................................................................. 63
2.10.2. Installation ............................................................................................................. 63
2.10.3. Settings ................................................................................................................. 64
2.11. Releasing joint brake......................................................................................................... 65
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2.12. Safety ................................................................................................................................ 66
2.12.1. Risks near the arm ................................................................................................ 66
2.12.3. Stopping times and angles .................................................................................... 67
2.12.4. Maximum energy generated by the robot in the event of an impact ..................... 70
2.12.5. Noise level............................................................................................................. 70
2.12.6. Outside temperature of the arm ............................................................................ 70
2.12.7. Accelerations, decelerations ................................................................................. 71
2.12.8. Axis range limitation .............................................................................................. 71
3 - ON-SITE PREPARATION ............................................................................................. 73
3.1. Working space................................................................................................................... 77
3.2. Attachment ........................................................................................................................ 78
4 - STORAGE, TRANSPORT AND INSTALLATION......................................................... 81
4.1. Arm packaging .................................................................................................................. 83
4.1.1. Conditions of storage and transport ...................................................................... 83
4.2. Handling of packing........................................................................................................... 83
4.3. Unpacking and installation of the arm ............................................................................... 83
4.4. Installation of arm .............................................................................................................. 85
4.4.1. Installation of arm on floor ..................................................................................... 85
4.4.2. Installation of arm on ceiling.................................................................................. 85
4.4.3. Mounting floor quality ............................................................................................ 86
4.4.4. Modification of ranges ........................................................................................... 86
4.4.5. Taking stopping zones into account ...................................................................... 87
5 - PREVENTIVE MAINTENANCE..................................................................................... 99
5.1. Rules to be applied for maintenance............................................................................... 101
5.2. Defining the levels of intervention ................................................................................... 102
5.3. Maintenance frequency ................................................................................................... 103
5.4. Paint touch-up procedure for he and steri robots ............................................................ 105
5.5. Procedure for replacing the flat seal................................................................................ 105
5.5.1. Removing the seal............................................................................................... 105
5.5.2. Fitting a new seal ................................................................................................ 105
5.6. Checking oil levels........................................................................................................... 107
5.6.1. Arm in floor-mounted position ............................................................................. 107
5.6.2. Wall-mounted arm (Axis 1 horizontal, connector downwards) ............................ 109
5.6.3. Arm in ceiling-mounted position .......................................................................... 111
6 - RECOMMENDED LUBRICANTS AND SPARE PARTS ............................................ 113
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Chapter 1 - Introduction
CHAPTER
1 - INTRODUCTION
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1.1. FOREWORD
The information contained in the present document is the property of STÄUBLI and it cannot
be reproduced, in full or in part, without our prior written approval.
The specifications contained in the present document can be modified without notice.
Although all necessary precautions have been taken to ensure that the information contained
in this document is correct, STÄUBLI cannot be held responsible for any errors or omissions
found in the illustrations, drawings and specifications contained in the said document.
If any difficulties are met with during operation or servicing of the robot that are not referred to
in this document, or if further information is required, please contact the STÄUBLI After Sales
Department, "Robot Division".
STÄUBLI, UNIMATION, VAL
are brands registered by STÄUBLI INTERNATIONAL AG.
1.1.1. OBJECTIVE OF THIS MANUAL

The objective of this manual is to provide information concerning the installation, operation
and maintenance of STÄUBLI robots. It provides help for the persons working on the
equipment, for reference purposes only. Indeed, in order to understand the present document
and the use of STÄUBLI robots, it is necessary for staff to acquire the corresponding
knowledge by following a "robots" training course as provided by STÄUBLI.
The photos are used to make the document easier to understand, they cannot be construed
as being of a contractual nature.
1.1.2. SPECIAL MESSAGES CONCERNING WARNINGS, ALERTS, AND INFORMATION

In this document, there are two formats for warnings and alerts. The messages contained in
the boxes inform staff of the potential risks involved in carrying out an action.
These boxes are as follows (they are shown in decreasing order of importance):
Danger message
DANGER:
Instructions drawing the reader's attention to the risks of accidents that could lead to
serious bodily harm if the steps shown are not complied with. In general, this type of
indication describes the potential danger, its possible effects and the steps necessary
to reduce the danger. It is essential to comply with the instructions to ensure personal
safety.
Caution message
CAUTION:
Instructions drawing the reader's attention to the risks of material damage if the steps
shown are not complied with. It is essential to comply with these instructions to
ensure equipment reliability and performance levels.
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Information message
Notes of the "information" type provide very important information to help the reader to
understand a description or a procedure.
Information:
Supplies further information, or underlines a point or an important procedure. This
information must be memorized to make it easier to apply and ensure correct
sequencing of the operations described.
1.2. DEFINITION OF THE ELEMENTS AROUND THE MACHINE

Person: general term identifying all individuals likely to come close to the STÄUBLI machine.
Staff: identifies the persons specifically employed and trained to install, operate, and service
the STÄUBLI machine.
User: refers to the persons or the company responsible for operating the STÄUBLI machine.
Operator: Refers to the person who starts or stops the robot, or controls its operation.
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1.3. SAFETY
1.3.1. REMINDER CONCERNING THE SAFETY STANDARDS
DANGER:
The robot is fast moving equipment. These movements can be dangerous. It is
essential to comply with the specified operating conditions and the recommended
safety standards covering robot use and inform operators of the hazards involved.
The robot is a "partly completed machinery" designed for integration in a robot cell called
"machine".
The user must make sure that the personnel programming, operating, maintaining or
repairing the robot or machine has undergone all necessary training and shown the
competence required to carry out these tasks in full safety.
Standards applicable
Installation of the robot must be planned in accordance with the standard instructions.
Robots are provided with a "declaration of incorporation and conformity" as indicated
hereafter.
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Declaration of Incorporation in accordance with Directive 2006/42/EC, annex II B
(Machine Directive) and of Conformity
The manufacturer: STÄUBLI FAVERGES

Address: Place Robert Stäubli, 74210 FAVERGES, France
Hereby declares that:
(Industrial robot or Industrial robot arm or Industrial robot controller) of the STÄUBLI make, serial number………..……,
x Is a partly completed machinery designed to be incorporated in a machine or to be assembled with other machines, in
accordance with the specifications set out in the documentation, to constitute a machine covered by the “Machines” Directive
2006/42/EC whose essential requirements in annex 1 have deliberately been met within the limits of the contents of the delivery:
Chapter 1.1 except paragraphs 1.1.4, 1.1.7, 1.1.8
Chapter 1.2
Chapter 1.3 except paragraphs 1.3.5, 1.3.6, 1.3.7, 1.3.8
Chapter 1.5 except 1.5.12, 1.5.14, 1.5.15, 1.5.16
Chapter 1.6 except 1.6.5
Chapter 1.7 except 1.7.1.2, 1.7.3.
Deliberate compliance with these essential requirements at the level of the partly completed machinery does not imply that the
corresponding requirements at the level of the machine are complied with.
x Has a technical file drawn up in accordance with annex VII B, and that we undertake to forward it to the competent authorities on
receipt of a duly motivated request to that effect. The person authorized to draw up this file is the signatory of the present declaration
x Is designed for incorporation in an enclosure that complies with the standards in force for the application and the country
concerned, and with the operating conditions as required in the documentation
The following harmonized European standards have been used:

EN ISO 10218-1: 2011 - Robots and robotic devices - Safety requirements for industrial robots
- Part 1
EN ISO 13849-1: 2008 and 13849-1/ AC1: 2009 - Safety of machinery - Safety-related parts of control systems - Part 1
NF EN 60204-1: 2006 and NF EN 60204-1/A1: 2009 - Safety of machinery – Electrical Equipment.
x Complies with the requirements set out in the “Electromagnetic Compatibility” Directive 2004/108/EC and the national legislations
transposing it
x Complies with the requirements set out in the following harmonized European standards:
EN 61000-6-4 - Electromagnetic compatibility – Generic emissions standard
EN 61000-6-2 - Electromagnetic compatibility – Generic immunity standard
x Complies with the requirements set out in the “Low Voltage” Directive 2006/95/EC and the national legislations transposing it.
The “CE” markings placed on the identification plates apply to the “Low Voltage” and “Electromagnetic Compatibility” directives. The
"CE" markings concerning the "Machine Directive" can only apply to machines, i.e. to the complete cell.
The manufacturer also declares that under the responsibility of the end user, this partly completed machinery must only be put into
production once the final machine in which it is to be incorporated, or of which it forms a part, has been considered and declared as
being in conformity with the requirements set out in the “Machines” Directive and in the national legislations transposing it.
This provision applies in particular to installations that:
- Do not use MCPs supplied by Stäubli
- Incorporate changes in operating methods on the MCP
- Feature an “LLI Runtime”, “Remote MCP” or a “UniVAL” option
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Guidelines for robot integration

Other standards are applicable to the robot cell called "machine" such as (non exhaustive
list):
• Standard ISO 10218-2 Safety requirements for industrial robots:

robot systems and integration
• Standard EN ISO 12100 General principles
• Standard EN ISO 13857 Safety distances
• Standard EN ISO 13850 Emergency stop equipment
• Standard EN 953 Protective elements
• Standard EN 349 Minimum clearances
• Standard EN 1088 Locking devices
• Standard ISO 13855 Speed on approach towards the human body
For the UL version:

• Standard UL 1740 Robots and Robotics Equipment
• Standard RIA15-06 American National Standard for Industrial Robots
and Robot Systems. Safety Requirements.
• Standard CSA Z434-03 Industrial Robots and Robot Systems. General
Safety Requirements.
• Standard NFPA 79 Electrical standard for industrial machinery
• Standard NFPA 70 National Electrical Code
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1.3.2. SAFETY DIRECTIVES CONCERNING TO THE WORK ENVIRONMENT
1.3.2.1. Analysis of safety around the machine

Safety must be taken into account for the machine from the design and development stage
on.
Before planning the installation of the machine, it is necessary to study the following points:
• Plan the safety strategies that reduce risks to an acceptable level.
• Define the tasks required for the foreseeable applications and assess the access and/or
approach requirements.
• Identify the sources of risks including the failures and the failure modes associated with each
of the tasks. The risks can involve:
• the cell itself
• its association with other items of equipment
• the interactions between persons and the cell.
• Assess and estimate the risks stemming from cell operation:
• programming risks
• operating risks
• risks during use
• maintenance risks for the machine.
• Select the protective methods:
• use of protective devices
• installation of signalling means
• compliance with safe working procedures.
These points are taken from the standards applicable to robots.
Information:
This list is not exhaustive. Above all, it is necessary to comply with the standards in
force in your country.
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1.3.2.2. Rules concerning the robot's work area

