CS8C Controller

Instruction manual

D28070504A – 26/03/2009
CS8C
© Stäubli 2009
 Documentation addenda and errata can be found in the "readme.pdf" document delivered with the
controller's CdRom.

2 / 248 © Stäubli 2009 – D28070504A CS8C

 TABLE OF CONTENTS

1 INTRODUCTION
1.1 FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.2 DEFINITION OF THE ELEMENTS AROUND THE ROBOT CELL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2 DESCRIPTION OF THE CONTROLLER

2.1 IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.2 LOCATION AND DESCRIPTION OF THE MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3 SAFETY
3.1 REMINDER CONCERNING THE SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.2 SAFETY DIRECTIVES CONCERNING TO THE WORK ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . 25

3.3 SAFETY DIRECTIVES CONCERNING TO STAFF PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.4 SAFETY DIRECTIVES CONCERNING TO PROTECTION OF THE EQUIPMENT . . . . . . . . . . . . . . . . 28

4 INSTALLATION
4.1 ROBOTIZED CELL ENVIRONMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.2 ON-SITE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.3 UNPACKING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.4 FIXING THE MCP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.5 FIXING THE WMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.6 CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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5 INTEGRATION
5.1 EMERGENCY AND SAFETY STOP CHANNELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.2 BASIC INPUTS/OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5.3 RS ROBOTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

5.4 AS-I DIGITAL INPUTS/OUTPUTS (RS ARMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

5.5 DIGITAL BIO INPUT/OUTPUT BOARD (OPTIONAL EXTRA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

5.6 FIELD BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

5.7 PROGRAMMABLE LOGIC CONTROLLER (PLC OPTION). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

5.8 ETHERNET LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

5.9 SERIAL PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

5.10 SOFTWARE CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

6 OPERATION
6.1 POWERING UP THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

6.2 PRESENTATION OF THE MCP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

6.3 ARM POWER-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

6.4 EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

6.5 CALIBRATION, ADJUSTMENT, RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

6.6 WORKING MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

6.7 JOG INTERFACE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

6.8 STARTING AN APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

6.9 STOPPING MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

6.10 VAL3 APPLICATION MANAGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

6.11 TEACHING FRAMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

6.12 TEACHING POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

6.13 MOTION DESCRIPTOR EDITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

6.14 CONTROLLER BACKUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

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7 PC UTILITIES
7.1 STÄUBLI ROBOTICS STUDIO (SRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

7.2 FTP ACCESS FROM A PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

7.3 FTP ACCESS TO A PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

8 MAINTENANCE
8.1 HOW TO USE THIS MANUAL ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

8.2 GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

8.3 COMPONENT LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

8.4 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

8.5 INPUT VOLTAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

8.6 ARPS AUXILIARY ROBOT POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

8.7 RPS POWER SUPPLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

8.8 RSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

8.9 STARC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

8.10 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

APPENDIX: PROTECTION OF THE POWER LINE FOR THE CS8C

CONTROLLER
8.11 CONTROLLER CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

8.12 PROTECTION UPSTREAM FROM THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

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Chapter 1 - Introduction

CHAPTER 1

INTRODUCTION

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Chapter 1 - Introduction

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, use and maintenance of the
Stäubli CS8C controller. It provides help for the persons working on the equipment, for reference purposes only.
This is because correct understanding of this document and use of the Stäubli CS8C controller imply that the staff
concerned have acquired the necessary knowledge by following a "robots" training course 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.

Warning 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.

Notes
Paragraphs of the "note" type provide very important information to help the reader to understand a description or
a procedure.
Note:
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.

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1.2. DEFINITION OF THE ELEMENTS AROUND THE ROBOT CELL

Person: general term identifying all individuals likely to come close to the Stäubli robot cell.
Staff: identifies the persons specifically employed and trained to install, operate, and service the Stäubli robot cell.
User: refers to the persons or the company responsible for operating the Stäubli robot cell.
Operator: refers to the person who starts or stops the robot, or controls its operation.

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Chapter 1 - Introduction

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Chapter 2 - Description of the controller

CHAPTER 2

DESCRIPTION OF THE CONTROLLER

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Chapter 2 - Description of the controller

2.1. IDENTIFICATION

Manufacturer's plate on each robot.

A plate is provided on the controller and on the arm (see figure 2.1).

Standard version

UL version

Figure 2.1

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.

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2.2. LOCATION AND DESCRIPTION OF THE MAIN COMPONENTS

2.2.1. THE CONTROLLER

The CS8C controller is made up of a processor (5), the intelligent part of the installation.
The processor controls the robot via digital power amplifiers (1) dedicated to each axis of the arm.
The electrical power is converted by the PSM (7) power section, the RPS (2) power supply, and the ARPS (3)
power supply which supplies to each of the above elements the voltage required for correct operation from the
mains voltage delivered by the electrical network.
The functions required for electrical safety are grouped together on the RSI (4) board.

2 3 4 5

7 6

Figure 2.2

To disconnect the system from the power supply, set the master switch (6), located on the front panel of the
controller, to 0. Before doing so, you must stop the arm motion and switch off arm power supply.

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Chapter 2 - Description of the controller

2.2.2. THE MCP

General description
The MCP (Manual Control Pendant) can be used to enable arm power supply and control its movements.

(#)

Figure 2.3
Location and handling of the MCP
To power the arm in manual mode, the MCP must be placed on the holder provided for the purpose. The holder
is fixed outside of the cell. It has two functions:
• Making the MCP easily accessible for the operator.
• Detecting the presence of the MCP outside the cell.
In the event that the MCP is used elsewhere than on its holder in manual mode, it is necessary to use the validation
button (#) located under the MCP. The button's location enables it to be used by right-handed or left-handed
persons alike.

2.2.3. WMS FRONT PANEL

Modes of operation are selected from the WMS front panel which has to be installed permanently outside of the
cell. The removable 3-position keyswitch prevents from changing the mode when it is not allowed.

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Chapter 3 - Safety

CHAPTER 3

SAFETY

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Chapter 3 - Safety

3.1. REMINDER CONCERNING THE SAFETY STANDARDS

DANGER:
The robot is a fast moving machine. These movements can be dangerous. Always
comply with the safety standards recommended for robot use and inform operators
about the dangers faced.

The robot is a sub-assembly designed for integration in a robot cell. It has been designed and built to enable the
"robot cell" unit to comply with regulatory provisions. Compliance of the robot cell is the responsibility of the prime
contractor who very frequently is the owner.
The user must make sure that the staff programming, operating, maintaining or repairing the robot or the robot cell
are correctly trained and show the skills necessary to carry out these tasks in full safety.
In France, for example, posters issued by the CRAM are available to remind operators of the safety rules
applicable in the vicinity of robot stations.
The electrical equipment of the robot and the robot cell must comply with standard EN 60204-1 and specific
standards if required, such as UL1740.
The characteristics of the power supply and the grounding terminals must comply with the manufacturers'
specifications.
The robot and its controller are designed to meet a "Category III" safety level.
Standards applicable
Installation of the robot must be planned in accordance with the standard instructions.

• ISO 10218-1, 2006 Robots for industrial environment - Safety

• EEC 98 / 37 "Machine Safety" Directive European Directive

• Standard EN 292 General principles

• Standard EN 294 Safety distances

• Standard EN 418 Emergency stop equipment

• Standard EN 953 Protective elements

• Standard EN 954-1 Machine safety

• Standard EN 349 Minimum clearances

• Standard EN 1050 Risk assessment

• Standard EN 1088 Locking devices

• Standard EN 60204-1 Electrical equipment on machines

• Standard EN 999 Speed on approach towards the human body

• Standard EN 61 000-6-4 Electromagnetic compatibility - Emission

• Standard EN 61 000-6-2 Electromagnetic compatibility - Immunity

• Standard CEI 34-1 Electrical rotating machines

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 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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Chapter 3 - Safety

3.2. SAFETY DIRECTIVES CONCERNING TO THE WORK ENVIRONMENT

3.2.1. ANALYSIS OF SAFETY AROUND THE ROBOT CELL

Safety must be taken into account for the robot cell from the design and development stage on.
Before planning the installation of the robot cell, 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 robot cell.
• 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.
Note:
This list is not exhaustive. Above all, it is necessary to comply with the standards in force in your
country.

DANGER:
To ensure reliability and precision in the robot's movements, the robot cell
environment must comply with the levels of disturbance set out in the safety
standards.

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).
Note:
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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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 controlled with great care by the
user of the robot cell. All staff using Stäubli robots must be familiar with the warnings and recommendations given
in this manual.

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 turn of power, set the CS8C main switch 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.
Note:
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.

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Chapter 3 - Safety

• 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.
Note:
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 3.1

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.

3.3.2. ROBOT CELL SAFETY DEVICES

The safety devices must form an integral part of the design and installation of the robot cell. Operator training and
compliance with the operating procedures constitute a major element in setting up the safety devices and systems.
Stäubli robots are equipped with various communication functions, helping the user to develop safety devices for
the robot cell. 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 (see chapter 5).

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3.4. SAFETY DIRECTIVES CONCERNING TO PROTECTION OF THE EQUIPMENT

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.

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.
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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Chapter 3 - Safety

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 workstation 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

CHARGE SOURCES

Work surfaces Packaging

Floors Handling

Chairs Assembly

Carriages Cleaning

Clothes Repairing

PARTS SENSITIVE TO STATIC CHARGES

Electronic cards
Power supplies
Encoders
etc

CS8C © Stäubli 2009 – D28070504A 29 / 248

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 anti-static 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 anti-static bags.
Anti-static wrist strap
Use an electrostatic wrist strap connected to the frame of the controller or to the frame of the arm and the ground
during all handling of boards or components. The wrist straps are supplied as part of the standard equipment for
the robot.

CAUTION:
Use an electrostatic wrist strap and an anti-static mat connected to the cabinet during
all handling of boards or components.

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Chapter 3 - Safety

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Chapter 4 - Installation

CHAPTER 4

INSTALLATION

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34 / 248 © Stäubli 2009 – D28070504A CS8C
Chapter 4 - Installation

4.1. ROBOTIZED CELL ENVIRONMENT

Installation of the robot must be planned in accordance with the standard instructions.
(see paragraph 3.1)

DANGER:
See the declaration of incorporation and conformity.

This declaration of incorporation and conformity relates to the CE mark. For UL robots, UL mark information can
be obtained on UL web site : http://www.ul.com. In the proposed menu list, select "Certifications" and fill in the UL
file number with e221459

4.1.1. POSITIVE SAFETY

The robotized cell must be designed, built and installed in a way ensuring that no foreseeable failures of any
components whatsoever (electric, electronic, mechanical or pneumatic) affects the safety functions. In the event
of a problem, the robotized cell must remain in a safe state (see chapter 3, page 21).
The safety functions include especially:
• Limiting the range of movements
• The emergency stop and the controlled stop
• Low speed
• Locking of the protective devices
Example: Fit safety locking bolts (electric door openers, twin contacts) on all the openings. Part
entrances and exits must be made safe: tunnels, light barriers,etc
The robot and its controller are designed to meet a "Category III" safety level.

4.1.2. POWER SOURCES

The electrical equipment of the robot and the robot cell must comply with standard EN 60204-1.
The characteristics of the power supply and the grounding terminals must comply with the manufacturers'
specifications.
Each robotized cell must be equipped with means of separating each of its power sources.

CS8C © Stäubli 2009 – D28070504A 35 / 248

4.2. ON-SITE PREPARATION

4.2.1. ELECTRICAL NETWORK

The system is linked to the mains power supply via a cable with 2 or 3 wires + ground connected to the controller.
Various power supply voltages are possible: 200V, 208V, 230V, 400V, 440V, 480V (50/60Hz) ± 10 %. The choice
of the power supply voltage and the type of network (single phase or three-phase) depend on the option selected
and the type of arm used.

CAUTION:
Make sure that the voltage supplied corresponds to the voltage shown on the manufacturer's
plate of the CS8C controller.

When making the connections, the ground wire must be connected first.
Power rating to be installed:

TX40 1,5 kVA

TX60 1,7 kVA

TX90 2 kVA

RX160 3 kVA

RS40B, 60, 80 1,7 kVA

Minimum wire cross section: 14 AWG / 2 mm2

Maximum wire cross section: 8 AWG / 6 mm2 (flex wire)
Maximum wire cross section: 7 AWG / 10 mm2 (solid wire)
Maximum tightening torque applicable on terminal block screw: 1.8 Nm

DANGER:
Use a cable whose cross-section is suitable for the power rating shown on the
manufacturer's plate and protect the line accordingly.

Note:
The controller is fitted with a filter to limit the induced disturbances (disturbances caused by the
controller). The filter can cause major leakage current peaks that have to be taken into account
when selecting the elements protecting the power supply circuit (using a time delay ground fault
circuit breaker). Leakage current can reach up to 250 mA for 3 ms. Nominal leakage current for
3-phase and single phase configurations is below 3 mA.

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Chapter 4 - Installation

4.2.2. PNEUMATIC NETWORK

For the arm, and if solenoid valves are used, it is necessary to provide a supply of compressed air, lubricated or
not, at a maximum pressure of 7 bar and filtered to 10 µm.

4.2.3. WORK ENVIRONMENT

• Working temperature: 5 to 40°C (NF EN 60204-1) with controller cooling via a filtered fan.
• Storage temperature: -25 to 55° C.
• Humidity: 90% maximum without condensation.
• Maximum altitude: 2000 m.
• Vibrations: please consult us.
• Protection index: IP20.
• Clean environmental air: Class 10 000 (Federal Standard 209E).
If these conditions of cleanness and temperature in particular are not complied with, the controller must be
integrated in a closed area in which the necessary conditions can be provided: A cooled industrial frame. If CS8C
is enclosed in a IP54 cabinet, the door of this external chassis has to remain closed during operation.
The heat generated by the controller is 400 W.

CS8C © Stäubli 2009 – D28070504A 37 / 248

4.2.4. CONTROLLER FOOT PRINT AND FITTINGS
The CS8C controller can be simply placed on the floor, in compliance with its environmental constraints, or fitted
in a 19" frame as shown in the layout below, to meet the airflow constraints.
For easier maintenance, we recommend slides to hold the controller in place while it is not kept in a vertical position
by its fastening points. The length of the Input/Output cables must also be taken into account.
Note:
In addition to the mechanical fastening of the controller, the brackets are also a good way to
ground the controller to the cell's frame and have a common reference potential with all other
equipements in the cell. The ground connection used on main input is providing personnal
protection, the ground connection from the brakets is providing EMI protection.
4.2.4.1. CS8C FOR TX AND RS ARMS

Detail: A
Scale: 1:1

Figure 4.1

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Chapter 4 - Installation

4.2.4.2. CS8C FOR RX160 ARM

Detail: A
Scale: 1:1

Figure 4.2

CS8C © Stäubli 2009 – D28070504A 39 / 248

4.2.5. AIR CIRCULATION
The airflow, which is directed upwards in the standard version, can be directed downwards as an option, except
in the CS8C controller for the RX160.
Note:
The surface used for the installation must be horizontal and free from vibrations.
If the CS8C controller is integrated in an industrial frame ensuring that the surrounding air is
dust-free, the filter (3) must be removed.

3
Figure 4.3

CAUTION:
Make sure that the controller is placed in such a way as to avoid obstructing the air inlets and
outlets (1) (2) (3) (4) of the airflow path.
Also make sure that the controller is placed in a location where the air can circulate freely
(figures 4.1, 4.2 and 4.3). If the controller overheats, this shortens the service life of the
components and can lead to malfunctions.
Take care to avoid damaging the interconnection cable when handling the controller.

4.2.6. ACCESSIBILITY
When designing the safety enclosure, it is necessary to ensure the accessibility of all the mechanical and electrical
elements (robot, sensors, mechanical assemblies, etc.).

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Chapter 4 - Installation

4.3. UNPACKING AND HANDLING

4.3.1. PACKAGING FOR THE CS8C CONTROLLER

7
CS8C FOR TX, RS CS8C FOR RX160

Standard packaging 900 x 640 x 570 mm 900 x 815 x 570 mm

LxHxD 354 x 252 x 224 in 354 x 321 x 224 in
4
Gross weight 70 kg / 155 lb 80 kg / 177 lb
International packaging 990 x 755 x 610 mm 990 x 930 x 610 mm
LxHxD 390 x 297 x 240 in 390 x 366 x 240 in
Gross weight 84 kg / 185 lb 94 kg / 208 lb
Net weight With transformer: 6
50 kg / 110 lb
60 kg / 132 lb
Without transformer:
31 kg / 68lb 5

3
4.3.2. HANDLING OF PACKING
By pallet truck under base (2).

4.3.3. UNPACKING AND INSTALLING

1 THE CONTROLLER
• Move the packing case as near as possible to the
installation site.
• Open the case (1).

• Fit a sling (4) (fabric sling 200 kg / 442 lb) using hooks (6) between the lifting rings (5) on the controller (3) and
the hook on the lifting tackle (7). The hooks (6) must also stand up to 200 kg / 442 lb.
• Slowly lift the controller using the lifting tackle and set it down beside the base (2).
• The lifting rings (5) on the controller are removable.
• Take out the box containing the MCP and the upper wedges.
• Take out the documentation and side wedges.
• Take out the box containing the connecting cable.

CS8C © Stäubli 2009 – D28070504A 41 / 248

4.4. FIXING THE MCP

4.4.1. CHARACTERISTICS
Protection class: IP54
Note:
The MCP must not be used in an explosive environment.
The MCP must be installed in accordance with the requirements of the installation. It must be accessible close to
the workstation and outside the cell (see figure 4.4).
It is installed on the holder provided for the purpose. The holder must be fixed to an outside element of the cell
(see figure 4.5). It must not be removable to prevent its use inside the cell. The fastening work must be carried out
using the oblong holes 8 x 12 mm and screws of suitable size (see figure 4.5).
The MCP holder has two functions:
• To ensure that the MCP is easily accessible for the operator.
• To detect the presence of the MCP outside the cell when the arm is powered on.

Figure 4.4

CAUTION:
The MCP is made of plastic. This means that it can pick up electrostatic charges and be a
source of electrostatic discharges to components located close by. This must be taken into
account for sensitive components in the robot cell.

CAUTION:
If MCP is not connected to the controller, it shall be removed from the cell to avoid having a
non-operating E-Stop push button.

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Chapter 4 - Installation

Holder measurements:

Figure 4.5

CS8C © Stäubli 2009 – D28070504A 43 / 248

4.5. FIXING THE WMS

Figure 4.6

The WMS (Working Mode Selection) front panel must be installed permanently outside of the cell to be able to
change the modes of operation from a safe location, outside of the cell.
To comply with the UL requirements, it cannot be provided or modified by the user / integrator.
The WMS is designed to be installed on a plate with following dimensions:

4 * M4
43 mm

52 x 93 mm hole

104 mm

Figure 4.7

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Chapter 4 - Installation

WMS overall dimensions:

4*φ5

ESTOP
43

Switch
54

104

115

Cable to CS8C
90 * 50

45
35

Figure 4.8

When installed, the board side has to be protected against direct contacts and dusty environment.
The cable between WMS and CS8C has a connector on both sides. It has to be connected to J113 on CS8C (RSI2
board).

CS8C © Stäubli 2009 – D28070504A 45 / 248

4.6. CONNECTIONS

Service and maintenance on the robot has to be taken into account when wiring the controller : cables have to be
long enough to be able to move components, cables should not obstruct air flow around the controller.

4.6.1. CONNECTION TO THE MAINS POWER SUPPLY

CAUTION:
Make sure that the voltage supplied corresponds to the voltage shown on the manufacturer's
plate of the CS8C controller.
Use a cable appropriately rated to the power mentioned on the identification plate, and protect
the line accordingly.

The mains input is connected via the terminal strip (1) that is underneath the cover. The cover can be removed
after the fixing screws (2) have been taken out. The cable must be held in place by ties at (4).

2 4 1
Figure 4.9

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Chapter 4 - Installation

If voltage configuration of the controller is not the good one, it can be changed on the terminal trip (1) of the
transformer:

1 98 7 6
Figure 4.10

Three-phase voltage configuration:

200 V 208 V 230 V 400 V 440 V 480 V

7F 8F 9F 7E 8E 9E 7D 8D 9D 7C 8C 9C 7B 8B 9B 7A 8A 9A

Single-phase voltage configuration:

115 V 230 V
8G 8D

Note:
If voltage is changed, fuses F1, F2, F3 have to be adapted to the voltage
• Fuses are 10 x 38 mm type, 500V for standard controllers.
• For UL type controllers, replace fuses with UL type.

THREE-PHASE THREE-PHASE SINGLE PHASE SINGLE PHASE

400-480 V 200-230 V 230 V 115 V

TX40 4Am 6Am 10Am 16Am

TX60 - RS 4Am 8Am 10Am 16Am

TX90 6Am 12Am

RX160 8Am 16Am

CAUTION:
• These fuses do not protect the mains power supply line which must be protected
separately.
• Never replace these fuses with fuses of a higher rating or with different
characteristics (see the "replacement parts" section).

Note:
Am means "slow-acting fuse" according to IEC 269-1.2.
AT means "slow-acting fuse" and AF "quick-acting fuse" according to IEC 127-2.

CS8C © Stäubli 2009 – D28070504A 47 / 248

4.6.2. CONNECTION BETWEEN THE ARM AND THE CONTROLLER
The arm is connected to the controller via 2 unpluggable connectors on the arm and on the controller. The
connectors must be locked in place to ensure correct connections and the cable has to be attached to the cell's
frame to avoid having mechanical constraints on connectors.
This connection includes optical fibers. When the cable is disconnected, during maintenance for example, cover
the ends to avoid soiling the ends of the optical fiber. In the event of soiling, the only cleaning product to be used
is water. Never use alcohol.