The controlled area or isolation area in which the robot moves must be determined using
protective devices (protective elements).
Information:
Protective elements are devices protecting persons from a dangerous area. See the
standards currently in force concerning safety for industrial handling equipment.
DANGER:
At the time of an emergency stop, the final position of the arm can never be
determined precisely because of the kinetic energy involved. It is thus necessary to
make sure that no persons or obstructions are present in the robot's work area when
the arm is powered up.
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1.3.3. SAFETY DIRECTIVES CONCERNING TO STAFF PROTECTION
STÄUBLI robots work with computer controlled mechanisms, capable of moving at high
speed and exerting considerable force. Like all robots and most industrial equipment, they
must be operated with great care by the user of the machine. All staff using STÄUBLI robots
must be familiar with the warnings and recommendations given in this manual. The safety
rules, warning, notes and recommendations provided in this safety chapter are only one part
of the over all safety instructions. Other information is provided throughout the manual.
It is prohibited to modify a robot without a written agreement from STÄUBLI.
1.3.3.1. Mechanical and electrical dangers
This sign, applied on different parts of the robot, indicates that there is a
potential electrical danger and that only qualified service personnel may
install or service the robot system.
DANGER:
Only qualified service personnel may install or service the robot system.
Ensure compliance with all local and national safety and electrical codes for the
installation and operation of the robot system.
Disconnect all the electrical and pneumatic power supplies before carrying out any
work on the controller or the arm
To disconnect the robot from the power supply, set the general isolating switch of the
controller to the "0" position.
To prevent inadvertent during the service operation, the main switch must be locked in 0
position using a padlock whose key is to be kept by the person carrying out the service
operation. The locked status must be shown by a sign. For example, put a "Do not operate"
sign in place.
Before powering up the system, make sure that all the electrical protection systems have
been fitted and that there is no risk of electric shocks.
Information:
When the main switch is set to 0, voltage remains present between the input terminals
(mains supply filter) and the main switch input.
DANGER:
Each time the arm is powered on, keep one hand close to the "Emergency stop"
button in order to be able to press it as quickly as possible in the event of a problem.
• For UL robots: When arm is powered-on, a light on the arm is on to indicate there is a
potential danger. This light is also on when manual brake release is performed (on axis 1 on
RX and TX robots, on axis 3 on Scara robots).
• Do not connect or disconnect components while the unit is under power. The connection
between the controller and the robot arm can only be made if the controller has been
switched off.
• Remove part or tool loaded on robot during maintenance operations.
• If unusual sounds or vibrations are noted on the robot arm, especially following a shock or
some other incident, it is necessary to inspect the tool and gripper fastenings carefully and
make diagnoses at low speed.
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Information:
If a crash of the arm occurs, all safety components involved in the safety have to be
checked carefully to verify they are still operating and not damaged: hard stop devices
on the arm, electrical limit switches, calibration of the robot. Don't hesitate to call
STÄUBLI service for any doubt.
Each time a calibration, adjustment or recovery procedure is done, the calibration of
the arm has to be controlled carefully to verify that the robot is able to move in its
expected angular range and not more. This verification has to be done at slow speed.
DANGER
All persons are prohibited from remaining in the isolation area in which the robot arm
operates. Certain robot working modes such as the "brake release" mode can lead to
unforeseeable arm movements.
Figure 1.1
Following maintenance work, whether it involves mechanical, electrical, pneumatic or
software operations, it is advisable to make sure that the robot functions correctly, first at low
speed while the person stays outside the cell, and then under the normal conditions of use. In
particular, make sure that all the protective and safety systems are correctly in place, and that
calibration of the robot is correct.
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1.3.3.2. Machine safety devices
The safety devices must form an integral part of the design and installation of the machine.
Operator training and compliance with the operating procedures constitute a major element in
setting up the safety devices and systems.
STÄUBLI robots feature various interfaces that help the user to develop safety systems and
devices for the machine. These functions include the emergency stop circuits, the digital
Input/Output lines, and the display system for error and warning messages (see the
"Integration" chapter). When the system is used without the MCP, these messages/warnings
can only be consulted via the application program.
1.3.4. SAFETY DIRECTIVES CONCERNING TO PROTECTION OF THE EQUIPMENT
DANGER:
To ensure reliability and precision in the robot's movements, the machine environment
must comply with the levels of disturbance set out in the safety standards.
1.3.4.1. Connections
• Before connecting the controller to the power supply, make sure that its nominal voltage
does indeed correspond to the network voltage.
• When connecting the controller, use a cable whose cross-section corresponds to the power
rating shown on the manufacturer's plate.
• Before removing or inserting an electronic component, switch off arm power and then switch
off controller power and comply with the procedure.
• Take care to avoid blocking the air inlets and outlets for the controller airflow path.
• Never use the emergency stop to power down the arm under normal conditions of use.
1.3.4.2. Information on electrostatic discharges

What is an electrostatic discharge?
Everyone has felt the effects of static electricity on their clothes or when they touch a metal
object, without being aware of the damage that can be done to electronic components by
static electricity.
Our desire to integrate the notions of quality and reliability in our products makes it necessary
to prevent electrostatic discharges from causing damage to them. This means that all the staff
and login users must be informed.
Storage of a charge
An electric charge is created simply by combining a conductor, a dielectric and the ground
(lowest reference potential, usually the ground in the case of an electrostatic charge).
Example: People, printed circuits, integrated circuits, components, conducting mats when
separated from the ground by a dielectric.
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Electrostatic discharges or ESD

Most people have experienced ESD by receiving an electric shock when walking on a carpet
and touching a doorknob or when getting out of a car.
In most case, the following is true:
• To feel an ESD, a charge of at least 3500 V is required.
• To hear one, a charge of at least 5000 V is required.
• To see a spark, a charge of at least 10 000 V is required.
This shows that it is possible to develop charges of over 10 000 V before noticing an
electrostatic discharge!
Risks created by an electrostatic discharge
A high ESD voltage (several thousand volts) creates danger for electronic components. A
semi-conductor must be handled carefully to prevent destruction by ESD. It is estimated that
ESD destroy only 10% of the components that they effect. The other 90% of components fall
into the "deteriorated" category. A component may be damaged with simply 25% of the
voltage required to destroy it.
These hidden faults can lead to problems that appear several days, weeks or even months
after the incident. Components may also undergo a change in their operating characteristics.
Initial tests are successfully passed but an intermittent error occurs under vibration or
temperature constraints. The same components will pass the "on/off" test successfully, as
carried out during repairs, but the problem will reappear again once on site.
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Typical ESD voltages
Low relative Average relative High relative

Source humidity humidity humidity
10 - 20% 40% 65 - 90%
Walking on carpet 35 kV 15 kV 1,5 kV
Walking on vinyl 12 kV 5 kV 0,3 kV
Working at the 6 kV 2,5 kV 0,1 kV

workstation
Plastified instructions 7 kV 2,6 kV 0,6 kV
Polyethylene bags 20 kV 2 kV 1,2 kV
Cellular polyurethane 18 kV 11 kV 1,5 kV
Charge sources
Work surfaces Packaging
Floors Handling
Chairs Assembly
Carriages Cleaning
Clothes Repairing
Parts sensitive to static charges
Electronic cards
Power supplies
Encoders
etc
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1.3.4.3. Prevention of damage due to electrostatic discharges

It is essential to guard against electrostatic discharges during an intervention concerning
electronic components, sub-assemblies and complete systems.
• Elimination of the danger due to ESD requires a combined team effort. By complying with the
following instructions, you can substantially reduce the potential damage caused by ESD
and ensure long-term reliability for the robot.
• Inform the staff of the risks stemming from ESD.
• Know the critical zones sensitive to ESD.
• Know the rules and procedures to deal with ESD.
• Always carry components and boards in a tray to protect them from electrostatic charges.
• Always ground yourself before working on a workstation.
• Keep non-conducting equipment (static charge generators) away from components and
boards.
• Use tools providing protection from ESD.
STÄUBLI workstation
To handle electronic cards, STÄUBLI workstations are given a grounded coating that
dissipates static electricity. An antistatic bracelet is required to handle boards or electronic
components.
Work zones
Remove objects that generate static electricity charges from the work area, such as:
• Plastic cups
• Polystyrene
• Notebooks
• Plastic files and document holders.
Printed circuits, boards and electronic components must be kept in antistatic bags.
Antistatic wrist strap
The wrist straps are supplied as part of the standard equipment for the robot.
CAUTION:
Use an electrostatic wrist strap and an antistatic mat connected to the controller or the
arm during all work to handle boards, electronic components or the electric harness to
which they are linked.
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1.3.5. ARM SAFETY DEVICES
1.3.5.1. Overview of the safety devices

The arm features the following safety devices:
Device Paragraph
2.12.8 Axis range limitation

Axis limitation devices
4.4.4 Modification of ranges
1.3.5.2. Residual risks

Whatever the safety functions implemented, there are some residual risks due to the type of
machine:
A Category 3 PLd safety function is usually adequate for a temporary protection of the
Adequate safety operator. A permanent protection of the operator may require a higher performance
performance level of the safety function. The required safety performance level can only be determined
by an application-specific risk analysis.
The robot must only be operated in faultless conditions. Some safety functions
require specific conditions of use to guaranty their integrity. It is recommended to
Faultless conditions keep records of all safety related actions on the robot and on the cell in a
"safety book" or the like. Special care must be taken during maintenance and
restarting phases.
Safe operation in the cell does not rely only on the safety functions of the robot. Refer
to the instruction manuals of arm and controller for robot conditions of use. These
Adequate conditions
recommendations do not prevent from a detailed risk analysis related to the
of use
specificities of the cell. Special care must be taken during installation and
maintenance phases.
ISO 10218-1, 5.7.3 recommends that "wherever possible, the manual mode of
operation shall be performed with all persons outside the safeguarded space".
The arm must be secured before any operation under its mechanical parts, in manual
mode, maintenance, or when using the manual brake release function.
Before operating near the robot it must be assured that the brakes are operational.
Risks of impingement between the moving robot and the cell environment.
Risks of contact with moving edges or hot parts of the robot, even at low speed.
Risks near the robot
Risks of potentially dangerous situations (falling part when opening the gripper,
command of other moving parts in the cell...) due to the activation of output signals.
Risks of reduced attention to other hazards in the cell (steps, other moving parts,
sharp edges...) when paying attention to the robot.
Risk of a sudden operator reaction to an unexpected robot movement, even at low
speed (incorrect command for an operation, major joint movement caused by a small
movement of the tool centre, untoward program command).
Risks of crushing during arm lifting or movement, or release of a joint brake.
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Chapter 2 - Description
CHAPTER
2 - DESCRIPTION
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6
5 F
Figure 2.1
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2.1. IDENTIFICATION
Robots are manufactured by
Stäubli Faverges SCA
Place Robert Stäubli
74210 Faverges France
They are identified by a plate attached to the controller and to the arm (see figure 2.2).
STÄUBLI FAVERGES SCA