DANGER:
Do not stand with your eyes directly opposite the optical fiber when it is lit, in order to
avoid damage to the eyes.

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Chapter 4 - Installation

4.6.3. CONNECTING THE SIGNALS

The Input/Output signals are connected via the connectors located on the front panel of the controller.

4 3 13 F2 2 5 12 7 11 6

14

8
8

10
Figure 4.11

2: Connector for MCP

3: Fast Inputs/Outputs
4: Connection with cell (emergency stop, door, etc.)
5: Digital I/O options (BIO)
6: Ethernet links
7: Serial links
9: USB links
10: Anti-static wrist strap
11: Optional encoder input
12: CAN output for Scara robots
13: Connector for WMS front panel
14: Optional fieldbus board

The signals must be connected using shielded cables whose shield is grounded at the both ends. This is
necessary both for the emergency stop signals (J109) and for the digital links (serial links, Ethernet, etc.).If screw
terminal type connectors are preferred, an adaptor from Sub D to screw terminal is commercially available from
several sources such as Phoenix Contact and others.
The brackets used to hold the controller in place also provides protection from electrical noise. It is thus useful for
the fastenings (8) to be linked to the ground circuit of the cell as a whole.
Note:
For RS robots, there are also Inputs/Outputs available on the arm.

CS8C © Stäubli 2009 – D28070504A 49 / 248

4.6.4. CABLE INLETS AND OUTLETS
The connections for the CS8C controller are on the front panel. They must then be protected by backshells with
good levels of mechanical strength and the cables have to be attached to the frame of the cell to avoid constraints
on connectors.
Note:
Grounded metal backshells provide improved protection from unwanted outside currents.
The cable layout must comply with a minimum radius of curvature for each type of cable. See the table below:

Minimum radius of curvature in mm

Standard interconnection cable 100

Flat interconnection cable static bend radius: 55

dynamic bend radius: 110

hand I / O cable 50

MCP and WMS cables 50

Other Depending on the cables used

Note 1:
During installation, the ends of the interconnection cable should be covered to protect them from
dust. The only cleaning product that can be used is water. Never use alcohol.
Note 2:
Flat interconnection cable requires more space on controller side. The flat cable has to be
installed in a chain to guaranty a good operation and dynamic constraints have to be applied to
the cable itself, not the connectors.
Flat cable characteristics:
• Minimum dynamic bend radius: 110
• Max speed: 4 m/s
• Max accel: 8 m/s²
• 5.000.000 cycles maximum

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Chapter 4 - Installation

32 71
25

52 74 73

55

43

Figure 4.12

The length of the cables must be taken into account to facilitate maintenance.
Interconnection cable:
• Cable Ø: 25 mm
• Connector passage Ø: 90 mm
WMS cable:
• Cable Ø: 7 mm
• Connector passage Ø: 25 mm

CS8C © Stäubli 2009 – D28070504A 51 / 248

52 / 248 © Stäubli 2009 – D28070504A CS8C
Chapter 5 - Integration

CHAPTER 5

INTEGRATION

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54 / 248 © Stäubli 2009 – D28070504A CS8C
Chapter 5 - Integration

5.1. EMERGENCY AND SAFETY STOP CHANNELS

In general, the "Emergency Stop Buttons" stop and remove power on the arm manipulator and all other
equipments in the cell, where the "Safety Stop Buttons" stop and remove power on the arm manipulator only.

Emergency stop circuit

Cell
Safety stop circuit

Robot

5.1.1. COMPOSITION OF THE EMERGENCY AND SAFETY STOP CHANNELS

(see figures 5.1 and 5.2)
The various elements forming the stop channel are as follows:
• The emergency stop (MCPES 1-2) on the MCP.
• The emergency stop (WMSES 1-2) from the WMS front panel.
• An emergency stop (UESA 1-2) to be wired according to the application.
• Two parallel channels corresponding to the automatic (COMP) and manual (MANU) modes, if controller
configuration is "configuration 1" (see below) (figure 5.1).
Each of these channels has to be used according to the application. As a general rule, in the channel concerning
the Automatic mode, there is an emergency stop (DOOR 1-2) triggered by the cell door. In the channel given
over to the Manual mode,there is also an emergency stop or an authorization for specific operation in Manual
mode (USER EN 1-2). These two emergency stop channels are specific to the application and depend to a great
extent on the working mode selected.
• A (UESB 1-2) safety stop to be wired depending on the application.
All the contacts making up these various elements of the emergency and safety stop channels are duplicated.
Note 1:
The emergency stop is not the normal method for stopping the robot or disabling power on the
arm.
Note 2:
The robot is delivered with a dummy plug connected to J109 (see figure 5.5).
When this connector is replaced with the final one, pay attention to the jumper between pins 18
and 37 (figure 5.2) which needs to be maintained, except if an external 24 V is required for EStop
lines (see below).
Status of the emergency stop channels (ESOUT1 and ESOUT2) are available for the application using one of the
controller configuration below (figure 5.1).

CAUTION:
Status of these outputs shall be identical: either both closed if there is no EStop, or both open
if there is an EStop. The coherency of these 2 outputs contacts has to be verified by the
external safety device managing the cell. If there is an incoherence, the fault shall be corrected
before restarting the robot. If there is no external safety device, this type of error is not
automatically detected.
The incoherence information is also displayed on the Teach Pendant (if connected) and in the
error logger.

The information available is:

• Either the status of MCPES, WMSES and UESA (configuration 1: the doors of the cell not included).
• Or the status of MCPES, WMSES, UESA and (USEREN or DOOR) (configuration 2: the doors of the cell are
included). This is the default configuration when CS8C is delivered. To modify this configuration, refer to chapter
"Software configuration".
The choice of position depends on the requirements of the application.
For applications requiring the emergency stop system status to remain valid even when the controller is switched

CS8C © Stäubli 2009 – D28070504A 55 / 248

off, it is possible to power the emergency stop lines via an external 24 V supply provided between J109-37 and
J109-19 (see diagrams below). The connection between J109-18 and J109-37 must be removed.
This mode of operation is only possible if controller is configured with "configuration 1" (see above).
Display on the control panel of the MCP
The status of the stop channels is displayed on the control panel.
Note:
In this display, an active input (ON) shows that an emergency stop has been activated (channel
in open position).

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CS8C
24Vfus
RSI2
Chapter 5 - Integration

MCPES2- MANU- MODE

MCPES1+
MANU+ SUBD-37M

MCPES1- MCPES2+ A1 10 UESA1+ J109-1

MANU UESA1- J109-20
WMSES1+
Emergency stop channels

WMSES2- UESA2+ J109-2

B1 9 UESA2- J109-21
WMSES1- WMSES2+ USEREN1+ J109-3
MANU-
USEREN1- J109-22
COMP-MODE USEREN2+ J109-4
UESA1+ UESA2-
COMP+ USEREN2- J109-23
A1 10 ESOUT1+ J109-5
UESA1- UESA2+ ESOUT1- J109-24
COMP ESOUT2+ J109-6
5 7
ESOUT2- J109-25
B1 9
COMP+ J109-7
5 7 COMP- COMP- J109-26
6 8
MANU+ J109-8
Without With MANU- J109-27
USEREN1+ USEREN2- 8
6 door door
DOOR1+ J109-9

Figure 5.1
DOOR2- UESB2- DOOR1- J109-28
DOOR1+
USEREN1- USEREN2+ DOOR2+ J109-10
UESA2+
DOOR2- J109-29
DOOR1- DOOR2+ UESB1+ UESB1+ J109-14
UESB1- J109-33

© Stäubli 2009 – D28070504A

UESA1-
24V UESB2+ J109-15
UESB1+ UESB2- UESB2- J109-34
UserES
Select
UESB1- UESB2+

ESOUT2+ ESOUT1+
A1 B1 UserES A1 B1 10 10
Select
ESR1 ESR2 UES1 UES2 UES2 UES1

B1 A1 B1 A1 5 5
ESOUT2- ESOUT1-
0V1 24Vfus 24Vfus

57 / 248
 RSI2
24V
SUBD-37M

J109-18

F2 24V_In
24Vfus J109-37 + 24 VDC
250 mA 1A
220uF 22-26 VDC
24V
50mA

J109-19 0 VDC

0V1

Internal External 24VDC

24VDC for E-Stop lines

Figure 5.2

58 / 248 © Stäubli 2009 – D28070504A CS8C

CS8C
24V 24Vfus
RSI2 0V
J114
Chapter 5 - Integration

LSW10+ LSW20+
DF+ LSW10 LSW20
Drive Fault
Relays LSW10- LSW20- (option)

DF- 8

A1 B1
5 4
RLS10 RLS20 RLS10 RLS20

B1 A1
4 2
0V 24Vfus

Figure 5.3
A1 A1

SCR1 SCR2

© Stäubli 2009 – D28070504A

B1 B1
DF+ J112-3
Internal DF- J112-4
faults

0V 0V LSW10+ J101-12
LSW10- J101-5
LSW20+ J101-6
LSW20- J101-13

59 / 248
60 / 248
RSI2
24V

5 5 SUBD-37M

SCR1 SCR2
USERPS1+ J109-12
4 4 USERPS1- J109-31
USERPS2+ J109-13
5 USERPS2- J109-32
8
BRS BRS

4 9
J105-12
J105-11
J105-10
Enable J105-9.
Pow er
PS-ON1+ J105-3

Figure 5.4
PS-ON2+ J105-4
F3 F4 PS-ON - J105-5

© Stäubli 2009 – D28070504A

375mA 375mA PWR-OK- J105-2
PWR-OK+ J105-1
PS-ON1+ PS-ON2+

A1 A1

PS1 PS2

A2 A2

PS-ON-

0V1

CS8C
Chapter 5 - Integration

5.1.2. CONNECTION WITH CELL

Description of connection point
The RSI board is connected to the equipment in the cell via the J109 connector on the board on the front panel of
the CS8C controller.
All the contacts to be connected up in the emergency stop channels must be duplicated dry contacts. An
emergency stop button must activate two contacts at the same time, and the maximum authorized time lapse
between the opening of the two contacts is 100 ms. If this time lapse is exceeded, an error message is displayed.
All the information supplied by the RSI board are in the form of dry contacts.

J110

J113

J111

J109

Figure 5.5

CAUTION:
The CS8C controller is supplied with a "shorting connector" for J109 that can be used to
power up the robot without wiring up the emergency stops. This connector is provided for
diagnosis purposes only. It must be replaced by suitable wiring on the emergency stop
circuits.

Note:
If screw terminal type connectors are preferred, an adaptor from Sub D to screw terminal is
commercially available from several sources such as Phoenix Contact and others.

CS8C © Stäubli 2009 – D28070504A 61 / 248

5.2. BASIC INPUTS/OUTPUTS

To display the status of the Inputs/Outputs or to programme them, select the "I/O" branch in the control panel
accessible via the main menu.

5.2.1. USER-IN INPUTS

2 inputs, User-in 1 and User-in 2, are available on the J109 connector.

USER - IN x+ +24V

USER - IN x- 100k

100k
0V1

Figure 5.6
Characteristics

Operational voltage range 0 to 30 VDC

"Off" state voltage range 0 to 1 VDC
"On" state voltage range 4 to 30 VDC
Operational current range 0 to 240 µA
"Off" state current range 0 to 5 µA
"On" state current range 33 to 240 µA
Impedance 100 kΩ
Response time for equipment + software 6,5 ms maxi

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Chapter 5 - Integration

5.2.2. FAST INPUTS/OUTPUTS

2 inputs (Fast-In 0 and Fast-In 1) and 1 output (Fast-Out 0) are provided on the J111 connector.

+ 24 VDC Fast-In1 + 3.3k

24V
100 pf
0 VDC Fast-In1 -

24V Fast-Out 2.4k

Load
+ 24 VDC
100 nf
24V Fast-Out0 +

0 VDC
Fast-Out0 - 1.2k

User
equipment

Figure 5.7
Characteristics
Inputs

Operational voltage range 0 to 30 VDC

"Off" state voltage range 0 to 2 VDC
"On" state voltage range 6 to 30 VDC
Operational current range 0 to 9mA
"Off" state current range 0 to 0,5mA
"On" state current range 2 to 9mA
Impedance 3,3 k
Response time for equipment + software 50 µs

Outputs

Power supply voltage range (24 V Fast-Out) 12 to 28 VDC

Current consumed 5,5 mA
Output voltage range 12 to 28 VDC
Range of use for current output 1 to 250mA
Voltage drop at output when I = 250 mA 1,2 V maxi
On state output resistance 1
Maximum leakage current in off state 5 µA
Response time for equipment + software 50 µs
Limit output current (overload) 2A

CS8C © Stäubli 2009 – D28070504A 63 / 248

Connection point table

External Name of electrical J109 Pin name Internal Switch open Switch closed
electrical diagram (Sub-D37M) electrical
diagram diagram

UESA 1-2 Emergency Normal operation

Emergency stop stop
1 UESA1+
20 UESA1-
2 UESA2+
21 UESA2-

USER EN1-2 Emergency Normal operation

Validation in stop in Manual
Manual mode 3 USEREN1+ mode
22 USEREN1-
4 USEREN2+
23 USEREN2-

DOOR1-2 Emergency Normal operation

Validation in Auto 9 DOOR1+ stop in Auto
mode 28 DOOR1- mode
10 DOOR2+
29 DOOR2-

UESB 1-2 Emergency Normal operation

Emergency stop stop
14 UESB1+
33 UESB1-
15 UESB2+
34 UESB2-

Note (1) ESOUT 1-2 Emergency Normal operation

Note (3) Emergency stop 5 ESOUT1+ stop
channel status 24 ESOUT1-
6 ESOUT2+
25 ESOUT2-

Note (3) COMP/MANU Automatic Automatic mode

Working modes 7 COMP+ mode invalid
26 COMP-

8 MANU+ Manual mode Manual mode

27 MANU- invalid

PS1 PS2
Note (3) Arm power-up 12 USERPS1+
31 USERPS1- Arm not Arm powered
13 USERPS2+ powered
32 USERPS2-

Note (2)
USER-IN X 16 USER-IN 1 +
35 USER-IN 1 -

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External Name of electrical J109 Pin name Internal Switch open Switch closed
electrical diagram (Sub-D37M) electrical
diagram diagram

Note (2)
USER-IN X 11 USER-IN 0 +
30 USER-IN 0 -

Note (4) 18 24 V for EStop Note (4)

19 lines
37

Note (1): This information is configurable (see chapter 5.1).

Note (2): See figure 5.6.
Note (3): Max. 48V AC/DC/ 0.5A.
Note (4): Refer to chapter 5.1 and figure 5.2.

CS8C © Stäubli 2009 – D28070504A 65 / 248

5.2.3. ENCODER INPUT
5.2.3.1. TWO ENCODER INPUTS FOR STARC2
With STARC2 board configuration, an optional DUAL ABZ board can be installed to provide 2 encoder inputs per
board. The encoders to be used must be of the incremental type with 5V differential A, B, Z signals (RS485
type). The 5V power supply is provided by the DUAL ABZ board, its level of current is limited to 250mA per
encoder. Each board has External Encoder Latch signals that can be used for with the encoders. The connector
used on the DUAL ABZ board is of the female SubD 25 point type.
These boards are installed in the computer (see figure 4.11, rep. (11)).
To install a new board:
• Extract and open computer part (CPT).
• Select board address with J324 jumper.
• Connect the board to STARC with cables provided with the board.

STARC2 + Dual ABZ encoder board

3.3V F2 L-COD1

5V F1 L-COD2
J3 21 J322

Dual ABZ

J
D u al
ABZ
S T A R C2

J3 24
Board 1

Board 0

Board 2 Board 1 Board 0

S0 S1 S0 S1 S0 S1

Figure. 5.8

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Chapter 5 - Integration

Note:
Each encoder has a corresponding set of digital and analog Inputs/Outputs. The name of these
Inputs/Outputs is the same for all encoders except for the first and second digits that represent
respectively the digit of the optional board (0 to 2) and the digit of the encoder on the board (0 or
1):
e01LatchSig is the latch signal of the second encoder input on the first optional board.
Note:
In this chapter, the Inputs/Outputs names are given for the first encoder input on the first board.

J320 SUBD-25F Dual ABZ board 5V

J320- 13 Coder1-A
J320- 12 Coder1-A* En co d er in pu t s 1k
J320- 11 Coder1- B
External
J320- 10 Coder1- B*
e n co der 1 cod -x
12 to 24V J320- 9 Coder1- Z
120
J320- 8 Coder1- Z*
F1
J320- 24 GND 2 50 mA
J320- 25 Coder1- 5V 5V cod -x*
J320- 21 La t ch En cod er 1
L- COD1 1k
J320- 20 GND
GND
J320- 7 Coder2-A
GND GND
J320- 6 Coder2-A*
J320- 5 Coder2- B
External
e n co der 2 J320- 4 Coder2- B*
12 to 24V J320- 3 Coder2- Z
J320- 2 Coder2- Z*
F2
J320- 15 GND 250mA La tch E nc oder x
J320- 14 Coder2- 5V 5V
J320- 19 La tc h E n co d er 2
L- COD2
J320- 18 GND
GND GND
GND
GND

Figure. 5.9
Recovery (preset)
Encoder recovery is used to define the zero position of the joint connected to the encoder. It is necessary to begin
by configuring the encoder resolution using the e00Counts analog output (in encoder points per rotation, coded
on an unsigned 16-bit integer). The resolution is saved by the system (encoder.cfx file).
Note:
When the encoder has moved by more than one turn, the system is able to detect its resolution
that is then written to the e00CountsMes analog input.
Note:
There are 4 pulses per encoder point. A 1024-point (or "counts") encoder thus has a resolution of
4096 pulses per rotation.
Recovery procedure (preset):
• Stop the encoder at a reference position defined by the application.
• Write the current encoder position in the e00PrstPos output (Preset position: signed 32-bit integer).
• Activate the e00EnPrst (Enable preset) output.
The current position e00CurrPos (Current position) then takes the value e00PrstPos, and the e00EnPrst
Input/Output is deactivated.
The recovery sequence is not saved by the system; it is necessary to repeat it each time the controller is powered
up.

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Position reading
The position reading is done with the e00CurrPos analog input. The position is in degrees, with an accuracy of
360/(4*e00Counts).

CAUTION:
The internal encoder position counter uses only 32 bits. When the encoder position reaches
2 ^ 31*360/(4*e00Counts) degrees, an overshoot occurs and the position becomes -
2 ^ 31*360/(4*e00Counts).
No error is reported: The overshoot must be managed by software programming, either by
using a preset to avoid it, or by correcting the position with an offset of 2 ^ 32*360*4*e00Counts
degrees.

The encoder position is updated every 4 ms. When a preset is done while the encoder is moving, it applies to the
start of the current 4 ms time interval. The encoder position is updated only with the next time interval, where it is
assigned the preset position plus the encoder movement of the last 4 ms. In that way, no encoder movement is
lost with the preset.
Position capture (latching)
Position capture is used to record the encoder position on a rising signal for a fast input, and then read the position
later.
Position capture procedure:
• Activate the e00EnLatch digital output.
• On the next rising or falling signal for the fast input e00LatchSig, the encoder position is recorded in the
e00LatchPos analog input and the e00Latch digital input is activated to show that the capture has been
executed. The e00EnLatch Input/Output is then automatically deactivated.
The precision of the capture is less than one microsecond. It is possible to cancel a capture request at any time
by deactivating the e00EnLatch output.
Note:
The position capture is made:
- On the rising edge of the e00LatchSig signal if the e00LatchEdgFall digital output is set to
False.
- On the falling edge if the e00LatchEdgFall digital output is set to True.
It is possible to filter out bounds on the latch signal by specifying a filter delay in milliseconds
using the e00LatchFilter analog output: the latch is then effective only if the signal remains
stable during the specified time. The latched position is then always the position at the rising or
falling edge of the latch signal.
Errors
An encoder reading error is signalled by the e00HwErr digital input. If the encoder is rotating too fast, it is not
possible for the controller to know for certain how many rotations the encoder has made. In this case, the
e00OvsErr signal is activated. The maximum encoder speed is 7500 rpm.
Note:
When the encoder has moved by more than one turn, the system is able to detect its resolution
that is then written to the e00CountsMes analog input. If this resolution does not match the
specified resolution e00Counts, the encoder is in error and the e00CountsErr signal is
activated.
The e00PowerErr digital output is activated when the encoder power supply is not correct.
To reactivate the encoder after an error, it is necessary to reset it using the e00RstErr digital output.

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5.2.4. SYSTEM INPUTS

The following inputs are accessible on the VAL3 to detect various errors.
RSI board temperature
The CBT_TEMP input shows the temperature (°C) measured on the RSI board (in the controller). Correct
controller operation can no longer be guaranteed if the temperature rises above 55°C. In this case, it is necessary
to check the ventilation system on the CS8C controller (fans running, air inlets unobstructed).
Power supply for the controller
The SECTEUR_OK input is activated when the controller is powered up. When the power supply to the CS8C
controller is cut off, the SECTEUR_OK signal is deactivated about 80ms before the power is actually cut off. The
SECTEUR_OK input may also be deactivated temporarily if the power supply voltage is too low.
Arm temperature thresholds
Temperature sensors are fitted in the arm to protect the motors and mechanical elements in the event of a
temperature rise that is too great. If the temperature of a motor rises above 120°C, the arm stops immediately. An
excessively high temperature on the DSI board (75°C) or the castings (100°C) stops the arm after a time lapse of
about ten seconds.
The GLOBAL_PTC input signals an overtemperature on one of the arm sensors. The DSI_BOARD input shows
an overtemperature on the DSI board (at the base of the arm).
On TX arms, the MOTOR_1_3_5, MOTOR_2_4_6 and CASTING inputs show an overtemperature on a motor and
on the castings.
On the RS arms, the MOTOR_1_3 and MOTOR_2_4 inputs show an overtemperature for a motor.
CPU board temperature
The CPU_TEMP input shows the temperature (°C) measured on the CPU board (in the controller). Correct
controller operation can no longer be guaranteed if the temperature rises above 85°C. In this case, it is necessary
to check the ventilation system on the CPU controller (fans running, air inlets unobstructed).

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5.3. RS ROBOTS

In the case of RS robots, Inputs/Outputs are available as an option on the forearm using the CIO board (first
generation) or ARMIO board (second generation):
• 8 x 24V digital inputs
• 8 x 24V digital outputs
• 4 x ± 10V analog inputs
• 4 x 0/+10V analog outputs (only for ARMIO second generation)

These Inputs/Outputs are driven from the controller via a dedicated CAN bus. The CAN bus is connected to J211
on controller side and J1202 at the base of the arm. A user cable can be supplied as an option to take the intputs
/ outputs as close as possible to the tool flange through the ball screw.

CAUTION:
If this cable is fitted, rotation of joint 4 must be limited to ± 180°. This limitation is configured
at the factory if the option is supplied.

An ASI bus can also be supplied as an option on the CIO board (not available on ARMIO board).
The "Control panel" page allows you to see the status of the CAN Inputs/Outputs.
Note:
To display the status of the Inputs/Outputs or to programme them, select the "I/O" branch in the
control panel accessible via the main menu.

5.3.1. INSTALLATION OF THE OPTION

The option includes:
• A CAN board to be installed in the CS8C computer module. The board is provided with a cable and mounting
screws.
• A cable between CS8C and the base of the arm.
• An I/O board for the arm.

Figure 5.10

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Chapter 5 - Integration

5.3.1.1. INSTALLATION OF CAN BOARD IN COMPUTER

• Refer to 8.9.2 to remove and open CS8C computer module.
• Plug the cable attached to the CAN board to CPU board.

Figure 5.11

• Install the CAN board on B1 location of front plate using the 2 screws provided with the board.

Figure 5.12

• Replace the cover and reinstall the CS8C computer module.

CS8C © Stäubli 2009 – D28070504A 71 / 248

5.3.1.2. INSTALLATION OF CABLE
• The cable has to be connected to J211 on CS8C computer module and on J1202 on arm.
5.3.1.3. INSTALLATION OF I/O BOARD IN THE ARM
Remove the 2 side covers and the outer cover of the forearm.
The board has to be attached by screws and connected to XB3 plug on the LPX5 board.
5.3.1.4. SOFTWARE SETUP
5.3.1.5. PROCEDURE FOR CONNECTING THE INPUTS/OUTPUTS IN THE FOREARM

CAUTION:
The RS40/60/80 arm must be switched off.

1) Remove the outer cover from the forearm.

Screws holding the cover on the forearm

2) Loosen the screws holding the cover in place and remove the cover.
3) The user cable comes out of the forearm cover:
• Towards the top by cutting out an opening (d = 23.5 mm) in the cover and inserting a seal (e.g.PG16) in
the opening.
4) Insert the cable through the connection and connect it to the terminals on the CIO/ARMIO board. Fit the
connectors on the CIO/ARMIO board. Group and fasten the cables together (for a cable exit on the side, on
the flat metal surface just below).
Note:
The connectors for the CIO/ARMIO board are included in the pack (constructor Weidmüller,
description 14 pin BL 3.5/14/F, order n° 160 676 0000).
5) Put the cover back in place.
6) Fit the outer cover on the forearm.

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Chapter 5 - Integration

5.3.1.6. CONNECTING THE INPUTS/OUTPUTS TO THE TOOL INTERFACE (OPTION)

Type of connections Molex 2.50 mm SPOX:
• 2 x 8-pin, article: 22-01-1084
• 1 x 4-pin, article: 22-01-10449

These connections are designed for use with the connection tool option (TC).

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5.3.1.7. CIO BOARD

JP1 JP2 LED3 LED2 LED1

External/internal ASI
power supply

X11

X21

X11

1 2 3 4 5 6 7 8 9 10 11 12 13 14

PIN CORRESPONDENCE

1 ASI-
2 ASI+
3 cDout0
4 cDout1
5 cDout2
6 cDout3
7 cDout4
8 cDout5
9 cDout6
10 cDout7
11 +24 VDC
12 0V
13 Configuration bridge for the ASI power supply
Remove the bridge if the ASI power supply is provided by an external source.
14

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X21

14 13 12 11 10 9 8 7 6 5 4 3 2 1

PIN CORRESPONDENCE

14 cDin0
13 cDin1
12 cDin2
11 cDin3
10 cDin4
9 cDin5
8 cDin6
7 cDin7
6 cAin3
5 PE analog ground
4 cAin2
3 cAin1
2 PE analog ground
1 cAin0

Characteristics:
• Digital inputs:
• Nominal voltage: 24 VDC (minimum 20 VDC, maximum 28 VDC)
• Voltage for logical 0: 0 to 3 VDC
Voltage for logical 1: 11 to 28 VDC
• Input current: 6 mA maximum
• Response time (hardware and software): 6 ms
• Digital ouputs:
• Nominal voltage: 24 VDC (minimum 20 VDC, maximum 28 VDC)
• Max. current per output: 0.5 A
• Max. current for all outputs: 2 A
• Response time (hardware and software): 6 ms maximum
• Analog inputs:
• Input voltage: ± 10 V
• Resolution: 78 mV
• Accuracy: 5 %
• Response time: 6 ms

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Hardware configuration

JP1 JP2

MEANING

JP1, JP2 present Power supply for the ASI bus provided via the CIO board
JP1, JP2 absent External power supply for the ASI bus

If the ASI bus is powered via the CIO board, only 4 slaves can be connected.
If an outside power supply is used, 13 slaves can be connected. This power supply must conform to AS-I
specification.

LED3 LED2 LED1

LIGHT EMITTING DIODES

MEANING
LED DISPLAY

LED1
Green Logic signal OK
Red Overload
LED2
Green ASI data transfer
Flashing green Waiting for CAN data
Red ASI voltage error
Steady OFF CIO board without ASI module
LED3
Red CAN bus not operational
Flashing red ID node not valid
Fast flashing red Module in passive error status
Green Module in operational status
Flashing green Module in pre-operational status

The CIO board has configuration switches whose positions must be as follows:
• 1, 7, 8 = on
• 2, 3, 4, 5, 6 = off (see figure 5.13)

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Chapter 5 - Integration

Switches

Figure 5.13

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5.3.1.8. ARMIO BOARD

LED3 LED2 LED1

X11

X21

X11

1 2 3 4 5 6 7 8 9 10 11 12 13 14

PIN CORRESPONDENCE

1 cAout 0
2 cAout 1
3 cDout0
4 cDout1
5 cDout2
6 cDout3
7 cDout4
8 cDout5
9 cDout6
10 cDout7
11 +24 VDC
12 0V
13 cAout2
14 cAout3

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Chapter 5 - Integration

X21

14 13 12 11 10 9 8 7 6 5 4 3 2 1

PIN CORRESPONDENCE

14 cDin0
13 cDin1
12 cDin2
11 cDin3
10 cDin4
9 cDin5
8 cDin6
7 cDin7
6 cAin3
5 0 V analog
4 cAin2
3 cAin1
2 0 V analog
1 cAin0

Characteristics:
• Digital inputs:
• Nominal voltage: 24 VDC (minimum 20 VDC, maximum 28 VDC)
• Voltage for logical 0: 0 to 11 VDC
Voltage for logical 1: 16 to 28 VDC
• Input current: 11 mA maximum
• Response time (hardware and software): 6 ms
• Digital ouputs:
• Nominal voltage: 24 VDC (minimum 20 VDC, maximum 28 VDC)
• Max. current per output: 0.5 A
• Max. current for all outputs: 2 A
• Response time (hardware and software): 6 ms maximum
• Analog inputs:
• Input voltage: ± 10 V
• Resolution: 78 mV
• Accuracy: 5 %
• Response time: 6 ms

CS8C © Stäubli 2009 – D28070504A 79 / 248

• Analog outputs:
• Output voltage: 0/+10 V
• Resolution: 2,4 mV
• Accuracy: 5 %
• Response time: 6 ms
Hardware configuration

LED3 LED2 LED1

LIGHT EMITTING DIODES

MEANING
LED DISPLAY

LED1
Green Logic power supply OK
Red Overload on logic power supply
LED2
Green Power supply OK
Red Overload on analog outputs
LED3
Red CAN bus not operational
Flashing red ID node not valid
Fast flashing red Module in passive error status
Green Module in operational status
Flashing green Module in pre-operational status

The ARMIO board has configuration switches whose positions must be as follows:
• 1, 7, 8, 9 = on
• 2, 3, 4, 5, 6 = off (see figure 5.13)76

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Chapter 5 - Integration

Switches

Figure 5.14

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5.3.1.9. CONNECTIONS ON THE TOOL INTERFACE
The user cable is connected on the forearm to X11 and X21 before leading to the tool interface. Once the cable
has been installed, connect the sockets X14.1, X14.2 and X14.3 as shown in the table below.

SOCKET PIN COLOUR SOCKET PIN FUNCTION

X21 14 Grey X14.1 1 cDin0

13 White, green X14.1 2 cDin1
12 White, yellow X14.1 3 cDin2
11 White, brown X14.1 4 cDin3
10 White, orange X14.1 5 cDin4
9 Orange X14.3 1 cDin5
8 Yellow X14.3 2 cDin6
7 Green X14.3 3 cDin7

X11 3 Grey X14.2 1 cDout0

4 White, black X14.2 2 cDout1
5 White, violet X14.2 3 cDout2
6 Blue X14.2 4 cDout3
7 Black X14.2 5 cDout4
8 White, grey X14.2 6 cDout5
9 White, blue X14.2 7 cDout6
10 White, red X14.2 8 cDout7

X11 11 Red X14.1 6 +24 V

12 Violet X14.3 4 0V
12 Brown X14.1 7 0V

X21 5 Green, yellow PE -

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Chapter 5 - Integration

5.4. AS-I DIGITAL INPUTS/OUTPUTS (RS ARMS)

Note:
The AS-I function doesn't exist on ARMIO board of second generation.
Description
The RS arms support additional digital inputs and outputs on the fore arm, through the use of the AS-I bus that is
present on the CIO board (see chapter 5.3.1.7). This AS-I bus supports up to 13 AS-I slave modules of 4 digital
inputs and 4 digital outputs.

WARNING:
• Only 4 slave modules are supported when they are powered by the CIO board. You need an
external power supply to support additional slave modules (up to 13).
• The AS-I bus of the CIO board supports the AS-I 1 specification: Analog Inputs/Outputs and
AB modules are not supported.
• Each slave module must have an address on the AS-I bus (a value between 1 and 13). This
address cannot be assigned with the CS8C controller. You need an external device to
configure it. Such AS-I configuration tools can be found by AS-I devices manufacturers.
• The slave modules present on the AS-I bus cannot be detected automatically by the CS8C
controller. You have to declare them to the controller (see Configuration hereafter).

Configuration
AS-I Inputs/Outputs are configured in the /usr/configs/asi.cfx file. Each CS8C controller is supplied with an
example in which the configurations are commented out. To activate a configuration:
• Rename the /usr/configs/asiExample.cfx file in /usr/configs/asi.cfx.
• Remove the slave configurations that are not needed.
• For each remaining slave configuration, remove the Inputs/Outputs configurations that are not needed.
• If desired modify the default name of each AS-I Input/Output, and select its logical mode (inverted / notInverted).
• Restart the CS8C.
It is possible to define analog Inputs/Outputs based on the digital Inputs/Outputs of an AS-I module (see provided
asiExample.cfx file):
• The "channel" and "bitCount"' parameters define the first and the number of digital signals to use to build the
analog signal.
• The format of the analog signal is either "signed" or "unsigned".
• The "coefA" and "coefB" parameters define the linear transformation to apply:
• When writing on analog outputs, the linear transformation y = a.x + b is applied.
• When reading an analog input or output, the linear transformation x = (y-b) / a is applied.
Any configuration errors in the asi.cfx file are listed in the events logger on start-up. You can check the status of
the AS-I Inputs/Outputs in the Control Panel display.

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5.5. DIGITAL BIO INPUT/OUTPUT BOARD (OPTIONAL EXTRA)

BIO 16I / 16O board description

RSI BIO
Figure 5.15

The kit is made up of a BIO board to be mounted on the RSI board. Up to 2 BIO boards can be used.
The BIO board is fitted with:
• 16 optocoupler inputs.
The signals are numbered from 0 to 15 on each board and they correspond to inputs 0 to 15 and then 16 to 31.
• 16 optocoupler outputs protected against overcurrents.
The signals are numbered from 0 to 15 on each board and they correspond to outputs 0 to 15 and then 16 to 31.

CAUTION:
The Inputs/Outputs have to be powered by a rectified, filtered external power source (not
supplied).

Wiring the I / 0s
Wiring is described in the "Electric Wiring" manual.

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Chapter 5 - Integration

Characteristics of the BIO Inputs

Each input channel is made up of an input and a corresponding return wire.

The connector pin out is given in the "Electrical Wiring" manual.

Operational voltage range 0 to 24 VDC

"Off" state voltage range 0 to 3 VDC

"On" state voltage range 11 to 24 VDC

Typical threshold voltage Vin = 8 VDC

Operational current range 0 to 6 mA

"Off" state current range 0 to 0.5 mA

"On" state current range 2 to 6 mA

Typical threshold current 2.5 mA

Impedance (Vin / Iin) 3.9 KΩ minimum

Current at Vin = 24 VDC Iin < 6 mA

Equipment and software response time 15 ms maxi

Insulation voltage / Leakage current 2,5 kV / 4 mm

Note:
The characteristics of the input current are given for informational purposes only.

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 Supplied Equipment User-Supplied Equipment
(BIO) (typical examples)

3.9k +
IN 0
_
+
3.9k +
IN 1
_ _

3.9k +
IN 2
_

3.9k + J601-24
IN 3
_
J601-6
+
3.9k + J601-25

IN 4
_ _
J601-7

3.9k + J601-26

IN 5
_
J601-8

+ + _
3.9k
IN 6
_

+ + _
3.9k
IN 7
_

J601
BIO board - Inputs

Figure 5.16
Note:
The inputs are numbered from 0 to n on each Input/Output board.

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Characteristics of the BIO outputs

The 16 outputs are installed in 4 groups of 4. Each group is electrically isolated from the other groups and optically
isolated from the controller. The 4 outputs of each group have a shared return connection. The outputs are
protected from overvoltages and inverse voltages.
Note:
The connector pin out is given in the "Electrical Wiring" manual.

Parameter Value

Power supply voltage range 10 VDC < Vsup < 30 VDC

Low voltage stop 5 VDC < Vusd < 8 VDC

Earth current Ig < 60 mA

Functional current per channel Iout < 700 mA, protected against short circuits

On state resistance (Iout = 0.5 A) Ron < 0.32 W @ 85 °C (Ron = 0,4 W @ 125 °C)

Output off leakage current Iout < 25 µA

Equipment and software response time 15 ms maxi

Output cut-off voltage on inductive charge (Iout = 0,5 (Vsup - 65) < Vdemag < (Vsup - 45)
A, L = 1 mA)

Maximum DC short circuit current 0.7 A < llim < 2.5 A

Peak short circuit current lovpk < 4 A

Insulation voltage / Leakage current 2.5 kV / 4 mm

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 Supplied Equipment User-Supplied Equipment
(typical examples)

OUTPWR1

OUT 0 load
OUTPWR1
+

OUT 1 load
OUTPWR1 _
OUT 2 load
OUTPWR1

OUT 3 load

OUTRET1
J602

BIO board - Outputs

Figure 5.17
Note:
The outputs are numbered from 0 to n on each input/output board.

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1
Figure 5.18

J601
4 3

J602 4
Figure 5.19

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Installation of the BIO option (figures 5.18 and 5.19):

CAUTION:
Before removing or inserting a board, disconnect the installation from the power supply,
following the procedure.
Furthermore, electronic boards must only be handled after an antistatic work area has been
created. To do this, the After Sales Support technician (or the customer) must use an anti-
static mat connected to the earth and to the cabinet, as well as wearing the anti-static bracelet
supplied with the controller.

• Remove the 4 fastening screws (1) from the RSI board and take it out of the controller.
Installing the first board:
• Insert the J601 and J602 connectors on the BIO board through the holes cut in the front panel of the RSI (2)
board and then plug the BIO board into the J603 (3) connector.
• Secure the BIO board using the locks on the J601 and J602 connectors and the 2 fastening screws (4).
Installing the second board:
• The second board is installed in accordance with the same principle, using the accessories supplied with the kit
(spacers, connector).
• Replace the RSI board.
• The presence of the BIO board is detected automatically by the CS8C cabinet on start-up. The "Control panel"
application enables you to see that the board is in place and check the status of its Inputs/Outputs.
Note:
To display the status of the Inputs/Outputs or to programme them, select the "I/O" branch in the
control panel accessible via the main menu.

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5.6. FIELD BUS

5.6.1. CHARACTERISTICS
There are various types of field bus (DeviceNet, Profibus, CANopen, ModBus TCP client).
Each of these options consists of a PCI format board located in the computer and a CD-ROM for installation of the
PC configuration software program.
The elements making up the bus as such are not supplied.
The characteristics and wiring for the field bus are specific to the equipment selected. See the constructor's
recommendations, especially for the terminal resistances at the end of the lines.
Wiring is described in the "Electric Wiring" manual.

CAUTION:
The Profibus board requires a straight connector on the field bus cable. It is not possible to
fit a 90° right angle connector.

5.6.2. CONFIGURATION
The CS8C controller is configured for a field bus using a PC ApplicomIO software application supplied on a
specific CD-ROM.
This tool enables you to configure the field bus board on the one hand, and to generate a ConfigTag.xml file on
the other hand. The file must be copied by Ftp in the /usr/applicom/io directory of the CS8C controller. If this file
is present on start-up, the Inputs/Outputs of the field bus are displayed on the control panel and are directly
accessible via a VAL3 application.
The Ethernet configuration procedure using the ApplicomIO console 2.2 software is as follows:
1) Preparation of the configuration (CS8C)
• The field bus board cannot be configured while it is operating. If the field bus board has already been
configured in the CS8C, press the "Init" menu on the MCP (Control Panel > I/O > Fieldbus). Restart the
CS8C. The field bus board is stopped and ready to be reconfigured.
• Give the CS8C an IP address and check that it is accessible via the network from the PC on which the
ApplicomIO software has been installed.
2) Remote creation of a configuration (ApplicomIO)
• Create a new field bus configuration (File > Configuration Manager > New).
• Enter the name of the new configuration.
• Select "On remote computer (LAN TCP/IP)","IP address" and enter the IP address for the CS8C. Leave
the port on 5001, with the "Automatic transfer" menu selected.
3) Defining the field bus configuration (ApplicomIO)
• Configure the board via the network (Description > Add board).
• Detect the equipment ("Network detection" tab and then Network > Read network configuration).
• Insert the equipment and configure the corresponding Inputs/Outputs.
• The analog Inputs/Outputs can have an unsigned format (default configuration) or a signed one. The
other ApplicomIO formats are not supported. The min/max value and processing configurations are
supported. The "off time" value is ignored. During writing on analog outputs, the linear transformation
y = a.x + b is applied and then the result is saturated with the min/max values, and finally sent to the field
bus. During reading of an analog Input or Output, the value read from the field bus is first saturated with
the min/max values, and then the linear transformation x = (y-b) / a is applied.
• Save the configuration (File > Save).

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4) CS8C configuration (ApplicomIO)
• Create the XML configuration file (File > Export > items -> XML).
• Initialize the board and download the configuration (File > Download in flash).
5) Checking the configuration (CS8C)
• Restart the CS8C.
• Check the field bus board Inputs/Outputs (Control Panel > I/O > Fieldbus).

5.6.3. DIAGNOSIS
Field bus errors are shown by messages on the MCP, which can also be accessed using the "events logger "
application. These errors start with the word "FIELDBUS", followed by a CS8C diagnosis, the identification of the
board, the equipment and the channel concerned, and the Status (Applicom diagnosis).
The CS8C diagnoses are:

InitSoftware #Status /usr/applicom/io/configTag.xml file missing.

BuildItem-#name The #name item has not been created (incorrect name,
already used, or insufficient memory).

Write #Board #Equip. #Channel #Status Writing error on the field bus.

Read #Board #Equip. #Channel #Status Reading error on the field bus.

EquipmentStatus #Board #Equip. #Status Problem with an item of equipment on the field bus.

RefreshIn #Board #Status Error during the board input update phase.

RefreshOut #Board #Status Error during the board output update phase.

InitBoard #Board #Status Error during initialization of the board CS8C driver. This error
is always present for board 2, if there is only one field bus
board.

ExitBoard Error during reinitialization of the CS8C driver for the board.

BuildPort Error during construction of a CS8C Input/Output port: The

/usr/applicom/io/ConfigTag.xml file must contain
contradictory information.

BoardId #Board Status=1 The OEM board number is not valid. Only boards purchased
from Stäubli are accepted.

ConfigBoard #Status Board initialization error. Check the .ply configuration file, and
the board type configuration (Compact PCI "CPCI" boards
are not accepted).