74210 Faverges, France
Machine : Date :
Type : Masse kg/lb :
Max Ic
Standard version UL version

Figure 2.2
For all requests concerning information, replacement part orders, or requests for intervention,
please state the type and the serial number of the machine concerned, as set out on the
manufacturer's plate.
Benelux - - - - - - - - +32 (0)56.36.40.04
Brazil - - - - - - - - - +55 11.2348.7402
China - - - - - - - - ++86 (0)571.8691.2161
Czech Republic - - +420 463.034.105
France - - - - - - - - +33 (0)4.50.65.61.52
Germany Service - +49 921.883202
Germany Support - +49 921.883303
Italy - - - - - - - - - - +39 0362.944242
India - - - - - - - - - +91 9821546287
Japan - - - - - - - - - +81 (0)6 6889 3295 (+221)
FIELD SERVICE SUPPORT Singapore - - - - - - +65 6266.0900
WORLDWIDE ORGANIZATION Spain- - - - - - - - - - +34 93.720.54.08
Switzerland - - - - - +41 (0)43.244.22.66
South Korea- - - - - +82 (0)53 650 6756
Romania - - - - - - - +40 374.040.494
Taiwan- - - - - - - - - +886 (0)2.8797.7795
Turkey- - - - - - - - - +90 212.472.13.00
United Kingdom - - +44 (0)1952.67.1917
USA - - - - - - - - - - - +1 (1)864.486.5429
Other countries- - - +33 (0)4.50.65.61.52
EN: Register this robot and you could benefit from a warranty extension. Visit http://www.staubli.com/robot-
registration for details and conditions.
FR: Enregistrez ce robot et vous pourriez bénéficier d'une extension de garantie. Visitez
http://www.staubli.com/robot-registration pour les détails et conditions.
DE: Registrieren Sie den Roboter und profitieren Sie dadurch von einer Garantieverlängerung. Besuchen Sie
http://www.staubli.com/robot-registration für Details und Konditionen.
ES: Registre el robot y podrá beneficiarse de una extensión de garantía. Visite http://www.staubli.com/robot-
registration para ver los detalles y condiciones.
IT: Registrate questo robot e beneficerete di un'estensione della garanzia. Visitate http://www.staubli.com/robot-
registration per dettagli e condizioni.
Figure 2.3
Label not contractual. Please refer to the label placed on your machine.
TX60 © Stäubli 2015 – D28082804C 25 / 116

2.2. GENERAL PRESENTATION
The arm consists of segments or members interconnected by joints (figure 2.1).
Movements on the arm joints are generated by servomotors coupled with position sensors.
Each of these motors is equipped with a parking brake.
This reliable, robust assembly is linked to an innovative counting system that provides data
concerning the absolute position of the robot at all times.
The arm assembly is flexible and is able to perform a great variety of applications.
Example: Handling of loads, assembly, process, application of adhesive beads, control/check
and clean room applications. This list is not exhaustive: for further information, please consult
us.
The various elements of the robot's arm are: the base (A), the shoulder (B), the arm (C), the
elbow (D), the forearm (E) and the wrist (F) (figure 2.1).
26 / 116 © Stäubli 2015 – D28082804C TX60

Figure 2.4
Standard arm - Rear cable outlet
TX60 © Stäubli 2015 – D28082804C 27 / 116

B
Figure 2.5
Standard arm - Vertical cable outlet
28 / 116 © Stäubli 2015 – D28082804C TX60

Figure 2.6
Long arm - Rear cable outlet
TX60 © Stäubli 2015 – D28082804C 29 / 116

Figure 2.7
Long arm - Vertical cable outlet
30 / 116 © Stäubli 2015 – D28082804C TX60

2.3. DESIGNATION OF ROBOTS OF THE TX SERIES 60 FAMILY
TX 6 0 cr
(1) (2) (3) (4)
(1) TX family arm
(2) Maximum working radius between axis 1 and axis 5 on the standard version,
expressed in decimetres:
dimension A + dimension B (figures 2.4 and 2.5)
(3) Number of active axes:

• 0 = 6 active axes.
(4) Letters to indicate an option.

• L = long version.
• cr = clean room application.
• scr = super-clean room application.
• he = wet environment application.
• steri = bio-contaminated environment application
These letters can be combined.
Example: L cr = long arm for clean room applications.
In the manual, the following terminology is used:

• Standard arm: for arm with standard geometry:
• Rear cable outlet (figure 2.4).
• Vertical cable outlet (figure 2.5).
• Arm L: arm with a different geometry where the forearm and the inter-link are longer:
• Rear cable outlet (figure 2.6).
• Vertical cable outlet (figure 2.7).
TX60 © Stäubli 2015 – D28082804C 31 / 116

2.4. GENERAL CHARACTERISTICS
2.4.1. DIMENSIONS
See figures 2.4, 2.5, 2.6 and 2.7.
2.4.2. WORK ENVIRONMENT

Working temperature: + 5°C to + 40°C
CAUTION:
It may be necessary to perform a warm-up cycle before nominal performances are
obtained. A high ambient temperature may lead to limitations in the robot's dynamic
performance levels.
• Humidity: 30% to 95% max. non-condensing

• Altitude: 2000 m max.
• Vibrations: Please consult us.
• IP65 arm protection and IP67 wrist protection ratings with the electric or blanking plugs inserted.
CAUTION:
If the robot is used in dusty surroundings or spattered with liquids, it is highly
advisable to use the pressurization system described in chapter 2.10.
CAUTION:
Any damage due to failure to comply with the recommendations inherent to the
environments below lies outside the scope of the guarantee.
Application of the clean room environment:

• cr: cleanness class ISO 4 in accordance with standard ISO 14644-1.
• scr: cleanness class ISO 2 in accordance with standard ISO 14644-1.
• The robot can be cleaned with wipes wetted with isopropyl alcohol diluted with 30 % of
water (IPA 70).
Wet environment application (he):
• Limits of application:
• 4,5 < pH < 8,5
• Resistance to salt spray: 300 hours in accordance with standard NS EN 60068-2-11
• Use of chlorinated products for cleaning is prohibited.
• The arm must be pressurized. We strongly recommend using the pressurization
system described in chapter 2.10. The latter must be protected from the wet
environment (he).
CAUTION:
A seperate pressurization system is needed for each robot.
• The threaded fastenings used on the wrist mechanical interface, those used to fix the
robot in place, the underside of the base, the socket holder plate and the equipment
fixed on the plate are not qualified for a wet environment (he), so they must be
protected from that environment. This protection is to be executed by the customer,
and hence under his responsibility. The guarantee does not cover any damage
occurring there.
32 / 116 © Stäubli 2015 – D28082804C TX60

• In the event of use of an optional mechanical limit stop system, depending on the
environment, the system may show limited chemical resistance. Check regularly that
it is in good condition (see also chapter 4.4.4). In the event of deterioration, the system
can be replaced. It should be noted that because of its complex shape, the mechanical
limit stop system makes the robot arm more difficult to clean and disinfect.
• Vertical cable outlet: Standard configuration
• See also chapter 3.2 for the particular aspects concerning he robot installation.
• Horizontal cable outlet: Option only.
• See also chapter 3.2 for the particular aspects concerning he robot installation.
Bio-contaminated environment application (steri):
• Limits of application:
• 4,5 < pH < 8,5
• Resistance to salt spray: 300 hours in accordance with standard NS EN 60068-2-11.
• Bio-decontamination with hydrogen peroxide on a wipe (concentration 35%) or in
vapor phase.
• Use of chlorinated products for cleaning is prohibited.
• The threaded fasteners on the wrist's mechanical interface, the threaded fasteners on
the robot, the underside of the base, the socket holder plate and the equipment fitted
on it, are not qualified for a bio-contaminated (steri) environment, so they must be
protected from that environment. This protection is to be executed by the customer,
and hence under his responsibility. The guarantee does not cover any damage
occurring there.
• In the event of use of an optional mechanical limit stop system, depending on the
environment, the system may show limited chemical resistance. Check regularly that
it is in good condition (see also chapter 4.4.4). In the event of deterioration, the system
can be replaced. It should be noted that because of its complex shape, the mechanical
limit stop system makes the robot arm more difficult to clean and disinfect.
• The robot can be cleaned with wipes wetted with isopropyl alcohol diluted with 30 % of
water (IPA 70).
• There must not be any pressure difference between the inside of the robot and the
exterior environment of the robot.
• Vertical cable outlets only:
• See also chapter 3.2 for the particular aspects concerning installation of steri robots.
2.4.3. WEIGHT
Standard arm Long arm
51.4 kg (113.3 lb) 52.5 kg (115.71 lb)
TX60 © Stäubli 2015 – D28082804C 33 / 116

2.4.4. CLEANING AND DISINFECTING RECOMMENDATIONS
STÄUBLI standard, cr, scr external robot surfaces
• Unpainted metal parts:
• Use wipes wetted with product recommended in the following compatibility chart.
• Painted metal parts or plastic parts:
• Use wipes soaked with a neutral pH aqueous soap solution (For example, use a
product listed in the following compatibility chart).
• Rinse with wipe wetted with clean water.
• Dry with wipes.
The interval between two cleaning or disinfecting actions depends on robot dirtiness (Typical
periodicity: 1 week).
STÄUBLI "he" external robot surfaces (Wet environment application):
• Use an aqueous product having a pH between 4.5 to 8.5 (For example, use a product listed
in the following compatibility chart).
• Rinse with clean water.
• Dry with wipes.
STÄUBLI "stericlean" external robot surfaces (Bio-contaminated environment
application):
• Use an aqueous product having a pH between 4.5 to 8.5 (For example, use a product listed
in the following compatibility chart).
• Rinse with clean water.
• Dry with wipes.
or
• Use other products recommended in the following compatibility chart (e.g. IPA 70, hydrogen
peroxide 35% on a wipe or in vapor phase) without any water rinse.
The interval between two cleaning or disinfecting actions depends on robot dirtiness (Typical
periodicity: End of every production).
CAUTION:
Information given herein shall not relieve you from checking the cleanliness of the
robot after the cleaning and disinfecting process. STÄUBLI shall not be liable for any
damage arising because of persistence of residue after the cleaning process
described herein.
CAUTION:
Use of chlorinated products for cleaning or disinfecting is prohibited. Use of any other
cleaning or disinfecting product than those specified may damage robot external
surfaces. In such case it is recommended to cover the robot by a protective bag.
CAUTION:
In case of cleaning or disinfecting process with liquid splash or low pressure liquid jet,
the robot arm has to be pressurized (see instruction manual).
34 / 116 © Stäubli 2015 – D28082804C TX60

CAUTION:
Nevertheless, the repetitive mechanical action of wiping may damage the brightness
of the paint.
In case of cleaning or disinfecting agents being out of specification, please consult STÄUBLI.
Type of product Disinfectant Cleaner
pH Neutral Neutral 2 to 4 - 8.5 Neutral -

Cleaner or disinfecting P3-topax 70% Isopropyl P3 70% Isopropyl
P3-alcodes H2O2 ELPON
product name 990 alcohol (IPA 70) aquanta tin alcohol (IPA 70)
ECOLAB ECOLAB
Manufacturer
http://www.ecolab.com http://www.ecolab.com
35% on a wipe
Concentration 100% 3% 100% 0.2% 3% 100%
or vapor phase
Unpainted
√ No No √ No No √
Standard
parts
Painted parts √
No No No √ √ No
or plastic parts
Unpainted
No No No No
scr & cr
parts √ √ √
Robot version
Painted parts √ √ No √ √ √ √
Unpainted
parts √ √ √ √ √ √ √
he
Painted parts No √ No No √ √ No
Unpainted
parts √ √ √ √ √ √ √
steri
Painted parts √ √ √ √ √ √ √
Usable for food industry
Please contact the product manufacturer to define cleaning or disinfected process.
CAUTION:
: Use only wipes wetted with the product.
: For painted part, it is also possible to use this product with a soft action of wiping
and without too long application. Nevertheless, the repetitive mechanical action of
wiping may damage the brightness of the paint.
TX60 © Stäubli 2015 – D28082804C 35 / 116