NetworkStatus #Board #Status Problem with the field bus.

Version Identification of the board version, its BIOS and the playerIO.

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The ApplicomIO diagnoses are:

STATUS DEFINITION

0 No anomaly detected. The function has been executed correctly.

1 Function unknown
The function requested is not accepted.

2 Address error
The address of the variable requested is incorrect.

3 Data error
MODBUS: Incoherency in the frame content.

4 Data inaccessible
MODBUS: The physical address does not exist, the module does not exist, or the data are
protected.

CANOPEN:
For reading / writing objects in SDO, the equipment refuses access to the object requested:
• The object does not exist
• The object is read or write protected
• The number of bytes written exceeds the size of the object
For sending or receiving a CAN message:
• The message cannot be sent
• The receiving COB-ID is already used by the board or is not valid

DEVICENET: The remote equipment is in error status. Check its status.

9 MODBUS: A MODBUS customer is trying to modify a write protected data item.

10 Negative layer 2 acknowledgement from the equipment (NACK).

PROFIBUS: UE (User Error), error in the remote equipment.

11 Negative layer 2 acknowledgement from the equipment (NACK).

PROFIBUS: RR (Remote Ressource), insufficient resources in the remote equipment or
initialization parameters not valid.

13 Negative layer 2 acknowledgement from the equipment (NACK).

PROFIBUS: RDL (Response FDL/FMA1/2 Data Low), remote equipment resources
insufficient to deal with the data received, low priority response.

14 Negative layer 2 acknowledgement from the equipment (NACK).

PROFIBUS: RDH (Response FDL/FMA1/2 Data High), remote equipment resources
insufficient to deal with the data received, high priority response.

32 Incorrect parameter sent to the function

Wrong number of variables.

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 STATUS DEFINITION

33 Response time exceeded

The equipment does not respond. Check its status and wiring.

MODBUS: Equipment configured but not connected to the network.

• Wiring problem, the CPU does not execute the communication blocks, connection not
declared or incorrectly declared in the CPU
• Incorrect IP address for the equipment or the gateway
• Check that the Ethernet frame format configured in the remote equipment is
"ETHERNET II"

DEVICENET:
• The DeviceNet master has no equipment to monitor in its configuration
• The slave has not been configured by the master during the initialization phase
• The slave has not been reached by the master during the time lapse defined by the
master during the initialization phase

PROFIBUS: The Input/Output configuration for the master does not correspond to the
Input/Output configuration for the slave.

34 Physical fault on the line

DEVICENET: No 24V supply detected.
The CAN component of the applicom interface is "bus off".
Check the wiring and the Baud Rate for the network.

35 Data not available for cyclic reading.

36 Equipment not configured

Define the equipment configuration using applicomIO Console and reinitialize the field bus
board.

40 Writing or reading attempt deferred by a task, although the maximum number of tasks that can
use the deferred mode at the same time has already been reached.

41 Writing or reading attempt made although the deferred request register is full.

42 Attempt to transfer a request deferred although the deferred request register is empty.

46 Board number not configured, or master / customer function attempting to use a channel with a
master / slave configuration, or the other way round.

47 The field bus board is invalid or incorrectly initialized by the IO_Init function.

49 Time delay fault for adding to the queue file

MODBUS: It was not possible to send the request due to a lack of resources (no communication
channel available). This period corresponds to 4 times the value of the time-out for the current
requests. Increase the time-out value, or the maximum number of simultaneous requests for the
equipment in question.

51 Driver system problem.

53 DEVICENET: Synchronization problem on the line.

The master DeviceNet is offline (no power supply detected or the CAN component of the
applicom interface set to "Bus Off").
Check the wiring and the Baud Rate for the network.

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STATUS DEFINITION

55 Response time exceeded - Message lost

Check the equipment status.

MODBUS: Queuing time exceeds the value of the "time-out for requests being processed",
connection made, question acknowledged but no response.

DEVICENET: The equipment has accepted the connection but has not responded to the request.

59 • Protection key missing from the applicom interface

• Use of applicom functions without prior initialization

63 Communication error on the serial port.

65 Connection refused.
DEVICENET: The connection to the master DeviceNet is in progress or refused by the
equipment.

66 Insufficient memory for the applicom interface.

Insufficient resources for a further connection.

70 MODBUS: Connection closed by the equipment following a communication problem.

Wiring problem, CPU off, the CPU is not executing the communication blocks.
The equipment does not accept this messaging system.
Check the equipment status.

DEVICENET: Connection over.

MAC ID duplication detected on the DeviceNet network. Modify the MAC ID of the master
DeviceNet.

79 Profile incompatible.
The equipment does not correspond to the configuration. Check the equipment and the
bandwidth of the connections.

93 Driver not accessible.

97 Operating mode not accepted.

99 The applicom interface is already in use.

255 Local reading buffer not initialized by the IO_RefreshInput function.

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5.7. PROGRAMMABLE LOGIC CONTROLLER (PLC OPTION)

The CS8C controller can be programmed using IEC61131-3 standard PLC languages: IL, SFC (GRAFCET), FBD,
LD, ST.
The PLC program must be written on a PC in the PLC programming environment supplied with
Stäubli Robotics Studio. It can then be downloaded and executed on the CS8C controller.
The PLC option requires a PLC licence for the SRS programming environment, and a runtime licence for each
CS8C controller.
Without a licence, it is possible to use the PLC programming environment for 30 minutes and execute the PLC
program on a CS8C for 15 minutes.

5.7.1. INSTALLATION
SRS
The PLC programming environment is supplied with SRS. During installation, it is necessary to keep to the
selected PLC option.
To activate the PLC programming licence, it is necessary to connect the PLC key to the PC and enter the licence
number using the SRS utility (Tools > PLC > Licence).
CS8C
The PLC option can be activated on a CS8C using the SRS options manager (Tools > PLC > Options manager).
After restarting, the option must be shown in the list of software component versions on the MCP (Control panel
> Controller > Versions).

5.7.2. OPERATION IN THE CS8C CONTROLLER

PLC cycle
The PLC program in the CS8C has access to all the digital and analog inputs and outputs in the system. It can
communicate with a VAL3 program via the analog or digital outputs of the system.
The PLC cycle is carried out as follows:
1. Reading the inputs and outputs
2. Execution of a cycle in the PLC program
3. Writing the outputs
4. Waiting for the rest of the time lapse required to reach the specified cycle time
The cycle time for the PLC program is defined in the PLC development environment (Generate > Execution
options). It can be modified at any time.
The CS8C supports cycle times that are multiples of 4ms. The sequencing accuracy of the PLC cycle (period
between two successive PLC cycle starts) is about ± 0.1 ms.
When the specified cycle time is null, the system automatically adapts the PLC cycle time to the system CPU load,
and more specifically to the VAL3 program. The PLC program has then less priority than the VAL3 program.
Starting
The PLC program is physically stored in the controller, in the /usr/plc directory. When the controller starts up, the
PLC program stored in this location is started automatically. The only way of inhibiting the automatic start is to
delete the file from the controller using Ftp.
During start-up, if an error is detected in the PLC program (PLC Input/Output not found in the CS8C, or PLC output
corresponding to a CS8C input), the unit does not start up and the error is displayed in the "Events logger" utility
of the MCP.

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Overrun error
If execution of a PLC cycle takes longer than the specified cycle time, the current cycle ends normally, and then
the following PLC cycle starts immediately. An Overrun error is generated (on the dOverrun digital output by
default) to enable a reaction to the PLC or VAL3 program.
The dOverrun digital output thus shows during each PLC cycle whether the previous cycle was carried out within
the specified time lapse or not. The name of the output can be changed (see"Configuration"). The value 1 shows
the Overrun error.
Input/Output error
If an Input/Output reading / writing error is detected, a RwError error is generated by the default dRwError digital
output to enable a reaction by the PLC or VAL3 program. The name of the output can be changed
(see"Configuration").
Interaction with the VAL3 program
When the PLC cycle time is not null:
Execution of the PLC program takes priority over the VAL3 program. The VAL3 program is only executed once
the PLC program is waiting, between two PLC cycles.

CAUTION:
If the delay between two PLC cycles is not long enough, execution of the VAL3 program can
be slowed down considerably. It is then necessary to increase the PLC cycle time to leave
more time for the VAL3, or to specify a null cycle time for the PLC (see "CPU load").

Execution of a VAL3 program can be interrupted at any time by a repeat of a PLC cycle. If synchronization is
required between the PLC and the VAL3, it has to be programmed using the Inputs/Outputs.
When the PLC cycle time is null:
Execution of the VAL3 program takes priority over the PLC program. The PLC program is only executed once the
VAL3 program is waiting, between two VAL3 cycles.
Inputs/Outputs are refreshed with each PLC cycle, each VAL3 synchronous cycle and each VAL3 asynchronous
cycle.
PLC utility for the MCP
The main menu of the CS8C includes a "PLC" utility that displays the main characteristics of the PLC program
being executed:
• Requested PLC cycle time (as defined in the PLC programming environment)
• Measurement of the execution period for the last PLC cycle (this period includes the execution time for
the critical system tasks)
• Maximum execution time measured for the PLC cycles since the previous PLC start
• TCP port for communication with the PLC programming environment
CPU load
The ratio between the execution period for the previous PLC cycle and the requested PLC cycle time gives the
current CPU load for the PLC program. The ratio between the maximum execution period for the PLC cycle and
the requested PLC cycle time gives the maximum CPU load for the PLC program.
The unused CPU load is allocated as a priority to the VAL3, and then to non-critical system tasks (screen
refreshing, Ethernet communication). As a rough guide, it is necessary to leave about 30% of the CPU load to
obtain correct execution of a VAL3 program and the system. For a very simple VAL3 program, we can let the PLC
use 90% of the CPU load. For a complex VAL3 program, the PLC program should not exceed 50% of the CPU
load.

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Configuration
The CS8C parameters of the PLC option are:
• The name of the digital output to be used for the Overrun error (dOverrun by default).
• The TCP port used for communication with the PLC programming environment (1100 by default).
• The name of the digital output to be used for the RwError error (dRwError by default).
• The percentage of idle time between two PLC cycles, when the PLC cycle time is null (50% by default).
For instance, if the last PLC cycle took 16ms and "idleTime" is 50%, 8 ms are left to the system before
a new PLC cycle is started.
These parameters are defined in the /usr/configs/plc.cfx file, which can be modified by Ftp.

5.7.3. PLC PROGRAMMING IN SRS

Definition of the Inputs/Outputs
The Inputs/Outputs must be declared in the PLC program as global datas with CS8_IO profile:
Right-click on the variable and then on Properties.

Tick this option (obligatory)

Select the CS8 IO profile

Fill in the boxes

Figure 5.20

• The ALIAS field can be used to give a PLC variable name that is different from the Input/Output linked to it. If
this field is empty (": 2 simple quotes) the name of the PLC variable is the same as that of the Input/Output.
• The direction field must be set to 0 for an input and 1 for an output.
Automatic creation of the PLC variables on the basis of the Inputs/Outputs for the CS8C controller can be carried
out using the SRS import tool (Tools > PLC > Import) (see figure 5.21).

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Figure 5.21

• If necessary, update the CS8C emulator inputs and outputs using the SRS downloading tool.
• Create or load the desired PLC application (File > Create / Open a PLC project). The CS8C Inputs/Outputs
emulated are then displayed in the left-hand frame.

CAUTION:
Make sure that the PLC programming environment has been closed before making any
modifications to a PLC project.

• Select the desired Inputs/Outputs from the CS8C list and drag them to the desired frame (outputs or inputs).
• Save the PLC project. The next time the program is opened in the PLC programming environment, the selected
Inputs/Outputs are predefined.

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Downloading a PLC program
PLC programs are downloaded from the PLC development environment:
• Log on to the CS8C controller (IP address, TCP port)
• Click on the download button
The progam is then sent to the controller and it starts immediately.
If a PLC program is already being executed, it may be necessary to stop it via the programming environment
before downloading the new program.
The download also copies the PLC program on the CS8C, which means that the last program downloaded is
executed automatically when the controller is started up.
Archiving the PLC program

CAUTION:
The source files of the PLC program must be archived with care.
The CS8C controller contains only a binary format that does not enable the source files to be
found.

The source files are necessary to log on to the controller again and take over control of the PLC.

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5.8. ETHERNET LINK

5.8.1. CONFIGURATION
The CS8C has 2 Ethernet ports, J204 and J205. The IP address of each of these ports can be modified via the
control panel. The modification takes effect immediately. On delivery, the first port is configured with the address
192.168.0.254 (mask 255.255.255.0) and the second one with the address 172.31.0.1 (mask 255.255.0.0).
It is also possible to get automatically an IP address from the network (with DHCP protocol).

CAUTION:
The DHCP protocol may not always assign the same IP address to the controller. The DHCP
mechanism should therefore not be used when the IP address of the controller is used by
other peripheral equipment.
The two Ethernet ports must correspond to different sub-networks. Two IP addresses on the
same sub-network are not supported.

The CS8C controller can reach other Ethernet sub-networks, through gateways configurable from the Control
Panel.
Each gateway is defined with:
• The IP address of the device used as gateway. The address must belong to the same sub-network as the CS8C
controller.
• The IP address of the sub-network to reach. A null address "0.0.0.0" can be used to define a default gateway,
to reach all sub-networks that are not handled by a specific gateway.

5.8.2. FTP PROTOCOL

The CS8C controller is an Ftp server that enables file exchanges over the Ethernet. All that is required is to define
the IP address of the CS8C controller to enable it to be accessed via Ftp, and use a network login and password
corresponding to a user profile as defined on the CS8C. The reading and writing access rights depend on the login
user profile selected (see paragraph 5.10.3).
A free client Ftp is supplied on the SRS CD-ROM.

5.8.3. MODBUS TCP PROTOCOL

The CS8C controller can be configured to exchange Inputs/Outputs via the Ethernet using the Modbus Tcp
protocol. In this case, the CS8C controller is considered as a Modbus Server.
The CS8C controller is configured for Modbus Tcp using the PC SRS software supplied on the CS8C CD-ROM
(Tools > Modbus IO Config). This tool is used to generate a modbus.xml file that has to be saved in the
/usr/applicom/modbus directory of the CS8C emulator. Then the file has to be transferred to the CS8C controller
using the SRS transfer tool (Emulator > I/O > Modbus). If this file is present on start-up, the corresponding
Modbus Tcp Inputs/Outputs are displayed on the control panel and are directly accessible via a VAL3 application.
The "Modbus TCP/IP Client" software option for your PC provides access to Modbus Inputs/Outputs declared
on CS8C from PC software using OPC Client, ActiveX, DLL interface (f.i Visual Basic, Delphi, Visual C++,
LabView, ...). The SRS CD-ROM provides a trial version of the software in the folder "DirectLink 3.9".

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Configuration
The configuration procedure for the Modbus Tcp Inputs/Outputs using the SRS Modbus IO Config tool is as
follows:
• Create a new configuration ("New") or load an existing configuration ("Load")
• In the "Items configuration", "Add Item" tab
• Define the name, type, size and access for each item
• Save the configuration ("General parameters", "Save" tab)
• Copy the file on the CS8C under /usr/applicom/modbus/modbus.xml
• Restart the CS8C
• Check the modbus Inputs/Outputs (Control panel > I/O > Modbus)
Diagnosis
Modbus Tcp errors are shown by messages on the MCP, which can also be displayed using the "events logger
" application. These errors begin with the word "MODBUS" followed by a CS8C diagnosis, identification of the
channel concerned, and the Status (applicom diagnosis).
The CS8C diagnoses are:

InitLib #Status /usr/applicom/modbus/modbus.xml file missing

BuildItem #name The #name item has not been created (incorrect name, already used, or insufficient
memory).
Write #Channel #Status Writing error
Read #Channel #Status Reading error
StartServer It has not been possible to start the Modbus server. The modbus.xml file must be
invalid.
StopServer It has not been possible to stop the Modbus server

The diagnoses given by the Status are the same as those given for the Modbus field bus (see chapter 5.6).

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5.8.4. ETHERNET SOCKETS (TCP)

The CS8C controller can be configured to communicate via the Ethernet using sockets (TCP). The CS8C
controller accepts up to 40 sockets simultaneously, in client mode or server mode. The Ethernet sockets are
configured via the "Control panel" application (Control panel > I/O / Socket). UDP sockets are not supported.
The parameters of a server socket are:
• The connection port between 0 and 65535.

CAUTION:
The ports between 0 and 1000 are reserved.

• The maximum number of simultaneous clients.

• The time lapse prior to triggering of an error message (maximum time lapse reached in reading or for a
connection). A zero value suppresses the time lapse control.
• The end of string character.
Details of the last two parameters are given in the VAL3 reference manual (SIO type).
The parameters of a client socket are the same, with the extra element of the IP address of the server socket to
be reached. A "Test" menu can be used to test the connection with the server.
A server socket is activated ("opened") in the CS8C each time a VAL3 program uses it, and deactivated ("closed")
when the last customer logs off. When the maximum number of clients has been reached for a server socket, other
clients attempting to log on are accepted but the communication is interrupted immediately by the server.

CAUTION:
If no VAL3 program has accessed the server sockets in the CS8C, they are not activated, and
all attempts by a customer to connect will remain fruitless. In particular, the "Test" menu used
on a CS8C controller to test a server socket on another CS8C controller produces an error
message if no VAL3 application is running on that controller.

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5.9. SERIAL PORT

Two serial ports are available on the CS8C controller (J203, COM1 and J201, COM2) to exchange data between
a VAL3 application and an equipment item in the cell.
The serial links are configured via the Input/Output display on the Control panel.
The parameters that can be configured in the Series link are:
• The transmission speed (from 110 to 115200 bauds)
• The number of data bits (from 5 to 8)
• The number of stop bits (1 or 2)
• Parity (even, odd or no parity)
• For J201 (COM2), the RS232/RS422 configuration. Default configuration is RS232.
• The flow control (none / hardware) (Influences COM1 only)
• The time lapse prior to triggering of an error message (maximum reading time lapse). A zero value suppresses
the time lapse control
• The end of string character
Details of the last two parameters are given in the VAL3 reference manual (SIO type).

CAUTION:
• Check the configuration of the Series link to the external equipment before connecting to
the electricity supply.
• When the controller is powered up, characters are sent via COM1 (start-up information for
BIOS, etc.) and they may disrupt operation of equipment connected to J203. This point must
be taken into account in the application.

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Chapter 5 - Integration

5.10. SOFTWARE CONFIGURATIONS

The software configuration can be used to modify certain characteristics of the controller, program user profiles to
limit access to certain functions, and program Inputs/Outputs to enhance CS8C integration in the cell.

5.10.1. CONFIGURATION OF THE CONTROLLER CHARACTERISTICS

The Control panel application gives the various system characteristics. The serial number of the controller is
displayed with the list of installed software and hardware versions.
Certain characteristics can be modified (depending on the login user profile selected):
• The software limits linked to the arm or the cell. The software limits linked to the arm must correspond
to the mechanical limit switches.
• The unit of length (millimeter or inch)
• The language (see hereafter)
• The date and time, fixed or (s6.4) from SNTP time server
• The address and IP mask of each Ethernet port (fixed or from DHCP)
• The list of gateways to reach other Ethernet sub-network
• The current user profile and the user profile when the CS8C is started
• The port number for different system Ethernet socket servers (SRS remote maintenance, telnet,
ApplicomIO fieldbus console, SRS 3DStudio)
• The maximum Cartesian speed in manual mode (up to 250 mm/s)
• The status of the emergency stop channels (ESOUT1 and ESOUT2) with or without DOOR signal (see
chapter 5.1.1)

Language configuration:
The controller is delivered with some predefined translations (English, German, French, Italian, Spanish, Chinese,
Japanese, etc.). Each translation is defined in a .cfx XML file with Unicode UTF8 encoding, located in the
/sys/configs/resources directory. The file itself consists in a set of string definitions, such as:
<String name="invalidBinaryOperator" value="Invalid binary operator for these types" /> where the name
attribute is a translation identifier (to be kept unchanged), and the value attribute is the corresponding translation.
The help attribute, if any, defines the help message associated with the main text.
It is possible to remove/add/modify a translation by removing/creating/modifying the corresponding .cfx file.
Missing texts in a language definition file are replaced with the default English translation, therefore a user-defined
translation file can be used on a newer VAL3 version: only new texts will not be translated correctly.
The Unicode UTF8 format of the language definition file makes it possible to use any Unicode character or symbol
in it. However, the correct display of the characters on MCP depends on the installed fonts on the MCP. Currently,
ASCII, Turkish, Czech, Hungarian, Polish, Scandinavian, Chinese, Japanese and Korean characters are
supported.

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5.10.2. CONFIGURATION OF THE ARM CHARACTERISTICS
The arm characteristics are displayed in the Control Panel. The serial number of the arm is displayed with the list
of installed software and hardware versions. This list also details the "Arm" version that shows:
• The arm type with its mechanical version, such as TX90-S1.
• The arm tuning version, such as R2.
• The arm mounting (floor / wall or ceiling).
• Possibly arm mechanical options.
The controller is delivered with the configuration of the arm delivered with it. If another arm is attached to the
controller, the arm characteristics, defined in the /usr/configs/arm.cfx configuration file, should be updated: This
can be done with the "Exp." export and "Imp." import buttons from the calibration menu.
If some arm characteristics must be updated, you need to edit the arm configuration file /usr/configs/arm.cfx that
is exported with the "Exp." export button from the calibration menu.

Arm mounting configuration

The arm mounting configuration is used by the controller for gravity compensation. It can be updated by changing
the value of the "mount" parameter in the arm.cfx file:
<String name="mount" value="floor" />
The value can be set to "floor" (floor mounting), "ceiling" (ceiling mounting), or "wall" (any mounting). When the
wall mounting is defined, the controller uses the gravity vector configured in the /usr/configs/cell.cfx file, and
displayed in history utility at boot time.

CAUTION:
• For a wall mouting, the coordinates of the gravity vector in World must be correct !
• Default value (gravity along the X direction of World) may not fit the reality !
• Ceiling and wall mounting are not possible for all models of arm. Refer to robot arm
documentation.

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5.10.3. CONFIGURATION OF THE USER PROFILES

The user profiles are configured using the PC SRS tool supplied on the CD-ROM for the CS8C. Each profile is
defined by a configuration file that must be installed on the CS8C under /usr/configs/profiles. There is no limit to
the number of profiles.
Profiles are selected via the control panel or using the Shift-User keyboard shortcut.
S6.1 The setProfile() instruction can also be used to change the user profile in a VAL3 program.
The file name determines the corresponding profile name. An user profile configuration is defined using the
following key words:

Key word Description

password Profile password.
connectionPassword Profile password for network connections (Ftp and remote maintenance).
Writing access to the VAL3 applications and the CS8C configuration (using
writeAccess the MCP or via Ftp). If writing access is activated, reading access is also
activated.
Reading access to VAL3 applications via the MCP or Ftp (opening, editing
readAccess without modification, exporting controller data, connection for the remote
maintenance tool).
Writing access to the specific data for the arm (software limits, adjustment
armWriteAccess
offsets, user marks).
recovery Access to the recovery from the calibration menu.
Activation of the "On"/"Off" menus for the Inputs/Outputs in manual mode.
ioWriteAccess
Does not prevent use of keys (1), (2) and (3).
123KeysControl Access to programming for keys (1), (2) and (3).
manualMode Access to manual working mode.
localMode Access to local working mode.
remoteMode Access to remote working mode.
monitorSpeed Access to the MCP monitor speed.
Activation of the power button in remote mode (only power cut-off remains
powerButton
possible, manual connection to the power supply remains prohibited).
moveHoldKey Activation of the Move/Hold button in remote mode.
stopKey Activation of the "Stop" button for the VAL3 application.
menuKey Activation of the "Menu" browsing button in the MCP interface.

The controller is supplied with 2 profiles:

• "default" (with empty profile and network passwords) providing complete access except for arm
configuration
• "maintenance" (with "spec_cal" as the login and network password) that provides complete access
Of course, the profiles can be adapted or deleted. If no profiles are defined, the default profile does not have any
access restrictions. This means that the network connections must use the "default" login with an empty password.

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5.10.4. CONFIGURATION OF SYSTEM INPUTS/OUTPUTS
System Inputs/Outputs are configured in the /usr/configs/iomap.cf file. Each CS8C controller is supplied with an
example /usr/configs/iomapExample.cf in which the configurations are commented out. To activate a
configuration, it is necessary to:
• Rename the iomapExample.cf file as iomap.cf
• Remove the "//" comments in front of the key words to be configured and replace the description after
the "=" by the name of an Input/Output. For example: enablePower = usrIn0
• Restart the CS8C
Any configuration errors in the iomap.cf file are listed in the events logger on start-up.
Configuration of system inputs
Certain CS8C functions require a user signal for which the default wiring can be reprogrammed:

Key word Description Type Default wiring

estopAcknowledge Acknowledgement of the Digital input Internal signal concerning
emergency stop in manual detection of the MCP on its
mode holder
The emergency stop is acknowledged if this signal is activated when the arm is
powered on.

DANGER:
Current standards require that power must be switched on from outside the cell
after an emergency stop. This digital input must thus be linked to an item of
equipment outside the cell.
enablePower Signal that the system has Digital input No wiring
been powered on in remote
mode (see chapter 6.6.3)

When the MCP is replaced by its shorting plug, it is possible to simulate pressing certain keys using inputs:

Key word Description Type

remoteMonitorSpeed Monitor speed selection [0, 100] Analog input
remoteMoveHold Replacement of the Move/Hold button Digital input

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Access to the system statuses and signals

The status signals for the safety system are set to "On" when an emergency stop has been activated.

CAUTION:
The wiring of the safety system makes it impossible to know the state of each signal when
several eStop signals are activated. The software then returns the last known state.

Key word Description Type

limitSwitch Signal that a limit switch has been reached on a joint
driveFault Variable speed controller fault signal
initSwitch Software command signal opening the safety system
watchdog Fault signal from the watchdog on the RSI board
fuse24V Status of the 24V supply at fuse F2
estopMCP Emergency stop signal from the MCP
estopWMS Emergency stop signal from the WMS
estopUser1-2 Emergency stop signal from UESA on the safety
system
estopUser3-4 Emergency stop signal from UESB on the safety
system
userEnable Emergency stop signal from USER EN on the safety
system
Digital output
Caution:
The USER EN signal is not valid in local or remote
mode. Its state is then not updated.
door Emergency stop signal from DOOR on the safety
system
Caution:
The DOOR signal is not valid in manual mode. Its
state is then not updated.
brakeSelect Signal from the joint selector at the base of the arm
brakeRelease Signal requesting brake release at the base of the arm
deadman Status of the MCP enable button
park Signal concerning detection of the MCP on its holder
power Arm power status
dummyPlug Signal that the MCP is replaced with a shorting plug
temperature Temperature (°C) measured on the RSI board Analog output
popup Messages displayed on the MCP Serial port

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Configuration for the "remoteMCP" option
This option can be used to make a full simulation of the MCP when it is replaced by its shorting plug. It thus enables
an MCP OEM to be connected to the CS8C controller.

CAUTION:
The "remoteMCP" option must be used with great care to meet the requirements of the safety
standards in force. In particular:
• A mutual supervision software mechanism must be set up between the MCP OEM and the
CS8C. It stops the robot as soon as the MCP OEM switches to fault status and checks that
the status of the robot on the MCP OEM is correct.
• The redundant entries for the enable button and the presence detector on the holder must
be wired to separate signals.

Key word Description Type

remoteEnablePower Signal for manual connection to the power supply
remoteTestMode Signal for activation of the test mode
remoteManualMode Signal for activation of the manual mode
remoteLocalMode Signal for activation of the local mode
remoteRemoteMode Signal for activation of the remote mode
remoteDeadman1 Signal from the enable button (1/2)
remoteDeadman2 Signal from the enable button (2/2)
remotePark1 Signal showing presence on the holder (1/2)
Digital input
remotePark2 Signal showing presence on the holder (2/2)
remoteJogJointMode Signal showing activation of the "Joint" mode for
manual movement
remoteJogFrameMode Signal showing activation of the "Frame" mode for
manual movement
remoteJogToolMode Signal showing activation of the "Tool" mode for
manual movement
remoteJogUserMode Signal showing activation of the "User" mode for
manual movement
remoteJogMove1 Speed of manual movement along the 1 or X axis
remoteJogMove2 Speed of manual movement along the 2 or Y axis
remoteJogMove3 Speed of manual movement along the 3 or Z axis
remoteJogMove4 Speed of manual movement along the 4 axis or in RX Analog input
rotation [-100, +100]
remoteJogMove5 Speed of manual movement along the 5 axis or in RY
rotation
remoteJogMove6 Speed of manual movement along the 6 axis or in RZ
rotation
remoteSpeedLimit Signal for incrementation of the maximum speed Digital input
authorized in test mode

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Chapter 6 - Operation

CHAPTER 6

OPERATION

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Chapter 6 - Operation

6.1. POWERING UP THE CONTROLLER

To start the controller, set the switch (1) to position "1" (figure 6.1).

1
Figure 6.1

DANGER:
Before carrying out any work on the components inside the controller, it is essential
to set the master switch (1) to position "0".

See the Safety chapter 3.3 for the procedure to isolate the system from the electrical power supply.

DANGER:
When the master switch (1) is on "0", the cables and the filter located upstream from
the switch remain live.

When the electricity supply to the controller is switched on, the MCP screen and all the LEDs flash on and off.
Next, a "Stäubli CS8" message is displayed on the screen, and then the main menu is shown after about 2
minutes.

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6.2. PRESENTATION OF THE MCP

6.2.1. GENERAL PRESENTATION

13
2

1
11
7

4
12

9 6 10 5
Figure. 6.2

Working mode (1)

The working mode selected on the WMS operator interface is displayed around the button located opposite the
working mode icons. The selected mode is also displayed on the WMS front panel.
Button turning on arm power (2)
This illuminated button enables you to connect the arm to the power supply or disconnect it. When the green
indicator light comes on steady, this shows that arm power is on. In manual mode, if the MCP has not been placed
on its holder, the enable button (11) must be pressed.
Enable button (11)
This button has three positions, and it states are:
- Open when the button is not pressed.
- Closed in the intermediate position.
- Open in the fully depressed position, which corresponds to tenseness in the user. These contacts stay open
until the button is released.
This button can be used to authorize connecting arm power in manual mode (see paragraph 6.3), but only when
it is in intermediate position. The 2 other positions prevent the arm from being powered up or cut off the power
supply if the arm is under power in manual mode. In automatic mode, the position of the button is not taken into
account.
The pendant is designed to enable the button to be pressed by right-handed operators (holding the MCP one way
up) or by left-handed operators (holding the MCP the other way).
Emergency stop (3)
The emergency stop must only be used in the event of absolute necessity for an unforeseen stop in your
application.

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Movement keys (4)

These keys are active in manual mode and they enable you to generate arm movements per axis or using
Cartesian coordinates, depending on the movement mode selected (see paragraph 6.6).
LEDs and Luminous indicator keys

DANGER:
When the MCP power is on all the LED (L) flash to enable you to check that they are
working correctly.
If a LED is found to be faulty, the MCP must be replaced for safety reasons.

L
L

L
L
L
L
L
L

L L L
Figure 6.3

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Movement mode selection keys (5)

Joint Frame Tool Point

When the arm power is on and in manual mode, each of these 4 keys enable you to select the desired movement
mode (Joint, Frame, Tool or Point). The indicator light associated with the key shows the current mode.

Speed adjustment key (6)

This key enables you to vary the speed within the limits imposed by the movement mode. It can be deactivated,
depending on the current user profile (see chapter 5.10.3).
The speed is shown in the MCP status display bar.
Note:
The speeds vary in accordance with predefined values (with a factor of about 2 each time the key
is pressed). The current speed is incremented or decremented by 1%, by pressing Shift at the
same time as the speed key.

Fonction keys (7)

These are used to select the menus displayed above them.

Alphanumerical keys (8)

These keys are used to enter the data for your application.

Interface and navigation keys (9)

The functions of these keys are described in paragraphs 6.2.3 and 6.2.4.

Application control keys (10)

These keys are used to start or stop an application and to enable arm movements. The functions of these keys
are set out in paragraph 6.2.2.

Enable button (11).

This is used in manual mode in the event that the MCP is used other than on its holder. This button can be used
in three positions. In the release position or when it is pressed down fully (pressed hard), the arm power is cut off.
In between these two positions, power is supplied to the arm (see paragraph 6.6.1).

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Digital output activation keys (12)

In manual mode, these keys change the status of the digital outputs that are associated with them (see
paragraph 6.2.4).

jog keys (13)

These keys are activated in manual mode and they enable you to generate arm movements, per axis or using
Cartesian coordinates, depending on the movement mode selected (Joint, Frame, Tool), with one hand (see
paragraph 6.7).

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6.2.2. CONTROL KEYS
Stop key
This key stops the current application. Depending on the user profile, it may be inactive (see
chapter 5.10.3).
Run key
This key enables you to start an application.
Move / Hold key

• In manual mode, the arm movements are allowed when the Move / Hold key is pressed. The arm stops
immediately on the programmed trajectory as soon as the key is released.
• In local and remote modes, the movements can be stopped and the robot set to pause mode, by pressing the
Move / Hold key. Press the key again to reactivate the movements.
• In remote mode, the Move / Hold key may be inactive depending on the user profile (see chapter 5.10.3).

In manual and local modes, the robot is always in pause phase when the arm power is switched on. In remote
mode, arm movements are authorized as soon as it is powered.

DANGER:
When the green light is on and an application has been started, the robot arm can carry
out movements at any time.

Shift + User keys

+ When these two keys are pressed together, the user profile change page is displayed.

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6.2.3. INFORMATION AND HELP KEYS

Online help
By pressing the Help key, you can access online help at any time. In the "online help" mode, the function
keys are desactivated. On the other hand, by pressing the function keys, you can call up a display
window explaining the associated function.
To exit the "online help" mode and reactivate the function keys, press the Help key or the Esc key
again.

Menu key
This key enables you to return to the main menu. Depending on the user profile, it may be inactive (see
chapter 5.10.3).
User key
By pressing this key, you can call up the VAL3 user display page (e.g. if the entry icon appears).
Pick list
The pick list enables you to access the element you are looking for directly in all the lists shown on the display unit.
All you have to do is use the keyboard to enter the first letter or letters of the name of the element you are looking
for. The selector moves to the first element whose initial characters correspond to the search criteria.
This key enables you to move on to the following element corresponding to the search criteria.

6.2.4. NAVIGATION KEYS

Arrow keys
Besides the classic browsing functions, these keys have some other functions that
are specific to the CS8C controller.
"End" key
Expands an element when it has been contracted (preceded by the "+" sign).
Home key
Contracts an element that has been expanded (preceded by the "-" sign).
Shift lock key
Provides access to the second function of each key (except for $ and \).
Shift + End keys
+ By pressing both these keys at the same time, you can move to the end of the list.
Shift + Home keys
+ By pressing both these keys at the same time, you can select the first item on the list.
Shift + Pg up keys
+ By pressing both these keys at the same time, you can move up one page in the display.
Shift + Pg dn keys
+ By pressing both these keys at the same time, you can move down one page in the display.
Shift + Shift Lock keys
+ By pressing both these keys at the same time, you can access capital letters and the characters
$ and \.
Note:
The full stop "." and the comma "," can be accessed in normal mode and in capital mode.

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 Esc key
Cancels the entry and restores the initial value in the box, or exits the current page.
Return key
Starts the action associated with the element selected.
Enables you to modify the box selected (see paragraph 6.2.5).
Validates the box being modified.

tab key
Enables you to switch quickly from one box to another.

backspace key
This key has the classic function of deleting the character to the left of the cursor.

Keys activating the digital outputs "1", "2", or "3"

In manual mode, these keys change the status of the digital outputs that are associated
with them.
The keys can be associated with the digital output using the control panel on the Input/Output display.
To allocate a key for a digital output, select the output in the list of Inputs/Outputs on the control panel and then
press the "Shift" key and the "1", "2", or "3" key at the same time. This operation may be inactive, depending on
the user profile (see chapter 5.10.3).

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6.2.5. MCP DISPLAY

The display is made up of three areas: (see figure 6.4)
Status bar
The status bar (A) gives the following information whatever the current navigation status:
• System activity indicator (1). When the indicator is present on the status bar, the system is not available for the
operator.
• Indicator showing the presence of new information messages (2). Its presence shows that one or more new
information messages have been stored in the events logger. This indicator always flashes and it remains active
until the user has consulted the information.
• Entry indicator (3). It flashes when a VAL3 application is awaiting an operator entry in the application page. It
stays active as long as the application under consideration is active and until the entry is made.
• Operating indicator for the programmable logic controller (PLC) (4).
s6.5 • Arm movement status indicator (5). ’M’ indicates arm movement, ’S’ indicates a stop, ’ @ ’ indicates, for manual
movements, that the arm has reached its target position. The indicator is blank when there is no pending move.
• Arm movement speed indicator (6). It is applicable to all the movements (manual and programmed).
The work page
The work page (B) is the part of the display screen located between the status bar and the menu sector. This page
is used to exchange all the information concerning the current application (display, information windows, entries).
The work page always has a title located on the line just below the status bar (see figure 6.4).
Menus
The menus (C) enable you to carry out a specific action for the element selected or the navigation page. To trigger
the action, press the key located below the corresponding label.
Note:
For ergonomic reasons and for certain interface elements, a default menu is defined (action
associated with the menu most often used). This action can be triggered by pressing the Return
or End keys, together with the corresponding menu key.

(2) (3)(4)(5) (6)

A
(1)

C
Figure 6.4

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Entry boxes
Entry boxes are areas on the display via which the user communicates information to the system when the system
requires it.

Figure 6.5
Press the Return key; this makes the cursor visible.
Modify the box (enter the information)
Validate the entry by pressing Return or cancel the modifications by pressing Esc.
Press the OK key on the menu to validate the display as shown, as a whole.

The backspace key enables you to delete the character to the left of the cursor.

Drop down lists.

When the information required by the system consists of a selection from a predefined list, the interface proposes
a selection of all the possible values in the list.

Figure 6.6
Press the Return key to display the list.

Use the Pg up / Pg dn keys or the lexical search to move around the list.

Validate the entry by pressing Return or cancel the modifications by pressing Esc.
Use the OK key in the pop-up menu to validate the entries displayed.

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6.3. ARM POWER-UP

DANGER:
Before powering up the arm, make sure that the cell is completely free from
obstructions and that there is no one within the work area of the robot. When power is
switched on, the robot arm is liable to follow unforeseen trajectories.

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.

Under normal operating conditions, the operating method is as follows:

Select the Manual Mode from the WMS front panel. The selected mode is displayed on WMS front panel and on
the MCP (1).
(see paragraph 6.2.1)
Press button (3) to switch the arm power on. This action is taken into account if the enable button (2) has been
put into its middle position in the last 15 seconds or if the MCP has been placed on its holder in the last 15 seconds.
If it is not possible to switch the arm power on, because the enable button was pressed more than 15 seconds
previously, it is necessary to release it and then press it again.
If it is not possible to switch the arm power on because the MCP has been on its holder for more than 15 seconds,
it is necessary to remove it and then put it back on its holder.
The button indicator light flashes for a few seconds and then comes on steadily; this means that the arm power
has now been switched on and it is ready to carry out movements.
Press the button (3) again to switch the arm power off and apply the brakes. It is then necessary to repeat the
procedure for switching the arm power on to make movements possible.
The power is also cut off if the enable button is released, if the MCP is removed from its holder, or if WMS key
position is changed (working mode changed).

3
2 1

Figure 6.7

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6.4. EMERGENCY STOP

CAUTION:
The emergency stop is not the normal method for stopping arm movements; it must only be
used in a case of absolute necessity for a stop not provided for in your application.
An emergency stop leads to a sudden cut-off of power to the arm (and other equipements in
the cell), which, if it is repeated too often, leads to damage and reduced motor service life.

When the emergency stop button is pressed, the power is removed from the arm and the brakes are applied. The
other equipment in the cell is also cut off from the power supply (depending on the cell wiring).
Following an emergency stop, a specific procedure is required to restore power to the arm:
• The operator must leave the danger zone.
• The MCP must be resting on its holder, fixed permanently outside the cell (a contact inside the MCP enables
this operation to be checked).

Restarting

DANGER:
When the robot is restarted, all persons are prohibited from remaining in the isolation
area in which the arm moves.

Once those concerned have made certain that safety conditions have been restored, the arm power procedure
can be carried out using the MCP.
Note:
This operation must be carried out with the MCP on its holder when in manual mode.
• Release the emergency stop button by turning it clockwise 1/4 turn.
• Restore power to the arm in accordance with the standard procedure, using the arm power button on the MCP.

DANGER:
If the MCP is not connected to the controller, it must not be left near the cell, because
its emergency stop button no longer works.

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Chapter 6 - Operation

6.5. CALIBRATION, ADJUSTMENT, RECOVERY

CAUTION:
Each time an adjustment or recovery procedure is done, the calibration of the arm has to be
checked carefully to verify that the robot is able to move in its expected angular range and not
more then that range. This verification has to be done at slow speed.

6.5.1. DEFINITIONS
Stäubli arms are calibrated in the factory, to determine the specific 'zero' arm position with maximum precision.
Calibration quality is essential for arm accuracy, i.e. its ability to respect the required Cartesian positions.
If drive elements (motor, encoder) have been replaced, or in the event of mechanical slippage due to a shock, the
specific "zero" arm position can be displaced on one or more joints: it is then necessary to adjust the joints to
restore the arm's original precision.
If one or more axis have been displaced, there are simple procedures for resetting them, using pre-established
reference positions. If more than two joints have been displaced, or if no reference positions are available, it is not
possible to adjust the arm correctly and it is necessary to carry out a full readjustment procedure.

CAUTION:
It is important to provide for an adjustment procedure in the cell and define the associated
reference positions beforehand.

The arm position at any given moment is shown by:

• The position measured for each motor (encoder).
• The "zero" resetting offsets
These offsets are stored in the respective encoders of each motor. A backup is saved in the arm.cfx file of the
controller, a copy of which is supplied on the CdRom delivered with each arm.
During start-up, if a zero offset from a motor encoder is different from the one in the arm.cfx file (f.i. replacement
of the arm linked to the controller), it is necessary to determine which offset is correct. This is done in the recovery
operation.
The motor encoder also stores a phase offset for the encoder-motor combination. In the same way as for the zero
offsets, the motor phase offsets are saved in the arm.cfx file of the controller. During start-up, if a motor phase
offset on a motor encoder is different from the one in the arm.cfx file, it is necessary to state which offset is correct,
using the recovery operation.

6.5.2. RECOVERY PROCEDURE

The recovery application is accessed via the main menu on the MCP.
This is used to update arm or controller data if an inconsistency is detected between the data on a motor encoder
and the data in arm.cfx file of the controller.
The procedure consists of determining which set of data is correct, using a series of questions:
• If you have simply replaced the arm linked to the controller, the arm.cfx file of the controller corresponds to the
former arm. You can then use the recovery menu to update it.