36 / 116 © Stäubli 2015 – D28082804C TX60
+F -F
+D
-D
Figure 2.8
TX60 © Stäubli 2015 – D28082804C 37 / 116

flange
flange
world
world
world
flange
flange world
Figure 2.9
38 / 116 © Stäubli 2015 – D28082804C TX60

2.5. PERFORMANCE
See figures 2.8 and 2.9 1 Brake release access area
Work envelope
R.M max. reach between axis 1 and 5 600 mm 850 mm
R.M max. reach between axis 2 and 5 600 mm 850 mm
R.m1 min. reach between axis 1 and 5 190 mm 209 mm
R.m2 min. reach between axis 2 and 5 189 mm 208 mm
R.b reach between axis 3 and 5 310 mm 450 mm
Maximum speed at load center of gravity 8 m/s 10.6 m/s
Placing Repeatability in accordance with ISO 9283 ± 0.02 mm ± 0.03 mm
2.5.1. RANGE, SPEED AND RESOLUTION
Axis 1 2 3 4 5 6
TX60 285
Range (°) 360 255 540 255 540 (1)
TX60L 305
C
TX60 E
Working range A B ± 142.5 D F
distribution (°) + 132.5
± 180 ± 127.5 C ± 270 ± 270
TX60L - 122.5
± 152.5
Nominal speed (°/s) TX60 &
TX60 287 287 431 410 320 700
TX60L
TX60 410 540

Maximum speed (°/s) (2) 435 995 1065 1445
TX60L 385 500
Angular resolution
0.057 0.057 0.057 0.114 0.122 0.172
(°.10-3)
(1) Can be configured by software up to ± 18 000°. See the "Software configuration" chapter in the "Controller" documentation.
Can be configured as a "continuous" axis under the continuousAxis license.
(2) Maximum speed for reduced conditions of load and inertia.
Low speed in manual mode: 250 mm/s at tool centre point and 45 °/s on each axis.
CAUTION:
In some arm configurations, the maximum joint speeds can be reached only if
payloads and inertias are reduced.
TX60 © Stäubli 2015 – D28082804C 39 / 116

flange
flange
Sectional view A - A
Max.
flange flange
flange
Detail C
Max.
Figure 2.10
1 Mechanical interface
2 End-effector
40 / 116 © Stäubli 2015 – D28082804C TX60

2.6. LOAD CAPACITY – MECHANICAL INTERFACE

See figure 2.10
The end-effector is not supplied with the robot arm assembly: its design depends on the robot's
specific applications. The end-effector design should be sufficient rigid to avoid affecting robot
performance levels. All studies can be undertaken in cooperation with STÄUBLI to obtain
optimum performance without exceeding the robot arm assembly load limits.
The end-effector is installed on the mechanical interface of the wrist, the dimensions of which
are given on figure 2.10.
Secured by 4 class 12-9 screws M5 (4), tightening torque 9.5 Nm ± 0.7 Nm.
Indexing via pin (3), diameter 5.
Mechanical interface designation:
NF EN ISO 9409-1-31.5-4-M5 - A31.5 as per Standard ISO 9409 - 1 : 2004 (F)
(except the localization of the 4 M5 threaded holes)
CAUTION:
Length of end-effector attaching screws is limited to avoid all interference with the
wrist (figure 2.10).
2.6.1. LOAD CAPACITY

See figure 2.10
Load characteristics:
Load center of gravity position M : z = 100 mm from centerline of joint 5 and x = 50 mm from
centerline of joint 6.

Load capacity
kg lb kg lb
At nominal speed 3.5 7.71 2 4.4
At reduced speed (1) 4.5 9.92 3.7 8.15

Maximum load capacity at low speed (see
figure 2.11)(2) 9 19,8 5 11
(1) In all configurations and taking maximum inertias into account. See table below.
(2) Maximum load for which the maximum arm extension cannot exceed that shown in figure 2.11.
°
40
70°
20°
Figure 2.11
TX60 © Stäubli 2015 – D28082804C 41 / 116

Nominal inertias (kg.m²) Maximal inertias (kg.m²) (2)
Standard Standard
Long arm Long arm
arm arm
For axis 5 ("I5") 0.045 0.025 0.325 0.125
For axis 6 ("I6") 0.009 0.005 0.1 0.032
(2) Under reduced speed and acceleration conditions.

Generally: VEL = 60%, ACC = 60%, DEC = 60% (consult us)
CAUTION:
The nominal values can be exceeded to a certain extent but imply a limitation to the
speed and the acceleration of the arm. If these limits are to be exceeded, please
consult STÄUBLI.
CAUTION:
The maximum levels of inertia cannot be used simultaneously on axes 5 and 6. In all
cases, the following two conditions must be complied with:
I5 load + I6 load < I5 maxi
I6 load < I6 maxi
42 / 116 © Stäubli 2015 – D28082804C TX60

View from G
Detail L
Scale 2
Figure 2.12
TX60 © Stäubli 2015 – D28082804C 43 / 116

2.6.2. TORQUE LIMITS
Reference axis
Axis 5 (Z6)
Axis 1 Axis 1
Static Axis Axis Axis Without With Axis 6
(floor (wall
torque (Nm) 2 3 4 torque / torque / (Z7)
mounting) mounting)
joint 6 joint 6
TX60 126 65 71 38 7 10 8 2
TX60L 126 40 47 32 7 10 8 2
Information:
These torques are available for a load carried equal to 0 kg.
2.6.3. ATTACHMENT OF ADDITIONAL LOAD ON FOREARM

See figure 2.12.
An additional load can be attached to the forearm using 3 M4 screws; maximum torque is
3 Nm.
Position of 3 M4 tapped holes: See figure 2.12.
Dimensions Standard arm Long arm
A 5.6 mm 117.4 mm
B 60 mm 88 mm
C 28 mm 33 mm
CAUTION:
The additional load depends on nominal load (see next page). In all cases, do not
exceed load characteristics.
2.6.4. ADDITIONAL LOAD DIAGRAMS

See figures 2.13, 2.14, 2.15 and 2.16.
These diagrams can be used to determine the additional load which can be attached to the
forearm depending on its center of gravity position from joint 3 and the load attached to the
mechanical interface of the wrist.
Figure 2.13: Standard TX60
Figure 2.14: Low-speed standard TX60(1)
Figure 2.15: TX60L
Figure 2.16: Low-speed TX60L(1)
(1) Reduced speeds:
For CS8C: ACC=60%, VEL=60%, DEC=60%
44 / 116 © Stäubli 2015 – D28082804C TX60

TX60 Additional loads at nominal speed

Mdes (100,100,100)
6,00
5,50
5,00
4,50 Load carried 0 kg
Load carried 0,5 kg
Additional loads (kg)
4,00
3,00 Load carried 1,5 kg
1,00
0,50
0,00
0,15 0,175 0,2 0,225 0,25
Positions Centre of gravity / axis 3 (m)
Figure 2.13
TX60 Additional loads at low speed

Mdes (60,60,60)
8,00
7,00
6,00
Load carried 0 kg

3,00
Load carried 3 kg
Load carried 4 kg
2,00
1,00
0,00
0,15 0,175 0,2 0,225 0,25
Figure 2.14
TX60 © Stäubli 2015 – D28082804C 45 / 116

46 / 116 © Stäubli 2015 – D28082804C TX60
TX60L Additional loads at nominal speed

Mdes (100,100,100)
3,50
3,00
Load carried 0 kg
2,50
Load carried 0,3 kg

Load carried 0,9 kg
Load carried 1,4 kg
1,00
Load carried 1,7 kg
0,50
0,00
0,15 0,2 0,25 0,3 0,35 0,4
Figure 2.15
TX60L Additional loads at low speed

Mdes (60,60,60)
6,00
5,00
Load carried 0 kg
4,00
Load carried 1 kg
Load carried 3 kg
1,00
0,00
0,15 0,175 0,2 0,225 0,25
Figure 2.16
TX60 © Stäubli 2015 – D28082804C 47 / 116

E
E
D
D
Figure 2.17
48 / 116 © Stäubli 2015 – D28082804C TX60

2.6.5. FIXING THE AUXILIARY HARNESS ON THE ARM CASING

See figure 2.17
Dimensions Standard arm Long arm
E 228 mm 337.5 mm
D 12.5 mm 10.5 mm
TX60 © Stäubli 2015 – D28082804C 49 / 116

50 / 116 © Stäubli 2015 – D28082804C TX60
B1
B2 P2
A2 A1
J1203
EV1
EV1
EV2
EV2
2
3
P1
J1202
P2
P3
4 J1201
Figure 2.18
Arm - Rear cable outlet
TX60 © Stäubli 2015 – D28082804C 51 / 116

Figure 2.19
Arm - Vertical cable outlet
52 / 116 © Stäubli 2015 – D28082804C TX60

2.7. USER CIRCUIT

See figure 2.18: Arm - Rear cable outlet
See figure 2.19: Arm - Vertical cable outlet
The electric wiring of the arm is assembled into a harness including several cables supplying
the motors (power, brakes, resolvers), the solenoid valves, the limit switches and user
connector. These components are connected by means of removable connectors.
The harness also includes pneumatic hoses which supply air to the solenoid valves (EV1 and
EV2).
The robot also has a pressure source (P2) close to the tool clamp.
The outlets of the solenoid valves EV1 and EV2 are on the forearm:
• A1 and B1 for solenoid valve EV1.
• A2 and B2 for solenoid valve EV2.
The wiring is inside the structure and routed through the centre of the joints. It is connected to
the arm base on a plate which includes several electrical and pneumatic components such as
(figure 2.18):
Arm with rear outlet (figure 2.18)

• Arm / controller (J1201) interconnection socket.
• Binder connector intended for the user for possible electrical connection of end of arm tooling
(J1202).
• Brake release selector (2).
• Brake release pushbutton (3).
• Pneumatic connections to the (P1) and (P2) compressed air networks.
• Connection for creating overpressure in the (P3) arm.
• Pneumatic exhaust muffler .
• Arm ground connection (4).
Arm with vertical outlet (figure 2.19)

• Arm / controller (J1201) interconnection socket.
• Binder connector intended for the user for possible electrical connection of end of arm tooling
(J1202).
• Socket (J1204) for connection of the remote box releasing the brakes.
• Pneumatic connections to the (P1) and (P2) compressed air networks.
• Connection for creating overpressure in the (P3) arm.
• Remote brake release box 4.
TX60 © Stäubli 2015 – D28082804C 53 / 116

• Brake release selector (2).
• Brake release pushbutton (3).
• Pneumatic exhaust muffler .
CAUTION:
The overpressure must never exceed 50 mbar (0.73 psi).
CAUTION:
Do not add wires or cables to arm wiring as this may cause premature wear of the
arm electrical wiring and lead to loss of the warranty.
54 / 116 © Stäubli 2015 – D28082804C TX60

SECTIONAL VIEW A-A
SECTIONAL VIEW K-K
Figure 2.20
Rear cable outlet
TX60 © Stäubli 2015 – D28082804C 55 / 116

SECTIONAL VIEW A - A
SECTIONAL
VIEW K - K
Figure 2.21
Vertical cable outlet
56 / 116 © Stäubli 2015 – D28082804C TX60

2.8. PNEUMATIC CIRCUITS (USING COMPRESSED AIR) AND ELECTRIC

CIRCUITS WITH STANDARD ROBOT EQUIPMENT (OR CLEAN
ROOM AS AN OPTIONAL EXTRA)
See figure 2.20: Rear cable outlet
See figure 2.21: Vertical cable outlet
CAUTION:
Check in the application that the gripper is designed to hold the load with the
accelerations programmed, and in the event of an electrical power or air supply
failure.
2.8.1. PNEUMATIC CIRCUIT
1 Plate attached to base
2 Forearm
Solenoid valves (EV1 and EV2):

• 5/2-way monostable.
• A- Electrically controlled (24 VDC).
• Working pressure: 1.5 to 7 bar (21.75 to 100 psi).
• Flow coefficient Kv = 2.86 S = 3.6 mm².
• Clip-on connector.
• Overvoltage protective circuit and indicator diode.
Description (figure 2.20):

• The arm is connected to the compressed air network (7 bar max., lubricated or not) via the
base P1.
CAUTION:
The air must be filtered by a 10 µm filter.
• There is a direct line between the base and the forearm (P2).
• The centralized solenoid valve exhaust is directed to the base and through a muffler
.
CAUTION:
It is preferable to use double-acting actuators: a single-acting actuator (with a weak
return spring) may be triggered in an untimely way by the air exhaust from the second
valve manifold.
• An orifice (P3) is provided to connect the pressurization system, if used, to the base of the
robot.
CAUTION:
Do not use this orifice for other purposes.
TX60 © Stäubli 2015 – D28082804C 57 / 116

2.8.2. ELECTRIC CIRCUIT
The electrical circuit consists of:
• A male 19-contact socket at the bottom of the arm.
• A female 19-contact socket on the forearm.
The contacts are connected in the following way:
• 2 shielded twisted pairs, cross-section AWG24.
• 6 twisted pairs, cross-section AWG24.
Supply voltage: 60 VDC - 25 VAC.
Permissible current:
• Pairs and shielded pairs AWG24: 1 A per contact.
CAUTION:
Do not use the shields as a conductive cable.
• Connection to the forearm (J1203) via a Binder straight male cylindrical connector.
• Connection to base (J1202) by Binder straight female cylindrical connector.
58 / 116 © Stäubli 2015 – D28082804C TX60

SECTIONAL VIEW A-A
SECTIONAL VIEW K-K
Figure 2.22
Rear cable outlet
TX60 © Stäubli 2015 – D28082804C 59 / 116

SECTIONAL VIEW A - A
SECTIONAL
VIEW K - K
Figure 2.23
60 / 116 © Stäubli 2015 – D28082804C TX60

2.9. PNEUMATIC CIRCUITS (USING VACUUM) AND ELECTRIC

CIRCUITS WITH CLEAN ROOM ROBOT EQUIPMENT (OR
STANDARD EQUIPMENT AS AN OPTION)
See figure 2.23: Vertical cable outlet
CAUTION:
Check in the application that the gripper is designed to hold the load with the
accelerations programmed, and in the event of an electrical power or air supply
failure.
2.9.1. PNEUMATIC CIRCUIT
1 Plate attached to base
2
1 Forearm
Solenoid valves (EV1 and EV2):

• 3/2-way monostable.
• A- Electrically controlled (24 VDC).
• Max. working pressure: vacuum only ~ - 0.8 bar (~ - 11.6 psi).
• Flow coefficient Kv = 2.86 S = 3.6 mm².
• Clip-on connector.
Description (figure 2.21):
• The arm is connected to the vacuum network via the base (P1).
• There is a direct line between the base and the forearm (P2).
CAUTION:
• Cleanliness of sucked in air must be equivalent to 10 µm filtered air.
• There is no exhaust to the outside of the arm for the solenoid valves controlling the
vacuum circuit.
2.9.2. ELECTRIC CIRCUIT

The electrical circuit consists of:
• A male 19-contact socket at the bottom of the arm.
• A female 19-contact socket on the forearm.
The contacts are connected in the following way:
• 2 shielded twisted pairs, cross-section AWG24.
• 6 twisted pairs, cross-section AWG24.
Supply voltage: 60 VDC - 25 VAC.
Permissible current:
• Pairs and shielded pairs AWG24: 1 A per contact.
CAUTION:
Do not use the shields as a conductive cable.
• Connection to the forearm (J1203) via a Binder straight male cylindrical connector.
• Connection to base (J1202) by Binder straight female cylindrical connector.
TX60 © Stäubli 2015 – D28082804C 61 / 116
Figure 2.24
Up
Down
Figure 2.25
62 / 116 © Stäubli 2015 – D28082804C TX60

2.10. PRESSURIZATION UNIT

2.10.1. PURPOSE
For applications with dusty conditions or with spattered liquids, the purpose of this option is to
prevent dust or liquids from getting into the arm by keeping its internal pressure above
atmospheric pressure.
CAUTION:
The overpressure must never exceed 50 mbar (0.73 psi).
CAUTION:
A separate pressurization system is necessary for each arm requiring protection
(never connect a single system to more than one arm).
CAUTION:
The pressurization system must be installed outside the areas exposed to dust or
spattering with liquids; if this is not possible, protect the system from its environment.
2.10.2. INSTALLATION
2.10.2.1. Arm configuration and connection

An arm can be connected to this pressurization system via the outlet identified as P3 on the
connection plate at the base of the arm. 2 airlines (outlet and return) are supplied, each 1 m
long.
It is possible to install longer hoses (up to 50 m long). Their characteristics must be identical
or equivalent to those of the hoses supplied (polyurethane piping, interior diameter 5.5 mm
mm, exterior diameter 8 mm mm). In all cases, the hoses must be protected from pinching or
crushing throughout their full length.
2.10.2.2. Installation
• Attach the unit using 4 screws (maximum diameter Ø 6) at the points marked (8) (screws not
supplied) on a rigid vertical surface, in compliance with the direction shown by the arrow (the
air supply (1) must be connected to the left-hand side of the regulator (2)).
• Connect the t-union supplied (13) on the arm inlet orifice.
TX60: G1/4
• Fit a Ø 8 mm exterior diameter hose between the unit (outlet 6) and the t-union (13) mounted
on the arm (in position 13A).
• Fit the other Ø 8 mm exterior diameter hose between the unit (outlet 10) and the t-union (13)
mounted on the arm (in position 13B).
• A connection (12) is available to connect an extra pressure switch that can be connected to
an alarm (detection of pressure loss in the arm).
• Before pressurizing the arm at (1), make sure that the regulator (2) is fully unscrewed and
that the valve (3) is fully closed. Also check visually that the arm is fully airtight (covers
closed, plugs in the tapped holes on the arm, etc.). Connect (1) to the compressed air
network (10 bar (145 psi) maximum) - hole G1/4.
TX60 © Stäubli 2015 – D28082804C 63 / 116

2.10.3. SETTINGS
Pressurize the arm:
• Gradually adjust the regulator (2) in. First adjust the pressure to 1 bar max. (pressure shown
on pressure gage 9).
Information:
At this stage, the low pressure gage (5) must remain at 0 mbar.
• Very slowly screw out the valve (3); the value on the pressure gage (5) must increase
progressively. When the value reaches 40 mbar ±10% (0.58 psi ±10%) and remains stable,
the adjustment is considered as being correct.
CAUTION:
An excessive value (above 60 mbar (0.87 psi)) will make the pressure gage (5)
unusable.
• If however the valve (3) is completely screwed out and it is impossible to reach 40 mbar,
check that:
a) The circuit is tight (unit, arm, pipe, etc.)
b) The pressure gage (5) is not unserviceable (damaged by a pressure greater than
60 mbar (0.87 psi)).
If the 2 points a and b are correct, the pressure can be increased by means of the (2)
regulator without however exceeding 2 bar (29 psi).
64 / 116 © Stäubli 2015 – D28082804C TX60

2.11. RELEASING JOINT BRAKE

CAUTION:
Make sure that the arm and load relevant to this joint are suitably supported.
The controller must be connected to the power supply.

Place the brake release selector in position corresponding to the joint to be released.
When the brake release pushbutton is pressed, the brake on the selected joint is released
and the motor is short circuited through the amplifier to reduce the speed at which the arm
drops due to gravity.
CAUTION:
In the event of an amplifier failure, the arm falling speed limitation created by the
amplifier may not be operational. In this case, the axis is completely free and it may
fall faster than usual.
During the controller start-up (boot) phase, the axis braking mechanism via the
amplifiers is not always operational. All arm movement is prohibited during controller
start-up, as this could affect its calibration.
DANGER:
A movement during the controller start-up phase can affect the variable drive
calibration mechanism. In that case, it is necessary to restart the controller to ensure
correct robot operation.
DANGER:
Arm can fall because of gravity when brake is released.
Information:
The brake on a joint can be released if the robot has to be moved manually, e.g. to
free an item of equipment or a person blocked in the cell.
TX60 © Stäubli 2015 – D28082804C 65 / 116

2.12. SAFETY
2.12.1. RISKS NEAR THE ARM
For the UL version, a yellow indicator light (1) is fitted on the robot arm to show that drive
power is available, motion is possible and that it represents a possible cause of risks for the
operator (figure 2.26).
CAUTION:
• Whenever possible, the manual operating mode should be activated while all
persons are outside the protected area.
• When it is necessary to operate in manual mode inside the cell, the operator must
keep in mind the inherent residual risks. Typical residual risks inside the cell are listed
in chapter 1.3.5.2.
Figure 2.26
2.12.2. BALANCING SYSTEM

None of the joints are equipped with a counter balancing system.
DANGER:
When a brake is released, short-circuiting the motor is the only way of limiting the fall
speed (see chapter 2.11).
66 / 116 © Stäubli 2015 – D28082804C TX60

2.12.3. STOPPING TIMES AND ANGLES
2.12.3.1. Stop conditions

Definition of stop categories (according to EN 60204-1):
Category 0: Immediate power off on motors and brakes activation.
Category 1: Controlled stop with arm power maintained followed by arm power off and brakes
activation.
The stopping category applied by the controller depends on the situation: See chapter 5.1 of
the controller instruction manual.
2.12.3.2. Category 1 stop

These are stops on a trajectory that do not depend on the load.
CAUTION:
The stopping times and angles change with the deceleration parameter for the
movement descriptor (see the "Type mdesc" paragraph in the VAL 3 reference
manual).
The maximum value curves correspond to extreme cases, such as high speed and
low deceleration levels.
If deceleration is more than 100 %, the stop times and angles are less than those
shown in the graphs.
TX60 © Stäubli 2015 – D28082804C 67 / 116