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 CAUTION:
The arm.cfx file contains other specific data for the arm (modified software limits, factory
marks, user marks) that are not updated during this operation. When replacing an arm, it is
preferable to recover the arm.cfx file for the new arm and install it on the controller ("Imp"
Import menu for the calibration application).

• If you have replaced a motor or an encoder, the maintenance procedure you followed should have updated the
offsets on the motor encoder and in the arm.cfx file. The recovery menu thus invites you to repeat the procedure
to deal with the problem.
• If you have not changed anything on the arm or the controller, the problem may be due to a faulty motor encoder
(data loss) or a corrupt arm.cfx file on the controller. Check the contents of the arm.cfx file ("Exp" Export menu
in the recovery application) and compare it with the original file. If it is corrupt, restore it from a backup, or using
the recovery menu to simulate an arm replacement. If the file is correct, the fault may be the motor encoder,
which can be reprogrammed using the recovery menu.

CAUTION:
The motor phase offsets for the encoders are critical, and if incorrect they can make a motor
uncontrollable. Never update an encoder if you are not sure of the data.

6.5.3. ADJUSTMENT PROCEDURE

Before adjusting one or more joints on the robot, it is necessary to set the joints to a reference position beforehand,
with the highest possible level of precision. The exact coordinates of the reference position must be determined
in advance.
Sequence of operations:
• Select the reference position (press Return and then use the arrows).
• If the reference position has not been entered beforehand ("Here" menu), it is possible to enter its coordinates
manually ("Edit" menu).
• Use the arrows to select the desired joint.
• Press 'Adj.' to carry out the adjustment process.
• Check that the arm has been reset correctly by moving to a known point at low speed.

Once the axis has been reset, you will be asked to save the new adjustment offsets for the arm on an external
device.
You can reset all 6axis at the same time by using the arrows to select the reference position instead of a joint.

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6.6. WORKING MODES

Selection of Working Mode is made from WMS front panel. The 3-position keyswitch allows to choose one of the
3 modes (local, remote or manual). The selected mode is indicated on a light on the WMS front panel and on the
MCP.
Depending on the application, it is possible that some working modes are not allowed according to the user
profile (see chapter 5.10.3). In that case, neither the lights on WMS front panel, nor those on MCP are On. Another
mode has to be selected from the 3-position keyswitch on the WMS front panel.

Local mode Remote mode Manual mode

6.6.1. MANUAL MODE

The manual mode is required in the following cases:
• Manual arm movements.
The operator controls the arm movements using the MCP.
• Test/fine tuning of an application.
In this case, it is a program that determines the arm movements.
The manual mode enables the robot to be moved at low speed (250 mm/s maximum).
Jog interface is made using the movement keys (see paragraph 6.7).
Program movements are only carried out if the Move / Hold key has been pressed. The movements stop as soon
as the key is released (see paragraph 6.2.2).
Power is only maintained on the arm if the enable button is kept pressed down to its intermediate position or if the
MCP is resting on its holder (see paragraph 6.2.1).
When the manual mode is selected, the other modes are disabled and the movements cannot be initiated via
outside equipment.

6.6.2. LOCAL MODE

The local mode enables the robot to be moved without any human intervention at the maximum speed defined for
the application. The movements are the result of a scenario written in a program.

DANGER:
When the robot is in local mode, all persons are prohibited from remaining inside the
isolation area in which the arm moves.

The robot is only operational when the following conditions are combined:
• The arm is powered up.
• A movement application has been loaded in the memory and is being executed.
The movement order is given via the MCP using the Move / Hold key (see paragraph 6.2.2).
The arm movements are controlled exclusively by the application.
Only the operator can only stop or start the movement and adjust the running speed using the "+/-
" key.

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6.6.3. REMOTE MODE
The remote mode operates in a similar way to the local mode.
The differences are as follows:
• The arm is powered on via an external system (controller, external MCP) on the VAL3 system signal, or
using the enablePower instruction (see the VAL3 language reference manual).
• The Move / Hold movement order can be generated automatically as soon as the arm power has been
turned on (see the autoConnectMove instruction in the VAL3 language reference manual).
• The Move / Hold button may be deactivated depending on the user profile.
• The power cut-off button may be deactivated depending on the user profile (see chapter 5.10.3).
The enablePower system signal must be configured beforehand to enable it to be linked to a digital input (see
chapter 5.10).
• To connect the arm to the power supply, turn on the enablePower signal for 200ms
• Turn on the enablePower signal again to cut off the power supply to the arm

DANGER:
When the robot is in remote mode, all persons are prohibited from remaining inside
the isolation area in which the arm moves.

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6.7. JOG INTERFACE

6.7.1. PRESENTATION
The jog interface is a utility dedicated to the manual control of robot movements and the teaching of robot
positions.
When arm power is disabled, the jog interface can be accessed by pressing a movement mode selection key
(Joint, Frame, Tool or Point), whatever the current robot working mode. When arm power is enabled, the jog
interface can be accessed with the same keys, but only in manual mode.
The jog interface displays the context of the movement under manual control. This context is important to avoid
unexpected movements. Therefore when the jog interface is exited, the movement mode is also reset
automatically. It is however possible to exit the jog interface while keeping the movement mode active by pressing
Shift-Esc.

3
2
1

4
Figure 6.8

• To select manual mode, turn the 3 position keyswitch to the appropriate position. The selected mode is indicated
both on WMS front panel and on MCP (1).

Manual mode icon

• Carry out the procedures for switching on power in manual mode (see paragraph 6.3).
• Select the movement mode (Joint, Frame, Tool, or Point) ; the corresponding indicator light (4) comes on.
• Press one of the movement keys (5 or 6) or, in Point mode, press the Move / Hold key.
Note:
In manual mode, the speed of movement is limited to 250 mm/s.

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 When one of the movement modes is selected, the jog interface page is shown automatically on the MCP display
(see figure 6.9).
To exit the page, press the Esc key. To return to the page, select a movement mode (Joint, Frame, Tool, Point).

1
2
6
3
4 5

Figure 6.9

Description of the jog interface page

(see figure 6.9)
Whatever the movement mode selected, this page enables you to see:
• The current tool (1).
• The current frame (2).
• The current position depending on the movement mode selected (3).
• In the Joint, Frame and Tool modes, a list of the Cartesian points for the current frame (4).
• In the Point mode, a list of all the Cartesian points for the application (4).
• A list of the points for the joints (5).
s6.5 • For joint positions and cartesian points, a position marker may preceed the name of the data:
• ’ @ ’ indicates that the robot is exactly at the position.
• ’~’ indicates that the robot is near the position.
• ’0’ indicates that the position is null.
• ’!’ indicates that the position is not reachable with the current tool.
s6.5 • The step mode (6), and, if enabled, the current step size. When the step mode is active, each manual movement
is a step of the specified size (in mm or degree). The step size can be easily modified by using the < and > keys.
It is also possible to move of several steps in one movement by pressing quickly several times the jog key. By
pressing 3 times the jog key, the robot performs a step of 3 times the initial step distance. The display of the step
size is updated with each key strike, and is reset to its default value when the movement is completed.

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 Chapter 6 - Operation

Menus
(see figure 6.9)
• Sel. (Selection) menu
This menu displays a window in which it is possible to select the current tool and the current frame in the
application data list.
s6.5 • Par. (parameters) menu
This menu is used to edit the manual movement parameters (step mode and step size).
• Here menu
This menu is used for teaching points. By pressing the key, you can modify the position of the point selected. A
confirmation window is then used to validate the selection.
• New menu
This is used to create a new data or Cartesian variable. A confirmation window enables you to give the variable
a name and validate it.
• Save menu
Used to save the application.
• Ins. & Del. Menu
Enables you to insert a new element in a table, delete an element from the table, or delete a variable.

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6.7.2. MOVEMENT IN JOINT MODE (JOINT)
After the arm has been powered up, press the Joint button (1) on the MCP. The corresponding indicator light
comes on.
The keys (3) enable you to carry out movements in joint (Joint) mode for the various axis (1, 2, 3, etc.). These
movements are carried out in the positive direction (set of keys with the "+" sign) or the negative direction (set of
keys with the "-" sign). It is possible to move several axis at once. Only the indicator light for the last joint key
pressed (+ or -) and the minijog indicator light then come on.

If one of the SEL keys on the minijog (4) is pressed, the joint number selected changes and the
corresponding indicator light comes on in the set of keys (3).

If one of the "+/-" keys on the minijog is pressed, the joint selected moves.

Note:
When the Joint mode has been selected, only the yellow indications are to be taken into account
in the set of movement keys (2 - 3 - 4). The black indications (X, Y, Z) are reserved for the other
movement modes.

Direction of rotation

2
4

1
Figure 6.10

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Chapter 6 - Operation

6.7.3. MOVEMENT IN CARTESIAN MODE (FRAME, TOOL)

After the arm has been powered up, press the Frame button (1) on the MCP. The corresponding indicator light
comes on.

Displacement
direction

Displacement
direction 2

6 1 4 3

Figure 6.11
By pressing the keys in the set of movement keys (2) or one of the Sel keys on the minijog (5), it is possible to
carry out movements along the three axis of the current coordinate system (Frame as default setting). These
movements are carried out in the positive direction (set of keys with the "+" sign) or the negative direction (set of
keys with the "-" sign).
The movements can be made in translation and rotation:
(see figures 6.12, 6.13, 6.14)
• In Translation (X, Y, Z keys):
A movement in the direction of the X axis is called X+, and a movement in the opposite direction to the X axis is
called X- (the same is the case for the Y and Z axes).
• In Rotation (RX, RY and RZ keys):
Rotation around the X axis in the direction of X+ is called RX+, and a rotation in the opposite direction from the
X axis is called RX- (the same is the case for the Y and Z axes).
Specific case (Arm RS):
RZ rotation is only possible if the Z axis of the current position coincides with the Z axis of the World mark. RX and
RY rotations are without any effect.

X X

RX+ RX-
Figure 6.12

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If the Tool key (3) has been pressed, the movements are made parallel to the axis of the current tool (Flange as
default setting).

Z+

X-
Z+

Y+ Y+

X+
X+

Z-
6.13

Z+
Y+ Z+
X+

Y+

Z-

6.14

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 Chapter 6 - Operation

6.7.4. MOVEMENTS IN POINT MODE

The POINT mode is used for movements to a point of the application. To display the points of an application, you
will first be asked to select a tool in that application.
When the POINT movement mode is selected, the display shows:
• The active movement mode (1):
• Line mode, the movements towards the target are made in a straight line.
• Joint mode, the movements are made from point to point.
• Align mode, the Z axis of the tool is lined up with the closest axis to the current marker. The end of the
tool rotates without translation.
• The approach parameters (2). The approach can be inactive (OFF) or active (ON).
s6.5 • The current step mode (3), and, if enabled, the current step size. When the step mode is active, each manual
movement is a step of the specified size (in mm or degree). The step size can be easily modified by using the <
and > keys.

Further menu keys are dealt with in Point mode:

• Mode key
This key enables you to switch successively from Joint mode to Line mode, on to Align mode and then back
to Joint mode.
• Par. (parameters) key
This key calls up a window in which it is possible to configure the approach and the step parameters for the
movement. The approach can be specified along X, Y, Z, RX, RY and RZ.

1 3
2

Figure 6.15

The minijog indicator light (5) and that of the last axis selected (2) remain off in this mode. Nothing happens when
the keys of the minijog(5) or the movement keys (2) are pressed.

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6.8. STARTING AN APPLICATION

6.8.1. STARTING UP IN LOCAL MODE

The local mode is the mode most commonly used in production.

DANGER:
In local mode, the robot arm makes high speed movements. These movements can be
dangerous. Always comply with the safety standards recommended for robot use and
inform operators about the dangers faced.

DANGER:
If an application has been configured in "Automatic start" mode, it starts as soon as
the controller is powered up.

Once the application has been opened:

• Turn the 3-position keyswitch to the appropriate position. The selected mode is indicated both on WMS front
panel and on MCP (1).

Local mode icon

• Carry out the powering up validation procedure in manual mode (see paragraph 6.3).
When the powering up process has been completed, the button comes on steadily.
• To start the application, press the Run key.

Run key

• Command the movement by pressing the Move / Hold key

Move / Hold key

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Chapter 6 - Operation

6.8.2. STARTING UP IN MANUAL MODE

Once the application has been opened: (see paragraph 6.10.1)
• Turn the 3-position keyswitch to the appropriate position. The selected mode is indicated both on WMS front
panel and on MCP (1).

Manual mode icon

• Keep the validation button in its intermediate position or place the MCP on its holder (see paragraph 6.2.1).
• Switch the arm power on by pressing the arm power button.
• To start the application, press the Run key.

Run key

• Command the movement by pressing the Move / Hold key

Move / Hold key

6.8.3. STARTING UP IN REMOTE MODE

In remote mode, the arm is powered up by an external system (external MCP, automatic controller) via a dedicated
digital input. The arm can also be powered up using the EnablePower instruction (see the Reference Manual for
the VAL3 language).
Once the application has been opened: (see paragraph 6.10.1)
• Turn the 3-position keyswitch to the appropriate position. The selected mode is indicated both on WMS front
panel and on MCP (1).

Remote mode icon

• To start the application, press the Run key.

Run key

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6.9. STOPPING MOVEMENTS

When the robot is carrying out programmed movements, it is always possible to stop them, using the MCP.
Depending on the stop mode selected by the user, the system can adopt several types of behaviour.

6.9.1. STOPPING/STARTING MOVEMENTS USING THE MOVE / HOLD KEY

Move / Hold key

• In manual mode, the arm movements are activated when the Move / Hold key is pressed. As soon as the key
is released, the arm stops immediately on the programmed trajectory.
• In local and remote modes, the movements can be stopped and the robot set to pause mode, by pressing the
Move / Hold key. Press the key again to reactivate the movements.
• In remote mode, the Move / Hold key may be inactive depending on the user profile (see chapter 5.10.3).

Movements on restarting
When programmed movements are stopped by pressing the Move / Hold key or during an arm power failure,the
system memorizes a stopping point.
When movements are restarted, the arm goes back to the stopping point using point to point movement, at a speed
limited to 250 mm/s.
The restarting movement is commanded by pressing the Move / Hold key in local and manual modes. The
restarting movement can be automatic in "Remote" mode.
Note:
The Move / Hold key does not stop the current application, it simply suspends the arm
movements. The robot is then in pause mode.

Stopping using the powering up/ power switch-off button

When switching off the power (See paragraph 6.3), the movements are first suspended as with the Move / Hold
key, and then the system applies the brakes and cuts off the power supply to the arm. To restart movements, follow
the particular procedure for the working mode selected (see paragraph 6.3).
Note:
The arm power can be switched off via the MCP in all the working modes.

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6.9.2. STOPPING/STARTING MOVEMENTS USING THE STOP KEY

Stop key

To stop the current application, press the Stop key and validate using the OK key in the pop-up menu. This key
may be inactive depending on the user profile (see chapter 5.10.3).
To restart, press the Run key; the controller restarts the application from the beginning.

Run key
Note:
Depending on the type of application, the arm may continue to move until it has finished the
current cycle.

6.9.3. STOPPING MOVEMENTS VIA THE EMERGENCY STOP BUTTON

(see paragraph 6.4)
During an emergency stop, the standard imposes a fast cut-off of the arm power supply, which may lead to a less
efficient control of the trajectory than that obtained using the power supply cut-off button. This means that the
emergency stop must not be used as a normal method for stopping the robot or switching off the power supply to
the arm.
Once those concerned have made certain that safety conditions have been restored, the arm power procedure
can be carried out using the MCP.
Note:
This operation must be carried out with the MCP on its holder (outside the cell) in manual mode.

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6.10. VAL3 APPLICATION MANAGER

6.10.1. OPERATIONS CONCERNING APPLICATIONS

The application manager can be accessed via the main menu.
In the application manager, the New menu enables you to create a new application and to give its storage location
(hard disk, USB key).
An application contains:
(see figure 6.16)
• The libraries (1)
The io library is necessary to use the controller Inputs/Outputs.
• The global variables (2)
The global datas for the application are classified according to type (see the Reference Manual for the VAL3
language). The Tool type variables are to be found under the Flange variable. The Frame, Point type variables
are to be found under the World variable.
• The progams (3)
• The Start program that is called up by the system when the application starts up.
• The Stop program that is called up by the system when the application stops.
These two programs do not have any parameters, and they cannot be deleted or renamed.

1
2
3

Figure 6.16
Opening an existing application
• Press the Open key in the pop-up menu
• Select the application
• Press the Ok key in the pop-up menu
Closing an application
This action is only possible in the applications opening page.
• Select the application and then press the Clo. key in the pop-up menu.
If there are modifications under way that have not been backed up, a confirmation window can be used to record
or delete the modifications.
Deleting an application
This action is only possible via the opening page of the application.
• Press the Del. key in the pop-up menu.
This operation is irreversible; it is preceded by a confirmation window.
Reloading an application
When the files on disk of an opened application have been modified through the network, it is possible to quickly
update the application in memory by using the menu Rld. (Reload). This action is equivalent to the closing / re-
opening of the application.

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Chapter 6 - Operation

Opening mode for an application

Behaviour for applications when the controller is started up can be configured in the application selection window.
Three types of behaviour can be selected by pressing the Mode contextual menu key:
• Manual: No action on the application.
• Autoload: The application is opened automatically.
• Autostart: The application is opened and then started up automatically.

Note:
It is not possible to apply the "Autostart" mode to more than one application at a time.

Saving a VAL3 application

The Save pop-up menu enables you to save the VAL3 application in full in its original location.
All the information is saved as soon as the key has been pressed:
• The global datas and their current value.
• The application programs.
• The configuration data for the application.

During the saving process, the system is not available and the system activity indicator is displayed on the status
bar.

Exporting a VAL3 application

To save the application under another name or in another storage location, use the Exp. menu.

Online commands
The Cmd. menu provides access to an online command enabling you to display the variable values (using the "?")
and execute a VAL3 instruction line.

CAUTION:
The use of an online command during execution of a program may modify its behaviour.

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6.10.2. MODIFYING AN APPLICATION
Library, data, program creation and edition
• To declare a new library, go to the library mode of the application, press the Add key in the pop-up menu, then
select the library to load and enter the corresponding identifier for the project.
• To create a new data, select the type of variable and press the New key in the pop-up menu.
• To add a frame or a point in a frame, go to it and press the New key in the pop-up menu.
• To add a tool, go to a tool and press the New key in the pop-up menu.

For further information on modifying programs, consult the Reference Manual for the VAL3 language.
Note:
It is not possible to delete a variable, a program, a point or a tool if they are used in a program. It
is not possible to add a parameter or a local variable to a program if the application is active.

Program editor
The VAL3 program editor can be accessed via the list of programs in the application manager; it enables you to
modify programs (to insert, delete, or modify an instruction).
Each instruction added to the editor is checked. If it is not valid, an error message is displayed and the instruction
is refused. In the event of an error, see the reference manual for VAL3 language to correct the instruction
concerned.
The editor proposes a program tree, which means that the instructions set up (if, while, for) are displayed in the
form of a node that can be expanded or contracted.
Example:

COLLAPSED EXPANDED

+ if nb>12 - if nb>12
- switch nb
- case 5
break
+ case 7
endSwitch
else
put("error")
endif

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The editor makes sure at all times that the program is coherent. This means that when a compound statement (if,
while, for …) is deleted, the corresponding instruction is deleted.
Example:

if nb>0 put("True")

put("True") put("false")

else Removal of if

put("false")

endif

if nb>0 if nb>0

put("True") put("True")

else Removal of else put("false")

put("false") endif

endif

It is possible to mark instructions in order to globalize certain actions (copy, delete).

• If a composite statement is selected, all the instructions between the start and the end are also selected.
• Deselection of a composite statement deselects only that statement.

This means, for example, that to mark all the instructions contained between a "while" and an "endWhile", all that
has to be done is to mark " While" twice.
Example:
while Selection of "While" or # while
put ("Press any key") "endWhile". # put ("Press any key")
get() All the instructions are selected and # get()
endwhile the selection goes after "endWhile" # endwhile

# while Deselection of "While" or while

# put ("Press any key") "endWhile". # put ("Press any key")
# get() Automatic deselection of "While" # get()
# endwhile and "endWhile" endWhile

There is a clipboard enabling you to copy instructions. Make sure that the instructions are valid in the program in
which they are pasted. Be careful with the local variables!

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When adding or modifying an instruction, a list of menus makes it easier to enter. (see figure 6.17)
• His. enables you to select an instruction in the list of the last 20 instructions entered.
• Loc. enables you to search for or create a local variable or a parameter.
• I/O enables you to select an Input/Output.
• Prg. enables you to select or create a new program.
• Glo. enables you to select or create a global variable.
• VAL3 enables you to select an instruction in the list of VAL3 instructions.

It is possible to insert a breaking point in an instruction (see paragraph 6.10.3).

To exit, press the Esc key.

Figure 6.17

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6.10.3. DEBUGGING AN APPLICATION

The VAL3 task manager (accessible via the main menu) provides access to a debugging program that supplies
the tools necessary to fine-tune tasks.
To access the debugging program, select a task and press the Dbg key in the pop-up menu. When the debugging
session starts, the task selected is suspended immediately and a display page is opened (see figure 6.19).
In the debugging page, the ">" program pointer(1) shows the next instruction to be carried out.
• The Bpts menu enables you to associate a break point (2) with an instruction, via a window, or to delete a break
point that has already been positioned. The stopping point is shown by the icon opposite the instruction
concerned.
• The menu enables you to add the selected instruction as a comment.
• The Data menu provides access to the variables for the instruction selected.
• The -> menu enables you to move the task pointer (1); this action does not execute any instructions.
• The {} menu activates the step-by-step mode. In this mode, the program is executed as it is shown in the
display (per display line).
• The { } menu activates the detailed step-by-step mode. In this mode, each step is equal to a VAL3 instruction
and the sets of instructions (if, while…) are expanded.
• The Rsm./Sus. menu enables you to suspend and restart execution of the task without exiting the debugging
program.
• The Save menu enables you to save the application.