TX60
Axis 1
0,60 100,0
0,50 80,0 M a x i mu m g u a ra n t e e d
time
0,40
60,0 Time decel 100%
Angles (°)
0,30
Time (s)
40,0
0,20 M a x i mum g u ara n te ed
0,10 20,0 angle
0,00 0,0 Angle decel 100%
0 72 144 215 287
Speed (°/s)
Axis 2
0,60 100,0
0,40 time
60,0
Angles (°)
Time (s)

40,0
0,20 M a x i mum g u ara n te ed
0,10 20,0 angle
0 72 144 215 287
Speed (°/s)
Axis 3
0,60 160,0
120,0 time
0,40 100,0
Time decel 100%
Angles (°)
Time (s)
0,30 80,0
0,20 60,0
40,0 Ma x i mum g u ara n te e d
0,10 20,0 angle
0 108 216 323 431
Speed (°/s)
68 / 116 © Stäubli 2015 – D28082804C TX60

TX60L
Axis 1
0,60 100,0
0,40 time
Angles (°)
0,30
Time (s)
40,0
0,20
Ma x i mum g u ara n te e d
0,10 20,0 angle
0,0 72 144 215 287
Speed (°/s)
Axis 2
0,60 100,0
0,40 time
0,30
Angles (°)
Time (s)
40,0
0,20
Ma x i mu m g u a ra n te e d
0,10 20,0 angle
0,0 72 144 215 287
Speed (°/s)
Axis 3
0,60 160,0
0,50 140,0
M a x i mu m g u a ra n t e e d
120,0
0,40 time
100,0
Time decel 100%
Angles (°)
Time (s)
0,30 80,0
0,20 60,0
40,0 M a x i mu m gu a ran t ee d
0,10 20,0 angle
0,0 108 216 323 431
Speed (°/s)
TX60 © Stäubli 2015 – D28082804C 69 / 116

2.12.3.3. Category 0 stop
Mains power failures and envelope errors are some of the typical common faults.
The stopping times and angles are about the same order of magnitude as category 1 stops,
but the stops are made axis by axis and not on a trajectory.
2.12.3.4. Exceptional fault stop

In the event of an exceptional fault (such as certain amplifier failures), the faulty axis is only
stopped by the brakes. The other axes then apply a category 0 stop.
The stopping times and distances for the faulty axis are measured with the arm extended, at
nominal load and nominal speed.
Stopping distance (axis degrees) Stopping time (seconds)
Axis 1 Axis 2 Axis 3 Axis 1 Axis 2 Axis 3

TX60 27 37 72 0.17 0.24 0.32
TX60L 39 62 100 0.25 0.4 0.43
2.12.4. MAXIMUM ENERGY GENERATED BY THE ROBOT IN THE EVENT OF AN IMPACT

This energy is calculated with the arm fully extended, with the nominal load and at the
nominal speed.
Maximum
energy
TX60 165 J
TX60L 234 J
2.12.5. NOISE LEVEL

The noise level generated by the robot depends on the conditions of use. In the event of use
of several axes at nominal speed and nominal load, the noise level measured at a height of
1.60 m and a distance of 1 m from the maximum work range can reach 70 dBa.
Precautions corresponding to the noise level generated must be taken concerning the
workstation, such as placing warning signs, providing hearing protection, etc.
Noise level
TX60 and TX60L 70 dBa
2.12.6. OUTSIDE TEMPERATURE OF THE ARM
DANGER:
The temperature at the surface of the arm can reach 80°C (176°F) under severe
operating conditions.
70 / 116 © Stäubli 2015 – D28082804C TX60

2.12.7. ACCELERATIONS, DECELERATIONS

The robot is capable of strong accelerations and decelerations. Check in the application that:
• The robot hand and the tool are correctly sized and firmly fixed in place. A gripper that is not
rigid enough considerably reduces dynamic arm performance and precision levels.
• The gripper is designed to hold the load with programmed accelerations and in the event of
an electrical power or air failure affecting it.
• The arm is correctly attached (see chapter 3.2).
2.12.8. AXIS RANGE LIMITATION

The arm is mounted in a way that provides the maximum angular amplitudes defined in
chapter 2.5.1.
Axis range can be limited, depending on the axes:
• by software.
• by an electric range limiter (for certain axes).
• by an internal mechanical limiter (on some axes).
• by an optional adjustable mechanical stop (on some axes).
The internal mechanical limiters are never reached during normal use of the robot (software
range limit).
CAUTION:
However, if the mechanical range limiters are hit, the fixed and mobile parts must be
replaced (consult the STÄUBLI services).
CAUTION:
Only the optional mechanical stops meet the safety requirements specified by the ISO
10218-1 standard to establish a restricted space around the robot. The range
limitation systems using software, an electrical limiter or an internal mechanical limiter
may be used solely to protect the equipment and not for functional safety in the cell.
It is possible to deliberately limit joint range by 'software' (see the chapter covering the
software configuration of the controller). The procedures for changing the ranges using
electric limiters and adjustable mechanical limit stops are defined in chapter 4.4.4.
TX60 © Stäubli 2015 – D28082804C 71 / 116

72 / 116 © Stäubli 2015 – D28082804C TX60
Chapter 3 - On-site preparation
CHAPTER
3 - ON-SITE PREPARATION
TX60 © Stäubli 2015 – D28082804C 73 / 116

74 / 116 © Stäubli 2015 – D28082804C TX60
View from H
(Base only)
world
world world
world
Sectional view Q - Q
Max.
Max.
Figure 3.1
Rear cable outlet
TX60 © Stäubli 2015 – D28082804C 75 / 116

Sectional view D-D
Max.
Sectional view C-C
Max.
O-ring housing, torus

diameter 5.33,
Zone with roughness to be complied with interior O-ring
diameter 222
(*) Opening to be left to put the connecting fittings through and disassemble the socket holder plate
Figure 3.2
76 / 116 © Stäubli 2015 – D28082804C TX60

3.1. WORKING SPACE

The user is responsible for performing all preparatory work required to complete the on-site
installation of the robot. Working space must be sufficient, installation surface appropriate;
the power supplies must be available (for the electric power supplies, see the characteristics
of the controller).
CAUTION:
To enable all maintenance operations to be carried out, it is essential to provide easy
access to the robot (e.g. removable safety barriers, etc.) and anchoring points for
easy handling of the arms, especially those whose weight exceeds 70 kg / 154 lb.
DANGER:
The arm's working area must be surrounded by a closed safety enclosure in
compliance with the country's safety legislation preventing personnel accessing the
dangerous area.
CAUTION:
There must be no obstacles within the robot work envelope.
TX60 © Stäubli 2015 – D28082804C 77 / 116

3.2. ATTACHMENT
See figure 3.2: Vertical cable outlet with minimum opening size to be made or left in the
attachment surface to put the cable through and access the connections. Seal the inner face
of the base on the holder via a static joint for the he and steri versions.
The arm can be installed in any position without mechanical modifications. In all cases, it
must be securely attached by 3 class 12.9 M10 hex. socket head screws.
CAUTION:
Par ticular as pects of the applicati ons in a "wet environment" (he) or a
"bio-contaminated environment" (steri) (figure 3.2).
Reminder (see also chapter 2.4.2):
The threaded fasteners on the wrist's mechanical interface, the threaded fasteners on
the robot, the underside of the base, the socket holder plate and the equipment fitted
on it, are not qualified for a wet environment (he) or a bio-contaminated environment
(steri), so they must be protected from these environments.
This protection is to be executed by the customer, and hence under his responsibility.
The guarantee does not cover any damage occurring there.
• Base / holder interface made waterproof with the exterior seal supplied:
. The surface of the holder on which the robot base is fixed must have surface
characteristics that provide static sealing.
. Lubricate and fit the exterior seal.
. The underside of the base must be protected from the wet or bio-contaminated
environment.
• Protection of the power socket holder plate and the equipment fitted on it:
. Protect the complete element from the wet or bio-contaminated environment.
• Protection of the threaded fasteners on the robot wrist interface:
. The end-effector must be assembled using mastic (Loctite Terostat 92 or
equivalent), to protect the threaded fasteners on the robot wrist interface from the
wet or bio-contaminated environment.
CAUTION:
For the "Vertical cable outlet" version, it is important to leave as big an opening as
possible in the robot holder, but without exceeding the dimensions shown in the
diagram, to facilitate access to the connections during installation and maintenance.
CAUTION:
It is necessary to configure the controller to suit the robot installation. To do so, see
the "Software configuration" chapter in the controller manual.
78 / 116 © Stäubli 2015 – D28082804C TX60

Attachment surface shall be flat and metallic. A deformable support will greatly reduce robot's
performance in speed and accuracy.
When calculating the size of the support, it is necessary to take into account the maximum
forces transmitted by the arm in movement at point 0, which are as follows for the standard
arm:
Floor or ceiling mounted arm
• FV = 923 N
• FG = 523 N
• CB = 524 Nm
• CP = 150 Nm
Under following load conditions:
Load position
Load Axis 5 Axis 6
kg lb mm inch mm inch
Standard arm 3.5 7.71 100 3.94 50 1.97
Long arm 2 4.4 100 3.94 50 1.97
The user can accurately position the robot by means of two 8h8 diameter centering pins (not
supplied).
TX60 © Stäubli 2015 – D28082804C 79 / 116

80 / 116 © Stäubli 2015 – D28082804C TX60
Chapter 4 - Storage, transport and installation
CHAPTER
4 - STORAGE, TRANSPORT AND INSTALLATION
TX60 © Stäubli 2015 – D28082804C 81 / 116

H
H
X
X
Y
L P
Y
2 L P
Standard packaging International packaging
Figure 4.1
Figure 4.2
82 / 116 © Stäubli 2015 – D28082804C TX60

4.1. ARM PACKAGING

See figure 4.1
Packaging position of the arm:
Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6
Angular position 0° -120° +120° 0° +90° 0°
Standard packaging:
L x H x D (mm) 800 x 850 x 570 800 x 930 x 570

[in] [32 x 34 x 23] [32 x 37 x 23]
Gross weight (kg) 75 76

[lb] [167] [169]
International packaging:
L x H x D (mm) 865 x 850 x 600 865 x 930 x 600

[in] [34 x 34 x 24] [34 x 37 x 24]
Gross weight (kg) 89 87

[lb] [198] [192]
The arm is packed in the vertical position. It is attached to the pallet (2) by 3 M10 bolts.
4.1.1. CONDITIONS OF STORAGE AND TRANSPORT

• Temperature for storage and transport : -20°C to +60°C
4.2. HANDLING OF PACKING

See figure 4.1
By pallet truck under base (2):
• X = 100 mm [4 in]
• Y = 650 mm [25 in]
4.3. UNPACKING AND INSTALLATION OF THE ARM

CAUTION:
The slings and lifting eye bolts used to lift the robot must comply with the Machine
Directive in Europe or with the rules in force for other countries.
• Move the packing case as near as possible to the installation site (figure 4.1).
• Remove the cardboard packaging, remove the packing material and the plastic cover.
• Place the fabric sling (3) around joint 3 as shown on figure 4.2.
TX60 © Stäubli 2015 – D28082804C 83 / 116

CAUTION:
500 kg [1102 lb] fabric sling.
• Remove the 3 M10 bolts from the arm.