To exit the debugging page, press the Esc key.

Figure 6.18

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6.10.4. METHODS FOR DIAGNOSIS
System events
System events can be shown in several ways in the MCP display:
• By showing a window with an explanatory message in natural language concerning the system error or
event.
• By a history, which provides access to the last 100 system events classified in chronological order with their date
and time. The messages are stored in the events logger that is accessible via the main menu.
• By showing the "information" indicator in the status bar. This shows that a new event has been added to the
history without opening a window to warn the user. The "information" indicator is removed when the user has
consulted the events list.
• By showing the "information" indicator in the status bar. This shows that a VAL3 application is awaiting an
operator entry in the application page. It stays active as long as the application under consideration is active and
until the entry is made.
Task status
The VAL3 task manager is accessible via the main menu and it can be used to display a list of tasks and their
status (for further information concerning errors, press the Help key).

Input/Output status
To display the Input/Output statuses, select the "I/O" branch in the control panel accessible via the main menu
(see paragraph 6.2.5).
This branch is used to display the status of the Inputs/Outputs of the controller boards defined in the system (RSI,
BIO boards, field buses, Modbus TCP).
Indicator lights for system boards
To find out the meanings of the indicator lights for the RSI board and the other system boards (see chapter 8).
Examples of frequent events and means of diagnosis

EVENT DIAGNOSIS

In spite of starting up the application • Check the indicator light associated with the "Move
using the "Run" key, the robot does not / Hold" key.
move.
• Check that the task has not been suspended using
a stopping point (see paragraph 6.10.3).
• Check that the task is not in error (the Task
manager is accessible via the main menu).
• Check that the application is not in waiting mode (
icon in the status bar, see paragraph 6.2.5).

The application has started, but nothing is shown The information shown for a VAL3 program can only
on the LED display. be seen via the user page (see paragraph 6.2.5).
See also the "userPage" instruction in the
Reference Manual for the VAL3 language.

A page is displayed automatically each time a This jog interface management page is indeed
movement mode is selected. displayed each time the movement mode is changed
(see paragraph 6.6).
To return to the previous page, press the"Esc" key.

The fact of pressing the "Rsm." (Resume) pull- • Check whether the task is in error status.
down menu key for a task does not have any
• Check whether the task has been stopped at a
effect.
break point. If this is the case, delete the break point
or use the Rsm. menu via the debugging program
(see paragraph 6.10.3).

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Chapter 6 - Operation

EVENT DIAGNOSIS

The robot does not go to the right place If the robot does not carry out the movements as
programmed when the "Move / Hold" key is
pressed:
• check whether the controller is in "Point" manual
mode (associated indicator light on); in this case the
robot moves to the last point selected for a jog
interface.
To return to the programmed movements, exit the
"Point" mode (see paragraph 6.6).

When an application is stopped using There must be a task still being debugged.
the "Stop" key, the "Run" indicator light • Exit the debugging program, and then kill the task in
stays on. the task manager.

When the "1" or "2" keys are pressed, • Check that these keys have not been assigned to
the solenoid valves are not switched. other outputs.

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6.11. TEACHING FRAMES

This paragraph constitutes a frame teaching procedure using the three-point method.
This method enables you to define the orientation of the new frame in a precise way by recording three points:
• The frame origin (O)
• A point (Ox) located on the X axis of the frame on the positive x side
• A point (Oxy) on the plane formed by the X and Y axis on the positive y side

The method used is as follows:

• After creating a new Frame type data, use the Teac key in the menu to call up a "Teaching" display (see
figure 6.19).
• Position the point of the robot tool at the desired point of origin using jog interfaces and press the Here key in
the pop-up menu.
• Repeat the operation for "X axis" and "Y axis" and then validate the orientation of the new frame (1).
• Save the modifications.

The frame coordinates are displayed in the box (2).

The point values and marker orientations can be modified using the Edit menu.

Figure 6.19

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Chapter 6 - Operation

6.12. TEACHING POINTS

Teaching points, the method used is as follows:

• Create a new data of "point" type.
• Use the Here pop-up menu to call up the "Teaching p1" display (see figure 6.9).
• Move the tool to the location and position where the teaching is to be done.
• Validate the position using the "Ok" key in the pop-up menu.
• Save the modifications.

The "Configuration" box (1) can be filled in in two ways:

• "No": The point configuration remains unchanged.
• "Yes": The point is taught with the current arm configuration (see the "Reference Manual for VAL3 language").

Figure 6.20

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6.13. MOTION DESCRIPTOR EDITOR

When editing a motion descriptor in the application manager, a simplified view is displayed where only speed and
blending type can be modified. The ">>" menu gives access to the advanced interface where all motion descriptor
parameters can be modified.
A change in the velocity parameter of the simplified interface modifies both the joint velocity and joint
acceleration/deceleration, so that the arm behavior remains harmonious. The accel and decel parameters should
indeed be roughly the square of the vel parameter. For instance, a velocity of 120% = 1.2 is best adapted with
accel and decel of 1.2 x 1.2 = 1.44 = 144%. Higher values for accel and decel give a more aggressive, but shakier
arm behaviour.
When the accel and decel parameters are modified in the advanced interface, this relation with the velocity
parameter may not be effective any more. In that case, when the simplified interface is displayed with the "<<"
menu, the speed parameter is displayed as "User". It can still be edited to recover the default relation between
joint velocity and acceleration/deceleration.

6.14. CONTROLLER BACKUP

A complete system backup on network (to a Ftp server) or on USB can be done from the Control Panel utility
('Bkup' menu on the Controller configuration node).
The backup takes several minutes, its duration depends on the number of user application files.

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Chapter 7 - PC utilities

CHAPTER 7

PC UTILITIES

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Chapter 7 - PC utilities

7.1. STÄUBLI ROBOTICS STUDIO (SRS)

SRS is the Stäubli software package containing all the tools available to develop and maintain a robotics
application.

7.1.1. INSTALLATION
SRS is supplied on a specific CdRom. Execute setup.exe.

7.1.2. FUNCTIONALITIES
The SRS functionalities are set out below. Some of them require a "USB dongle" for activation.
CS8C emulator
Used for full emulation of a CS8C controller and for configuration.
Transfer
Used for easy transfer of a VAL3 application or input/output files to or from a CS8C via Ethernet communication:
• Used to proceed a full backup of a CS8C.
Configuration tools
These various tools can be used to:
• Modify the CS8C controller options (activation or demonstration mode)
• Modify SRS options
• Editing user profiles
• Emulator configuration
• Conversion of VAL3 applications from s3.0 format to s4.0 format
VAL3 Studio option (demonstration version available)
Enables editing of VAL3 applications with an advanced editor. The editor deals with the variables, the programs
and the libraries. It includes a syntax checking system that can be used to check the applications at any time.
The tool is supplied in demonstation form. It includes all the functionalities except saving.
PLC option (demonstration version available)
See chapter 5.7
Remote maintenance option (no demonstration version)
Enables work to be carried out remotely on a CS8C controller. The tool acts in the same way as a remote MCP,
on which the following keys are inactive:
• Working mode
• Power on
• Move / Hold
• Run
• Stop
• Monitor speed (+ / -)
• Activation of digital outputs (1 / 2 / 3)
• Manual movement mode (Joint / Frame / Tool / Point)
• Jog interface
To log on remotely, it is necessary to give:
• The IP address of the controller
• The connecting port (800 by default). This TCP port can be modified in the CS8C control panel.
• A user profile
• The Ftp password for the user profile
The connection is refused if the profile has not been defined on the CS8C or if the wrong password is entered.

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7.2. FTP ACCESS FROM A PC

This action enables you to download VAL3 applications from a PC to a controller and update certain configuration
files that are accessible to users.

7.2.1. FTP CLIENT

A FTP client is accessible using Windows (95, 98, NT, 2000, XP). To set up a connection:
• Open an online command session and enter: ftp w.x.y.z (w x y z corresponds to the IP address of the controller)
(see chapter 5.8 Ethernet link).
• Then when the "User" prompt is displayed, enter the name of a user profile, and when the password prompt is
displayed, enter the network password for the profile (see chapter 5.10.3).
• Go to the USR reader using the cd /usr command and then carry out the desired actions.
Note:
The freeware "Ftp surfer" is supplied with the robot CD ROM.

7.2.2. IP ADDRESS CONFIGURATION

The IP address of the controller is configured via the control panel. This is accessible via the main menu. The IP
address is in the controller node (see chapter 5.8).

7.2.3. FUNCTIONS VIA FTP

All the information available for the user is on the disk called "usr".
Updating the configuration file:
Using a FTP client.
Connect up to the controller and go to the /usr/configs directory.
The files enabling login user configuration of the controller are as follows:
• "arm.cfx" contains the configuration concerning the arm (recovery, marks). This file is only accessible
for a backup prior to maintenance.
• "cell.cfx" contains the configuration linked to the cell (language, max. Cartesian speed, etc...).
• "network.cfx" contains the network configuration of the controller (IP address, systemp TCP ports,
gateways...).
• "controller.cf" contains the controller configuration.
• "ep.cf" contains the configuration linked to the (autostart, autoload) applications.
• bio.cfx, bio2.cfx, mio.cfx, sio.cfx, can.cfx, encoder.cfx, cio.cfx, asi.cfx contain the Input/Output
configurations.
• plc.cfx contains the configuration of the PLC program

DANGER:
All ill-considered modifications made to the configuration can lead to bodily injury or
serious material damage.

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Chapter 7 - PC utilities

7.3. FTP ACCESS TO A PC

This function enables centralization of the VAL3 applications on a PC (backup on a CD, just one storage location,
etc).
To do so, it is necessary for an FTP server to be executed on the PC to share a directory containing the VAL3
applications. Stäubli supplies the free Cesar FTP server enabling this functionality but cannot be held responsible
in the event of incorrect use of the software. To install the server, see paragraph 7.3.1.
Configuration of an FTP node on the MCP
On the home page of the application, press the key of the "Ftp" pop-up menu to move on to the next page:

Figure 7.1

• The name enables you to give the FTP connection a name.

• The IP address corresponds to the IP address of the PC on which the FTP server is executed.
• The path corresponds to the shared directory on the FTP server. With Cesar FTP, if the shared directory is
c:\temp\VAL3\apps, enter only \apps.
• The user corresponds to the user name created on the FTP server
• The login password must correspond to the FTP user password (Be careful with upper and lower case letters).

Once the parameters have been entered, validate the page using "OK". In the applications opening page, there
is now a new node corresponding to the FTP server that has just been created. The applications that can be seen
in this node are used in the same way as local VAL3 applications.
Note:
To enable a backup of the applications, the Ftp connection must be conserved. However, it is not
necessary to run the application.

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7.3.1. INSTALLING CESAR FTP
This paragraph does not set out to explain the FTP connections, it simply supplies a guide to installing the software
and creating the login user account.
• Execute the CesarFTP.exe file to be found on the robot CD-ROM and follow the installation instructions.
• Once the software has been installed, create a new user.
• In the user creation window, add the sharing of the directory containing the VAL3 applications (File Access
Right button). To add it, drag and drop the directory onto the user.
• Select the default directory by right clicking and then "set as default".
• Close the files window, and validate the new login user.
Note:
For further information, see the software documentation.

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Chapter 8 - Maintenance

CHAPTER 8

MAINTENANCE

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Chapter 8 - Maintenance

8.1. HOW TO USE THIS MANUAL ?

8.1.1. SAFETY RECOMMENDATIONS

The recommendations for safety are found in the chapter 3 "Safety". They have to be read and understood. In
case of doubt or incomprehension, contact the STÄUBLI technical support. Refer to the service organization label
inside the controller.
Even if it is not specified at every step of trouble shooting, each component change or component disconnection
has to be made with the main switch of the CS8C in the 0 position (off).
Some of the diagnostic steps require to power to be turned on or off. Do not forget to turn it off before changing
components.

8.1.2. REQUESTED LEVEL

Service personnel have to have the experience to be able to perform electrical and mechanical interventions.
Refer to the regulations currently in force in the country concerned.

8.1.3. INTERVENTION LEVELS

The different troubleshooting steps represented below use 3 intervention levels:
• Level 1 (by default): 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.
• Level 3: Operations that must be carried out by the STÄUBLI After-Sales Service.

8.1.4. SERVICE METHODOLOGY

The following chapters give a general methodology to trouble shoot the robot. It is based first on visual indicators
provided by the controller (led, display) and on indications provided on MCP (popup messages, statuses).
For each point, it is assumed that previous ones have been checked and operate properly.

8.1.5. ELECTRICAL DRAWINGS

Electrical drawings provided in this manual are for information only. The electrical drawings of the robot is provided
in a separate manual.

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8.2. GLOSSARY

ABZ ABZ Encoder board ABZ Encoder board

ARPS Auxiliary Robot Power Supply (logical voltages) Auxiliary Robot Power Supply (logical voltages)

BIO Basic Inputs Outputs Basic Inputs Outputs

BRB Brake Release Board Brake Release Board

BRK Brake Brake

COD Arm Encoder Arm Encoder

CPT Computer Computer

DIG Digital part of the amplifier Digital part of the amplifier

DOOR Door contact Door contact

DSI Dual Sensor Interface board in Arm Dual Sensor Interface board in Arm

EV Solenoid valve Solenoid valve

IC Interconnect Cable Interconnect Cable

LSW Limit Switch Limit Switch

MCP Manual Control Pendant Manual Control Pendant

MCPES Manual Control Pendant Emergency Stop Manual Control Pendant Emergency Stop

MOT Motor Motor

PSM Power Supply Module (power voltage) Power Supply Module (power voltage)

PWR Power part of the amplifier Power part of the amplifier

RPS Robot Power Supply Robot Power Supply

RSI Robot Safety Interface Robot Safety Interface

STARC Stäubli Advanced Robot Control Stäubli Advanced Robot Control

Th Thermo Sensor Thermo Sensor

UESA User Emergency Stop User Emergency Stop

UESB User Safety Stop User Safety Stop

USEREN User validation User validation

WMS Working Modes Selection front panel Working Modes Selection front panel

WMSES Working Modes Selection Emergency Stop Working Modes Selection Emergency Stop

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Chapter 8 - Maintenance

8.3. COMPONENT LOCATION

Fan 1

Regen

ABZ Starc Fieldbus

PWR + DIG
CPT

RPS ARPS RSI CPT

CPU

PSM BIO S1

T1 PS1-PS2

PSM

Filter

D1 D2 F1-F3 S1
Figure 8.1

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8.4. SAFETY

To disconnect the system from the power supply, set the master switch (6) located on the front of the controller to
0. Before doing so, you must stop the arm motion and switch off arm power supply.

DANGER:
Disconnect all the electrical and pneumatic power supplies before carrying out any
work on the controller or the arm. Wait for at least 1 min before starting to work.

See the Safety chapter 3.3 for isolation of the system.

CAUTION:
Use an anti-static wrist strap and an anti-static mat connected to the controller for all work
involving handling of boards or components.
Take all the necessary precautions as set out in paragraph 3.4.3 to avoid the risk of
electrostatic charges.
During maintenance and/or diagnostic operations, if parts are replaced or exchanged between
different systems, make sure that they are fully compatible (hardware and software
compatibility). Check, at low speed, that the robot is operating correctly, especially for
calibration.

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Chapter 8 - Maintenance

8.5. INPUT VOLTAGE

8.5.1. DESCRIPTION
The following components are located in PSM (Power Supply Module) located at the bottom of the
cabinet.

S1 200 - 480VAC
F1 7x 230VA C
1 4. 7
L1 L1 .7
2 F2 8x 8
L2 L2 5. .8 T1
Filter F3
3 6. 9x 9
L3 L3 .9 3 * 230VA C

T T

x:
A = 48 0 VAC
B = 44 0 VAC
C = 4 00 VAC
D = 2 30 VAC
E = 20 8 VAC
F = 20 0 VAC

10T 11T 12T 11M 12M

RPS ARPS RSI CPT 1.1 2.1 3.1 1.1 2.1

Fan 1 . . .
D2
. .
D1

1.2 2.2 3.2 1.2 2.2

Fan 2
15 16 17 13 14

Amplifiers and ARPS

PSM
motors

115 - 230 VAC

S1
230VA C
F1 8
L1 2 5 8 8
L1 . .
Filter F2 T1
N 3 6. .9 9x 9
N

T T
230VA C

x:
D = 2 30 VAC
G = 1 15 VAC

12T 11T 12M 11M

1.1 2.1 1.1 2.1

D2 D1
. . . .

1.2 2.2 1.2 2.2

15 16 17 13 14

Amplifiers and ARPS

motors

Figure 8.2

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8.5.2. ACCESS
Remove 3 screws (4) to remove cover.

4
Figure 8.3

To access the components of the PSM, remove the screws (1) and pull it forward.
CS8C TX/RS CS8C RX160

3
2
3
2

1
1
Figure 8.4 Figure 8.5

CAUTION:
• To remove it completely, disconnect connectors (2) and (3).
• The PSM is heavy; take all necessary precautions to avoid dropping it and to avoid
making efforts in an incorrect position.

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Chapter 8 - Maintenance

8.5.3. TROUBLE SHOOTING

8.5.3.1. CASE 1

Problem:
? All lights of ARPS are off.

Solution:

• Check that main switch S1 is on position 1 and that input voltage is provided to CS8C
(external line).
• Switch off CS8C.
• Turn off main switch S1 to position 0.
• Check input fuses (F1, F2, F3):
• Fuses are 10 x 38 mm type, 500V for standard controllers.
• For UL type controllers, replace fuses with UL type.

THREE-PHASE THREE-PHASE SINGLE PHASE SINGLE PHASE

400-480 V 200-230 V 230 V 115 V

TX40 4Am 6Am 10Am 16Am

TX60 - RS 4Am 8Am 10Am 16Am

TX90 6Am 12Am

RX160 8Am 16Am

CAUTION:
• These fuses do not protect the mains power supply line which must be protected
separately.
• Never replace these fuses with fuses of a higher rating or with different
characteristics (see the "replacement parts" section).

Note:
Am means "slow-acting fuse" according to IEC 269-1.2.
AT means "slow-acting fuse" and AF "quick-acting fuse" according to IEC 127-2.
• Check D1 circuit breaker.

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8.5.3.2. CASE 2

Problem:
? D1 circuit breaker light is off.

Solution:

• Check that D1 circuit breaker is on position 1.

• If D1 circuit breaker does not remain on position 1, change ARPS and / or D1 circuit
breaker.
• Check input fuses (F1, F2, F3):
• Fuses are 10 x 38 mm type, 500V for standard controllers.
• Check voltages at the input of the controller (L1, L2, L3).
• Check voltages after the transformer. At this point, voltages are 230 VAC ±10% for all
the input voltages.
• Change D1 circuit breaker.
To change D1 or D2 circuit breakers, remove PSM.

DANGER:
Main switch S1 should be in off position AND main power to the controller has
to be disconnected.
Orange wires inside PSM indicate that dangerous voltage remains even if S1
is off.

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Chapter 8 - Maintenance

Remove 3 screws (4) to remove cover.

4
Figure 8.6

To access the components of the PSM, remove the screws (1) and pull it forward.
CS8C TX/RS CS8C RX160

3
2
3
2

1
1
Figure 8.7 Figure 8.8

CAUTION:
• To remove it completely, disconnect connectors (2) and (3).
• The PSM is heavy; take all necessary precautions to avoid dropping it and to avoid
making efforts in an incorrect position.

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 The frame of circuit breaker can be separated from the front face with a screw driver
allowing it to be pulled back.

D1

D2

Figure 8.9

Push on (1) to separate it from the front face (3) and disconnect the wires (2).

3
2

Figure 8.10

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Chapter 8 - Maintenance

8.5.3.3. CASE 3

Problem:
? D2 circuit breaker light is off.

Solution:

• Check that D2 circuit breaker is on position 1.

• If D2 circuit breaker does not remain on position 1, change D2 circuit breaker.
• Check input fuses (F1, F2, F3):
• Fuses are 10 x 38 mm type, 500V for standard controllers.
• Check voltages at the input of the controller (L1, L2, L3).
• Check voltages after the transformer. At this point, voltages are 230 VAC ±10% for all
the input voltages.
• Change D2 circuit breaker.

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8.6. ARPS AUXILIARY ROBOT POWER SUPPLY

8.6.1. DESCRIPTION
ARPS is powered with 230 VAC from the D1 circuit breaker. Its outputs are overload protected, which
means that output voltages are automatically set to 0 when there is a short circuit in the components it
supplies.

Normal status, arm power off:

GREEN LEDS STATUS

ON ON
(1)
13V ON
(2)
(3) 24V1 ON
(4) 24V2 OFF
(5) ON 24V3 ON
13V
24V1
Normal status, arm power on:
24V2
24V3 GREEN LEDS STATUS

ON ON

13V ON

24V1 ON

Figure 8.11 24V2 ON

24V3 ON

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Chapter 8 - Maintenance

8.6.2. ACCESS
• Turn off main switch S1 to position 0.
• Remove the 4 screws (1) and pull the ARPS.

5
4
3
2

1
Figure 8.12

8.6.3. TEST POINTS

BRK-ON
Pin 8
BRK-REL-EN 24V3
SECTEUR-OK
ALIM-OK
24V1
24V1 24V3
24V2
Pin 1 13V
+ 0 V DC

+ 0 V DC
Figure 8.13

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8.6.4. TROUBLE SHOOTING
8.6.4.1. CASE 1

Problem:
? ON indicator remains off.