• Slowly raise the arm using the hoist.
CAUTION:
The robot will swing when raised and moved (see figure 4.2).
Figure 4.3 Figure 4.4
Figure 4.5 Figure 4.6
84 / 116 © Stäubli 2015 – D28082804C TX60

4.4. INSTALLATION OF ARM

CAUTION:
The arm can be fixed with its base facing downwards (floor-mounted version),
upwards (ceiling-mounted version), or against a wall, without requiring any
mechanical modifications. However, it is necessary to configure the controller
accordingly. To do so, see the "Software configuration" chapter in the controller
manual.
CAUTION:
Throughout all handling and installation operations concerning the arm, it is essential
to keep the protection on the main connector at the foot of the robot in place at all
times to avoid damaging and soiling the electrical and optical contacts.
4.4.1. INSTALLATION OF ARM ON FLOOR

See figure 4.3
• Position the arm on the support at its final attachment points.
• Attach the arm with 3 class 12.9 M10 hex. socket head screws (3), tightened to
77 Nm ± 5 Nm.
• Remove the sling.
DANGER:
For safety reasons, keep the sling slightly tensioned until the arm is securely attached
to the floor.
4.4.2. INSTALLATION OF ARM ON CEILING

See figure 4.4
CAUTION:
Do not rotate joint 2.
• Carefully lay down the arm on a flexible support as shown on figure 4.5.
• Place the fabric sling (7) around joint 2 as shown on figure 4.4.
CAUTION:
500 kg [1102 lb] fabric sling.
• Position the arm on the support at its final attachment points.

• Attach the arm with 3 class 12.9 M10 hex. socket head screws (3), tightened to
77 Nm ± 5 Nm.
DANGER:
For safety reasons, hold the sling slightly tensioned until arm is securely attached to
the ceiling.
TX60 © Stäubli 2015 – D28082804C 85 / 116

4.4.3. MOUNTING FLOOR QUALITY
The user must make sure that the mechanical characteristics of the floor (or the supporting
structure) and the fastening systems are able to bear the maximum forces placed on them by
the arm when it is moving (see chapter 3).
CAUTION:
The height of the robot support can strongly influence the forces on the floor
(figure 4.6).
4.4.4. MODIFICATION OF RANGES

The arm is mounted in a way that provides the maximum angular amplitudes defined in
chapter 2.5.1.
It is possible to deliberately limit axis range using software (see the chapter on controller
software configuration) or by fitting a mechanical limit stop system on axis 1 (available as an
option). Moreover, the locations of the electrical limiters on axes 2 and 3 can be modified
using a certain number of positions.
CAUTION:
Only the optional mechanical stops meet the safety requirements specified by the
ISO 10218-1 standard to establish a restricted space around the robot. The range
limitation systems using software, an electrical limiter or an internal mechanical limiter
may be used solely to protect the equipment and not for functional safety in the cell.
86 / 116 © Stäubli 2015 – D28082804C TX60

4.4.5. TAKING STOPPING ZONES INTO ACCOUNT

Joint range limitation by an electric or mechanical system must take the stopping distances
into account:
Work area
Triggering position for
the electric range limit
Software or the optional
range mechanical limit stop
limit
Stopping zone
Stopping
zone
Figure 4.7
• Work area: Angular range within which the robot moves during normal operation. It is
possible to deliberately limit the range of the articulations using software (see the chapter on
controller software configuration), and also using optional adjustable mechanical stops (see
chapter 4.4.5.1).
• Stopping zone (abnormal operating zone): Maximum angle necessary to stop the robot. In
the event of use of the optional adjustable mechanical limit stop system, the stopping angle
depends on the violence of the impact (its maximum value is 15°). The stopping angle for an
electric limit switch is defined in paragraph 2.12.3.3 (Category 0 stop).
DANGER:
After changing a software range limit, check at low speed that the axis is able to move
through the planned angular range, but no further.
CAUTION:
In the event of use of optional adjustable mechanical limit stops, check that they are
correctly placed as compared with the desired limitations, and then define the
software range limit at least 2.5° smaller.
TX60 © Stäubli 2015 – D28082804C 87 / 116

88 / 116 © Stäubli 2015 – D28082804C TX60
5
2
4
1
Figure 4.8
TX60 © Stäubli 2015 – D28082804C 89 / 116

Horizontal cable Vertical cable
outlet outlet
position 0
Positive direction of rotation
Figure 4.9
90 / 116 © Stäubli 2015 – D28082804C TX60

4.4.5.1. Axis 1
Factory settings:
• No mechanical stops are fitted.
• The software range limit is set at ±180°.
• The electric range limit is set at ±182.5°.
Information:
The software range limit can be reduced. The electric range limit is not adjustable.
Optional mechanical limit stop

See figure 4.8.
The optional mechanical limit stop system is able to stop the robot at nominal load and
nominal speed. It is sized to absorb the kinetic energy of the axis.
Description:
• The optional mechanical limit stop system is made up of a two-part ring (1) on which
one or two adjustable limit stops (2) can be placed to limit the working range of axis 1.
• The ring is fitted on the robot base (3).
• A limit stop fitted with 2 resilient pads (4) is fixed on the robot shoulder (5).
• The working range is changed by placing one or two adjustable limit stops as shown
in the tables on page 94 and in accordance with figure 4.9.
Installation of the optional mechanical limit stop:
1) Fit the ring (1) on the robot base (3), resting on the chamfer.
2) Line the ring slot up with the axis marker (figure 4.9).
3) Tighten the two screws supplied (CHc M10 x 45, class 12-9, protected by Deltaprotekt
treatment) holding the ring (1) in place, to a torque of 50 Nm.
4) After removing the plastic caps, fit the limit stop (4) on the robot shoulder and fix it using
three CHc M8 x 25 steel screws, class 12-9, protected by Deltaprotekt treatment, tightened
to a torque of 38 Nm.
5) Position the two adjustable limit stops (2) as shown in figure 4.9 and the tables on page 94.
6) Fix the two limit stops (2) using the screws supplied (CHc M10 x 45, class 12-9, protected
by Deltaprotekt treatment) tightened to a torque of 77 Nm.
7) Check operation at low speed.
DANGER:
The system performance levels are only guaranteed in the case of correct assembly
(compliance with the required torque values, etc.), with clean, degreased parts.
Any failure to comply with the instructions can lead to incorrect operation of the range
limiting system, with accompanying risks for users.
TX60 © Stäubli 2015 – D28082804C 91 / 116

Information:
What should be done if the robot is stopped by an optional mechanical limit stop?:
1) Check that the robot has not suffered any visible damage.
2) Check that there is no unusual noise or backlash on the various axes during brake
release and in manual mode.
3) Put the ring back in place if it has slipped. Follow the points concerned in the
installation procedure.
4) Replace the resilient pad that absorbed the impact (Reference: D60017700).
5) Check operation at low speed.
DANGER:
If any ring damage or slippage is noted (or in the event of doubt following an impact or
a suspected impact), consult the STÄUBLI services for an arm diagnostic.
Check the following points at least once a year:

• No visible damage.
• Tightening torque 50 ± 3.5 Nm for the two screws holding the ring (1) in place.
• No slippage for the ring (1). The verification is made by checking the alignment of the ring
slot with the axis marker.
Example of positions for the adjustable limit stops:
• Mechanical stop in position "1a":
• Mechanical limitation at 178° in the positive direction and 98° in the negative direction.
• One limit stop in position "1a" and another in position "1b"
• Mechanical limitation at 98° in the positive and negative directions.
• Further reduction in steps of 25° if positions 2 to 4 are used.
92 / 116 © Stäubli 2015 – D28082804C TX60

TX60 © Stäubli 2015 – D28082804C 93 / 116

Arrays defining the ranges of the optional mechanical limit stop :
Usual cases:
1a 2a 3a 4a
1b 98 -98 98 -73 98 -48 98 -23
2b 73 -98 73 -73 73 -48 73 -23
3b 48 -98 48 -73 48 -48 48 -23
4b 23 -98 23 -73 23 -48 23 -23
Other possible cases:
1b 2b 3b 4b
1b 98 -178 73 98 48 -178 23 -178
2b 73 -178 73 X 48 X 23 X
3b 48 -178 48 X 48 X 23 X
4b 23 -178 23 X 23 X 23 X
Information:
X = No mechanical limitation. Software range limit at -180°.
1a 2a 3a 4a
1a 178 -98 178 -73 178 -48 178 -23
2a 178 -73 O -73 O -48 O -23

3a 178 -48 O -48 O -48 O -23
4a 178 -23 O -23 O -23 O -23
Information:
O = No mechanical limitation. Software range limit at +180°.
Safety: See chapter 2.12.8
94 / 116 © Stäubli 2015 – D28082804C TX60

4 Original position
Axis mark
5
Original
position 7
6
Figure 4.10
TX60 © Stäubli 2015 – D28082804C 95 / 116

4.4.5.2. Axis 2
Factory settings:
1 pin is fitted in position n°4 and another in position n°5 (see figure 4.10). This setting
provides the following range limits:
• Software range limits: ±127.5°
• Electric range limits: ±130°
• Mechanical range limits: ±140°
Changing ranges:
The electric range limits can be reduced by moving the pins to positions 1 to 7 (see
figure 4.10).
Array showing the electric range limits depending on the pin positions:
Positions 1 2 3 4 5 6 7
Electric range limits +35° +65° +95° +130° -130° -100° -70°

Electric limiter pin reference:
• Axis 2: D60016100, tightening torque 2.8 Nm.
96 / 116 © Stäubli 2015 – D28082804C TX60

This position
must not be used
Axis mark
6
2
5
4
Original
position
Figure 4.11
TX60 © Stäubli 2015 – D28082804C 97 / 116

4.4.5.3. Axis 3
Factory settings:
A screw is fitted in position n°4 to determine the electric range limit in the negative direction.
The screw also fixes a cam that determines the electric range limit in the positive direction.
This setting provides the following range limits:
Software range limits Electric range limits
TX60 ±142,5° ±145°
TX60L ±152,5° ±155°
Changing ranges:
The electric range limits can be reduced by moving the screw and the cam to positions 1 to 7
(see figure 4.11).
Information:
To reduce the working range in the negative direction, place a D.600.121.00 screw
with a C.133.014.10 washer in one of the positions 5, 6 or 7. These screws and
washers are not supplied with the robot. Apply Loctite 242 compound on these
screws.
To reduce the working range in the positive direction, move the cam and its fixing
screw to one of the positions 3, 2 or 1.
Array showing the electric range limits depending on the pin positions:
1
Positions (cam + 2 3 4 5 6 7
screw)
TX60 +0° +30° +95° ±145° -80° -50° -20°
TX60L +10° +40° +105° ±155° -90° -60° -30°

CAUTION:
Use an electrostatic wrist strap and an antistatic mat connected to the controller or the
arm during all work to handle boards, electronic components or the electric harness to
which they are linked.
98 / 116 © Stäubli 2015 – D28082804C TX60

Chapter 5 - Preventive maintenance
CHAPTER
5 - PREVENTIVE MAINTENANCE
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5.1. RULES TO BE APPLIED FOR MAINTENANCE

• To keep the performance of the arm at an optimal level the arm requires preventive
maintenance.
DANGER:
Poor maintenance can lead to premature wear, or even cause safety hazards for
production or maintenance operators.
• All maintenance operations must be carried out solely by personnel who have undergone the
appropriate training provided by STÄUBLI.
DANGER:
The maintenance technician must be informed of the hazards linked to the robot
environment, and especially the risks of activity on the machine during maintenance.
CAUTION:
To ensure a correct seal, it is essential to replace the seal each time a cover is
removed (see chapter 5.5).
CAUTION:
Use an electrostatic wristband and an antistatic mat connected to the controller or the
arm when handling any boards or electronic components, together with the electric
harness to which it is connected.
CAUTION:
Particular case of he and steri robots
• In the event of damage to paintwork (he or steri arm), it is essential to touch up the
paintwork as soon as possible, to protect the part concerned from corrosion (see
chapter 5.4).
• We strongly recommend contacting the STÄUBLI after-sales services to ensure that
the repairs are carried out correctly.
• In the event of damage, any failure to comply with these instructions can affect the
product's technical characteristics, and hence bring into question the STÄUBLI
company's liability as to guarantee.
CAUTION:
For restarting after any maintenance operation:
• Make sure that the maintenance procedure was followed until its term.
• Check that the connections of the arm have been restored.
• Stay away from the arm during the functioning tests.
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5.2. DEFINING THE LEVELS OF INTERVENTION
Level 1: Operations that can be carried out by a maintenance technician without specific
STÄUBLI training.
Level 2: Operations that can be carried out by a maintenance technician who has undergone
specific STÄUBLI training. The documentation corresponding to these operations will be
provided during the training.
Level 3: Operations that must be carried out by the STÄUBLI After-Sales Service.
DANGER:
Failure to comply with the levels of intervention can lead to incorrect operation of the
robot and entail risks for the user and the machine environment.
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5.3. MAINTENANCE FREQUENCY
Periodicity
Intervention levels
Every (first reached)
See chapter
TX60
10 000 hours
20 000 hours
40 000 hours
Preventive maintenance
5 years
Month
Year
Safety
- External hard stop (option): Visual check, change if
1
needed
- Remote brake control (option): Check operation,
1
replace if necessary
- Brake: Check brake operation 2
- Brake: Replace if necessary (axes 1, 2 and 3) 3
- Brake: Replace if necessary (axes 4, 5 and 6) 2
- Fastenings (base, tool interface flange, etc.):
1
Check tightness and for corrosion
- Power light PWRL (option): Check, change if
1
needed
- Check continuity of the protection circuit 2
General state of the arm
- External: Visual check for corrosion and collision
1
damage
- Painted parts: Visual check, touch up the paintwork
5.4 1
if it has been damaged
Gear boxes
- Oil level: Check 5.6 1
- Operation (backlash, hard spots) 2
- Oil change (axes 1, 2 and 3) 2 H1
- Oil change (axis 4 and wrist) 2

- Replacement (except wrist) 3
- Wrist replacement (axes 5 and 6) 2
Belt (axis 4)
- Visual check 1
- Replacement 2
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Periodicity
Intervention levels
Every (first reached)
See chapter
TX60
10 000 hours
20 000 hours
40 000 hours
Preventive maintenance
5 years
Month
Year
Sealing
- Lip seals: Visual check of seepage 1
- Lip seals: Visual check 3
- Cover seals: Visual check 1
- Cover seals: Replacement 5.5 1
- Pressurization unit (option): Check operating
1
pressure on dial
Electrical and pneumatic harness
- Visual check of the harness and connectors,
1
condition of the fixings (covers removed)
- Harness lubrication 2
- Harness replacement 3
- Solenoid valves (option): Check operation 1
- Solenoid valves (option): Replacement
1
Typical lifetime: 47 million cycles at 5 Hz
: Recommended periodicity: To be adapted in the light of the risk analysis for the
application.
: Typical periodicity ("Standard maintenance" level from OptimizeLab).
: Recommended typical periodicity for heavy duty applications. ("Adapted maintenance"
level from OptimizeLab). Consult the STÄUBLI support services.
: Recommended typical periodicity for applications in harsh environments (such as damp
environments) or clean environments (such as CRs). Consult the STÄUBLI support services.
H1 : Typical periodicity for arm lubricated with H1 oil. Consult the STÄUBLI support services.
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5.4. PAINT TOUCH-UP PROCEDURE FOR HE AND STERI ROBOTS

To protect the surfaces of painted parts from the environment, it is essential to make all
necessary touch-ups in the event of scratches.
A paint touch-up kit is available. To order one, contact the STÄUBLI after-sales department.
The kit includes the paint and the procedure to be followed to carry out the touch-up work.
CAUTION:
In the event of damage to the paintwork, failure to comply with these instructions may
lead to deterioration in the product's technical characteristics and bring into question
STÄUBLI's liability concerning warranty.
5.5. PROCEDURE FOR REPLACING THE FLAT SEAL

The flat seal is made up of 2 sections:
• A section made of foam (1),
• An adhesive section (2).
5.5.1. REMOVING THE SEAL

• To remove the flat seal, peel off a corner of the seal and pull it towards you.
If the adhesive section (2) remains stuck to the cover, use "C" fluid (ethyl acetate) to remove
it.
• Clean the surface, remove all paint and all other particles present on the surface, without
scratching it.
• Clean the whole surface using "C" fluid (ethyl acetate).
5.5.2. FITTING A NEW SEAL

The new seal is made up of 3 sections:
• A section made of foam (1),
• An adhesive section (2),
• A protective paper covering the adhesive (3).
• Remove the cut-out sections such as screw holes.
• Present the seal. Line the contour of the seal up with that of the surface.
• Apply the new seal to the surface. Remove a corner of the protective paper covering, apply
that part to the surface, and then continue to remove the paper and put the seal into contact
with the surface.
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3
Figure 5.1
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5.6. CHECKING OIL LEVELS

Information:
The greasing and lubrication work is carried out by STÄUBLI in the factory. At the time
of delivery, the robot is ready for use.
5.6.1. ARM IN FLOOR-MOUNTED POSITION

See figure 5.1
5.6.1.1. Software angular position of joints for checking levels
Joint position
Check Joint 1 Joint 2 Joint 3 Joint 4 Joint 5, 6
Joint 1 - - - - -
Joint 2 - - - - -
Joint 3 - 0° 90° - -
Joint 4 - 90° 90° - -
Joint 5 - 0° 110° 0° -110°
5.6.1.2. Levels to be observed

With the robot in position specified above, the oil levels to be observed are as follows:
• Joint 1: Oil level has to be in the middle of sight glass (2) ±3 mm.
• Joint 4: The oil level is at the middle of the wheel after removing the steel cap (20 mm
from the inner face of the cap).
• Joint 5: The oil level coincides with the base of the thread, after removing cap (5).
CAUTION:
Too much or too little oil can prevent the robot from operating correctly.
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1
Joint 1 1 Joint 1
1
negative 30° positive 57°
Joint 2 Joint 2
2
Figure 5.2
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5.6.2. WALL-MOUNTED ARM (AXIS 1 HORIZONTAL, CONNECTOR DOWNWARDS)

See figure 5.2
5.6.2.1. Software angular position of joints for checking levels.

The positions for checking depend on arm orientation.
2
1 1 : ω = 0°
2 : ω = -90°
3 : ω = +180°
4 : ω = +90°
3 4
Position
Check Joint 1 Joint 2 Joint 3 Joint 4 Joints 5, 6

Joint 1 -120° + ω - - - -
Joint 2 0°+ ω - - - -
Joint 3 180°+ ω 0° -58° - -
Joint 4 180°+ ω 0° -90° - -
Joint 5 0°+ ω 90° 70° 0° 110°

• Joint 1: The oil level coincides with the base of hole after removing cap (1).
CAUTION:
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2
6
4
Figure 5.3
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5.6.3. ARM IN CEILING-MOUNTED POSITION

See figure 5.3
5.6.3.1. Software angular position of joints for checking levels
Position
Check Joint 1 Joint 2 Joint 3 Joint 4 Joints 5, 6

Joint 1 No checks
Joint 2 - - - - -
Joint 3 - 0° -90° - -
Joint 4 - 90° -90° 0° -
Joint 5 - 0° -110° 0° 110°

• Joint 1: No checks.
CAUTION:
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Chapter 6 - Recommended lubricants and spare parts
CHAPTER
6 - RECOMMENDED LUBRICANTS AND SPARE

PARTS
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Chapter 6 - Recommended lubricants and spare parts
CAUTION:
To ensure correct operation of the robot, it is essential to use original STÄUBLI parts
when making repairs.
Type of lubricants and approximate quantities (the quantities are given for information
purposes only, please refer to the oil level):
Drainable
Standard lubricant H1 option Quantity
quantity
Axis 1 ROBOLUB 68-S ROBOLUB 100-H1 250 ml 100 ml
Axis 4 ROBOLUB 1000-H1 ROBOLUB 1000-H1 100 ml 60 ml
Axis 5
ROBOLUB 1000-H1 ROBOLUB 1000-H1 100 ml 70 ml
Axis 6
Recommended spare parts:

• Electric distributor.
• Cover seal kit.
• Paint touch-up kit for he and steri robots.
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1.1.1. OBJECTIVE OF THIS MANUAL

1.1.2. SPECIAL MESSAGES CONCERNING WARNINGS, ALERTS, AND INFORMATION

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1.2. DEFINITION OF THE ELEMENTS AROUND THE MACHINE

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The manufacturer: STÄUBLI FAVERGES

Hereby declares that:

The following harmonized European standards have been used:

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Guidelines for robot integration

• Standard ISO 10218-2 Safety requirements for industrial robots:

For the UL version:

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1.3.2.1. Analysis of safety around the machine

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1.3.2.2. Rules concerning the robot's work area

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1.3.3.1. Mechanical and electrical dangers

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1.3.4. SAFETY DIRECTIVES CONCERNING TO PROTECTION OF THE EQUIPMENT

1.3.4.2. Information on electrostatic discharges

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Electrostatic discharges or ESD

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Low relative Average relative High relative

Walking on carpet 35 kV 15 kV 1,5 kV

Walking on vinyl 12 kV 5 kV 0,3 kV

Working at the 6 kV 2,5 kV 0,1 kV

Plastified instructions 7 kV 2,6 kV 0,6 kV

Polyethylene bags 20 kV 2 kV 1,2 kV

Cellular polyurethane 18 kV 11 kV 1,5 kV

Work surfaces Packaging

Parts sensitive to static charges

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1.3.4.3. Prevention of damage due to electrostatic discharges

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1.3.5.1. Overview of the safety devices

2.12.8 Axis range limitation

1.3.5.2. Residual risks

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STÄUBLI FAVERGES SCA

Type : Masse kg/lb :

Standard version UL version

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2.3. DESIGNATION OF ROBOTS OF THE TX SERIES 60 FAMILY