Solution:

• Refer to chapter 8.5 to check input voltages:

• Check that main switch S1 is on position 1.
• Check fuses (F1, F2, F3).
• Check D1 circuit breaker.
• Change the ARPS.

8.6.4.2. CASE 2

Problem:
? 13V, 24V1 or 24V3 light remains off.

Solution: Step 1

• Unplug J1102 (3), J1103 (4), J1104 (5) connector at ARPS outputs (see figure 8.12):
• If the indicator lights remain off, change ARPS.
• If the indicator lights come on again, there is a short circuit on the corresponding
outputs.

Solution: Step 2

• Plug only J1104 (24V3) for internal fans (fan 2 and fan 3):
• If 24V3 light goes off, check wiring and fans.
• Change the defective part.

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Chapter 8 - Maintenance

Access to fans

DANGER:
When fans are defective, cooled parts can be very hot.

The fan 2 (2) is accessed by removing the screws (1) holding the grille and the air filter in place.
The fan 3 (3) for the RPS power supply can be accessed by removing the amplifier for joints 3-6 (see
pages 181 and 182).
To remove it, take out the 2 screws (4).

2 Fan 2

Figure 8.14

3
Fan 3

Axis 3-6

Figure 8.15

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 Solution: Step 3

• Plug only J1103 (24V3 for fan 1 on top of CS8C)

• If 24V3 light goes off, check wiring and fans.
• Change the defective part.

Fan 1

Figure 8.16

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Chapter 8 - Maintenance

Figure 8.17

4 3

Figure 8.18

Figure 8.19

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 DANGER:
• The cover (2), the resistor (8) and the amplifiers (7) may be very hot,
especially in the event of a ventilation malfunction.
• This disassembly operation provides access to the regeneration resistor
powered at 400 V during normal operation. It is essential to cut off all power
supplies before carrying out this operation. Wait for at least 1 mn before
starting to work.

• Remove the 6 screws (1).

• Partially remove the cover (2)
• Remove the connectors J1301 (3), J1303 (4) and the ground wire (5).
• The 4 fans can be accessed by removing the screws (6).

Advanced information

Fan 1 Fan 2 Fan 3

ARPS x4 x3 x1

24V3 J1103-1 J1301-1

0V3 J1103-2 J1301-2

24V3 J1104-1 J1302+

0V3 J1104-2 J1302-
AC
J1304-1
J1101-2 Ph1 DC J1304-2
J1101-1 Ph2 J1102
13V 1
0V13 9
24V2 2
0V2 10
24V1 3
0V1 11
24V1 4
J1101-3 0V1 12
ALIM-OK+ 5
ALIM-OK- 13
SECTEUR-OK+ 6
SECTEUR-OK- 14 CS8C
BRK-REL- EN+ 7
BRK-REL- EN- 15
BRK-ON+ 8
BRK-ON- 16

Figure 8.20

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Chapter 8 - Maintenance

Solution: Step 4

• Plug only J1102 (24V1 for RSI, drives and CPT ; 24V2 for brakes ; 13V for DSI inside
arm).
• If 13V light goes off, repeat the same operation with the interconnection cable
disconnected.
• If 13V light comes on, there is a short circuit either in the cable or in the DSI in the
arm. Change the defective part.
• If 13V light remains off, the short circuit is inside CS8C. Check wiring from J1102
and J1200: short circuit, damaged wire ...

AR P S 13V J1102-1 J1200 M8- 1 J1201 M8- 1 J406- 2 13V 5V , 3.3V ,

1.8V DSI F
0V 13 J1102- 9 J1200 M8- 2 J1201 M8- 2 J406- 1 0V 13 F2 2A
IC F1 2A T
5V
encoder
D1 D7
DSI Board o o
DS I M D1 D7

o o o o
D S I- M
D3 D2 D1 D0
DS I F

D0 ON: DSI = OK
D1 ON: Encoder = OK
D2 ON: Thermo = OK
D3 Slow: Init. Fast. = OK
Figure 8.21

Solution: Step 5

• Plug only J1102 (24V1 for RSI, drives and CPT ; 24V2 for brakes ; 13V for DSI inside
arm).
• If 24V1 light goes off, repeat the same operation with powered components
disconnected one by one: CPU, RSI, drives in order to differentiate the defective
component or wiring.

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 ARPS 13V J1102- 1 RS I2 Leds:
0V 13 J1102- 9
F2 24V
5V
24V 2 J1102- 2 5V-safe
0V 2 J1102- 10
EV2
EV1
24V 1 J1102- 3 J200- 1 24V 1
0V 1 J1102- 11 J200- 2 0V 1 CPU

J206- 1 Fan 4
J206- 2

R SI
24V 1 J1102- 4 J104- 1 24V 1 J112- 1 J921- 1 24V 1
0V 1 J1102- 12 J104- 6 0V 1 J112- 2 J921- 2 0V 1 DIG 1

24V

0V 1
J922- 1 24V 1
J922- 2 0V 1 DIG 2
A LIM- OK+ J1102-5 J104- 2 A LIM- OK+
out
A LIM- OK- J1102- 13 J104- 7 A LIM- OK-
SECTEUR- OK+ J1102- 6 J104- 3 SECTEUR- OK+
out
SECTEUR- OK- J1102- 14 J104- 8 SECTEUR- OK-
BRK- REL- EN+ J1102- 7 J104- 4 BRK- REL- EN+ J923- 1 24V 1
in DIG 3
BRK- REL- EN- J1102- 15 J104- 9 BRK- REL- EN- J923- 2 0V 1
BRK- O N+ J1102- 8 J104- 5 BRK- O N+
out
BRK- O N- J1102- 16 J104- 10 BRK- O N-

Figure 8.22

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Chapter 8 - Maintenance

8.6.4.3. CASE 3

Problem:
? 24V2 light remains off when enabling power on arm.

Solution: Step 1

1) Brake command signal (BRK_REL_EN) not received by ARPS.

2) Brake command is not taken into account by ARPS.
Refer to chapter 8.6.7, BRK-x signals.

Solution: Step 2

3) Short circuit on brakes or wiring.

Check if all brakes are operating in Manual Brake Release mode:

DANGER:
Refer to safety chapter (3).
Pay attention to risks related to the size of the robot, the size of the payload,
and so on when using Brake Release mode.

• If 24V2 light goes off when a specific brake is released, check this particular brake
and its wiring from the robot base to the brake.
• If 24V2 light goes off whatever is the selected brake, check brake release board in
the robot base and the wiring from ARPS to the arm.
Note:
Changing a brake requires an intervention level 2 or 3 depending if brake is
integrated or not in the motor.

AR P S IC BRB
24V 2 J1102- 2 J1200 M8- 4 J1201 M8- 4 J700- 6 24V 2
0V 2 J1102- 10 J1200 M8- 5 J1201 M8- 5 J700- 3 0V 2

Figure 8.23

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8.6.4.4. ADVANCED INFORMATION

ARPS Fan 4 Arm

(25.6 VDC) CPU

24V1

RSI Drives

BRK_REL_EN
24V2
(25.1 VDC) Brakes

13V DSI
(13 VDC)
24V3
Fan 1

24V3 Fan 2
(25.1 VDC) Fan 3
Voltages ±10%

Figure 8.24

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Chapter 8 - Maintenance

8.6.5. ALIM_OK SIGNAL

8.6.5.1. DESCRIPTION

- Controller status
- I/O
-SystemIO
- Inputs Status Signal from ARPS to RSI
...
28 ALIM_OK ON Normal status
... OFF Fault
Figure 8.25

8.6.5.2. ACCESS
See chapter 8.6.2, page 177.

8.6.5.3. TROUBLE SHOOTING

Problem:
? ALIM_OK status = OFF : There is a fault detected by ARPS and corresponding output is
set to 0 V.

Solution:

1) It can be a short circuit on one output (see chapter 8.6.4, page 178).
2) Or it is an internal fault: Change the ARPS.

CS8C © Stäubli 2009 – D28070504A 187 / 248

8.6.5.4. ADVANCED INFORMATION
This output is a 24 VDC signal.
When there is no fault (status in control panel = ON) ALIM_OK signal is set to 24 V.
When there is a fault (status in control panel = OFF) ALIM_OK signal is set to 0 V.

ARPS RSI
J1102-5 ALIM_OK+ J104-2 24 V

J1102-13 ALIM_OK- J104-7

GND

BRK-ON
Pin 8
BRK-REL-EN
SECTEUR-OK
ALIM-OK
24V1
24V1
24V2
Pin 1 13V

+ 0 VDC

Figure 8.26

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Chapter 8 - Maintenance

8.6.6. SECTEUR_OK SIGNAL

8.6.6.1. DESCRIPTION

- I/O
- Controller
- FastIO
Status Signal from ARPS to RSI
...
2 SECTEUR_OK ON Normal status

Figure 8.27

This signal provides the status of input voltage of ARPS.

Normal status: Input voltage of ARPS is correct (>190 VAC).
Status = OFF: There is a power supply failure detected by ARPS.
Failure means that input voltage is <190 VAC for more than 20 ms.
In that case, 24V1 output is maintained for ~100 ms, 13V output is maintained for ~ 300 ms, there is no
voltage backup on 24V2 and 24V3 outputs.

8.6.6.2. ACCESS
See chapter 8.6.2, page 177.

8.6.6.3. TROUBLE SHOOTING

Problem:
? SECTEUR_OK status = OFF : As this condition shut off the controller, this status is
recorded in the error logger.

Solution:

• Check input voltage to the ARPS.

• Check main voltage quality. A voltage drop can be caused by bad connections in the line
or by too much of a power draw by the other equipment on the same line.

CS8C © Stäubli 2009 – D28070504A 189 / 248

8.6.6.4. ADVANCED INFORMATION
This output is a 24 VDC signal.
When there is no fault (status in control panel = ON) SECTEUR_OK signal is set to 24 V.
When there is a fault (status in control panel = OFF) SECTEUR_OK signal is set to 0 V.

ARPS RSI
J1102-6 SECTEUR_OK+ J104-3 24V

J1102-14 SECTEUR_OK- J104-8

GND

BRK-ON
Pin 8
BRK-REL-EN
SECTEUR-OK
ALIM-OK
24V1
24V1
24V2
Pin 1 13V

+ 0 VDC
Figure 8.28

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Chapter 8 - Maintenance

8.6.7. BRK_x SIGNALS

8.6.7.1. DESCRIPTION

- Controller status
- I/O
-SystemIO
- Inputs
... Arm Off Arm On
26 BRK_REL_EN OFF ON
...
- Outputs
...
5 BRK_EN OFF ON
...

Figure 8.29

These signals provide status of command and feedback signals for the brakes. Brakes are off when arm
power is disabled. Brakes are on when arm power is enabled.
Note:
These signals operate the same way in Manual Brake Release mode which is easier to test.

DANGER:
Refer to safety chapter (3).
Pay attention to risks related to the size of the robot, the size of the payload,
and so on when using Brake Release mode.

ARPS RSI Arm

BRK_REL_EN

24V2 Brakes
(25.1 VDC)

BRK_EN

Figure 8.30

CS8C © Stäubli 2009 – D28070504A 191 / 248

8.6.7.2. ACCESS
See chapter 8.6.2, page 177.

8.6.7.3. TROUBLE SHOOTING

Case 1

Problem:
? When trying to enable power on arm, 24V2 led on front of ARPS remains off. BRK_REL_EN
remains off: no brake command issued to ARPS.

Solution:

• Change the RSI.

Case 2

Problem:
? When trying to enable power on arm, 24V2 led on front of ARPS remains off. BRK_REL_EN
is on and BRK_ON remains off.

Solution:

• Check 24V2 led on ARPS:

• If it is on, brakes are activated but there is no feedback to RSI:
• Check wiring between ARPS and RSI.
• Change the RSI.
• If it off, ARPS is not receiving the command from RSI:
• Check wiring between ARPS and RSI.
• Change the ARPS.

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Chapter 8 - Maintenance

8.6.7.4. ADVANCED INFORMATION

Input and output are 24 VDC signals.
BRK_REL_EN is active (status in control panel = ON) when BRK_REL_EN signal is set to 0V.
In that case, BRK_ON feedback signal goes to 24 VDC (RSI input = ON, status in control panel = ON).

ARPS RSI
J1102-7 BRK_REL_EN+ J104-4 24V
Output from RSI to ARPS
BRK_REL_EN- J104-9

J1102-15

Output from ARPS to GND

RSI J1102-8 BRK_ON+ J104-5 24V

J1102-16 BRK_ON- J104-10

GND

Pin 8 BRK-ON
BRK-REL-EN
SECTEUR-OK
ALIM-OK
24V1
24V1
24V2
Pin 1 13V

+ 0 VDC
Figure 8.31

CS8C © Stäubli 2009 – D28070504A 193 / 248

8.7. RPS POWER SUPPLY

8.7.1. DESCRIPTION
RPS is the 325 VDC power supply for the drives. It is powered through D2 circuit breaker and contacts
on the PS1, PS2 relays closed by the RSI board when arm is powered on. It has an overvoltage
protection mechanism called regeneration.

RSI
HPE_EN x

HPE x

BUS_On x PWR_OK
ARM
RPS
PS1
PS2 Regeneration
resistor
400 VDC
REGEN

325 VDC Motors

230 VAC Drives
D2 ON

Figure 8.32

Normal operation:

STATUS ON LIGHT REGEN LIGHT

Arm not powered OFF OFF

Arm powered on ON OFF

Arm powered, motion with high deceleration ON ON

8.7.2. ACCESS

CAUTION:
When the power supply to the arm is cut off, the output voltage is still present even
when the indicator light goes off.
Wait for at least 1 min before starting to work.

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Chapter 8 - Maintenance

8.7.2.1. CS8C FOR TX OR RS ROBOTS

• Set aside the ARPS power supply (see chapter 8.6.2, page 177).
• Remove the 4 screws (1) holding the RPS325 power supply.
• Remove the 4 screws (2) holding the J1200 (5) connector.
• Release the connector (5) and the cable clamps (6).

3
4

2 5
2 6
1
Figure 8.33

CS8C © Stäubli 2009 – D28070504A 195 / 248

 • When replacing the RPS325 power supply, make sure the wire (12) is correctly placed, in the same
position as on the original power supply.

12

Figure 8.34

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Chapter 8 - Maintenance

8.7.2.2. CS8C FOR RX160 ROBOTS

• To access the connectors, remove the ARPS (3) power supply wires held in place by 4 screws (4)
(see chapter 8.6.2) and the metal plate (5) holding the socket and kept in place by 4 screws (6).

5 4 3

Figure 8.35

• Disconnect the connectors J1001 (1), J1002 (2), J1003 (3), J1004 (4), J1005 (5).

5
4
3
2
1

Figure 8.36

CS8C © Stäubli 2009 – D28070504A 197 / 248

 • Remove the plastic cover (2) held in place by 3 screws (1).

Figure 8.37
• Remove the 8 screws (2) holding the PSM (6) power module in place.

3
4
7

2
6
Figure 8.38

CAUTION:
The PSM is heavy; take all necessary precautions to avoid dropping it and to avoid
making efforts in an incorrect position.

• Pull the PSM (6) forward to take it out. To remove it completely, disconnect connectors J010 (3) and
J011 (4).
• To access the RPS (5) power supply, lift it up in front to extract it from the fixing point (7), and then
pull it to free it from the rear lug.

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Chapter 8 - Maintenance

8.7.3. TROUBLE SHOOTING

8.7.3.1. CASE 1

Problem:
? ON indicator light remains off when arm is powered.

Solution: Step 1

• Check D2 circuit breaker inside PSM:

• If it is off, turn it on. It may be due to a temporary overload on power part.
• If it comes back to off position, change D2.
• If its light remains off when it is turned on:
• Check fuses F1, F2, F3.
• Change D2.

Solution: Step 2

• Check the operation of PS1/PS2: Output command signals and feedback information
can be checked from MCP Control Panel and RSI 7-segments error codes.

- Controller status
- I/O
-SystemIO
- Inputs
...
Step 2: Enable power command applied to
4 HPE2 = On
PS1 and PS2 relays
5 HPE1 = On (RSI error codes o, P)
...
17 BUS_ON1 = On Step 3: Feedback signals from PS1 and PS2
18 BUS_ON2 = On relays
(RSI error codes L, n)
- Outputs
0 HPE1_EN = On
1 HPE2_EN = On Step 1: Command signals to enable power on
... arm
(RSI error codes i, J)

Figure 8.39

CS8C © Stäubli 2009 – D28070504A 199 / 248

 HPEx_EN HPEx BUS_ONx ACTION

Arm is Off

OFF OFF OFF Normal status when arm is Off

ON OFF - Change the RSI

OFF ON - Change the RSI

OFF OFF ON Bad connection in the wiring between RSI and

PS1/PS2 or PS1/PS2 defective

Arm enable power sequence requested

OFF OFF OFF Change the RSI

ON OFF OFF Change the RSI

ON ON OFF PS1/PS2 relays are not operating or there is a bad

connection in the wiring between RSI and PS1/PS2

Arm is On

ON ON ON Correct status when arm is powered on

Solution: Step 3

• Check PWR_OK signal from MCP Control Panel.

• If PWR_OK signal is off, change RPS.

- Controller status
- I/O
-SystemIO
- Inputs
... Normal Fault
27 PWR_OK= ON OFF

Figure 8.40

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Chapter 8 - Maintenance

8.7.3.2. CASE 2

Problem:
? REGEN indicator light (yellow) remains on.

Solution:

• Change RPS and check that regeneration resistor has not been damaged.
Regeneration resistor is located at the back of CS8C.

Figure 8.41

CS8C © Stäubli 2009 – D28070504A 201 / 248

8.7.3.3. CASE 3

Problem:
? Not able to move the arm due to the error message "... under voltage ..." or "... envelop error
...". The DC bus voltage applied to the amplifiers is too low or power requested from
amplifier is too high.

Solution: Step 1

• Check that main voltage is correct according to identification plate of the controller. In
case of 3-phase, it is important to verify voltages on the 3 phases.
• Check fuses F1, F3.
• Check D2 circuit breaker.

Solution: Step 2

• If error occurs only when arm is accelerating very high:

• Check that payload conforms to the arm specifications.
• Reduce speed and/or acceleration parameters in the application program.

Solution: Step 3

• Check in manual brake release mode that there are no damages to the mechanics.

DANGER:
Refer to safety chapter (3).
Pay attention to risks related to the size of the robot, the size of the payload,
and so on when using Brake Release mode.

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Chapter 8 - Maintenance

8.8. RSI

Note:
First CS8C controller generations were equipped with RSI(1) board which changed to RSI2 from
2007. "RSI" applies for both RSI(1) and RSI2 where RSI(1) or RSI2 applies specifically to a
dedicated board version.

8.8.1. DESCRIPTION
RSI board manages all hardware signals for safe operation of the robot.
RSI2 board front view:

J110

A 7-segment display indicates status of

J113 internal signals. Refer to page 209 for error
codes.

Power status is indicated with green lights:

D49: 24 V power supply
J111 D50: 5 V internal power supply
D52: 5 V power supply from STARC2
board
D74: Valve 2 through F5 fuse
D73: Valve 1 through F6 fuse
J109
Refer to pages 204 and 208 for trouble
shooting.

Figure 8.42

CS8C © Stäubli 2009 – D28070504A 203 / 248

8.8.2. ACCESS
• Remove the 4 screws (1) and pull the RSI (2).

1
2

Figure 8.43

8.8.3. TROUBLE SHOOTING

8.8.3.1. CASE 1

Problem:
? D49 remains off (24V1 from ARPS).

Solution:

• Check ARPS (see chapter 8.6, page 176).

• Check wiring between ARPS J1102 and RSI J104.

ARPS RSI
24V1 J1102-4 J104-1 24V1

0V1 J1102-12 J104-6 0V1

Figure 8.44

• Change the RSI.

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Chapter 8 - Maintenance

8.8.3.2. CASE 2

Problem:
? D52 remains off (5V from STARC).

Solution:

• Check 5V on STARC (see chapter 8.9, page 232).

• Check wiring between STARC J302 and RSI J100.
• Change the RSI.

8.8.3.3. CASE 3

Problem:
? D52 is on and D50 remains off.

Solution:

• Refer to STARC chapter (8.9) if there is an error message from STARC (STARC has the
possibility to shut off 5V on RSI in case of major error).
• Check wiring between STARC J302 and RSI J100.
• Change the RSI.

CS8C © Stäubli 2009 – D28070504A 205 / 248

8.8.3.4. CASE 4

Problem:
? D73 (EV1) or D74 (EV2) remains Off when corresponding I/O on front panel is set to On.

- I/O
- Controller
- UserIO
+ Inputs
- Outputs
0 valve = on D73 = ON
1 valve = on D74 = ON
Figure 8.45

Solution:

• Check F5 and F6 fuses on RSI. If fuses are blown, check that there is no short circuit in
the wiring from RSI to the arm and no short circuit in the valves.
• Change the RSI.

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Chapter 8 - Maintenance

8.8.3.5. ADVANCED INFORMATION

ARPS

J1102-12 J1102-4

J104-6 J104-1
0V 24V1 RSI Drives
J112-1

J112-2
External 24V
F6
J101-1 EV1+
J109 F2
D73

0V1 J101-9 EV1-

0V 24V Relays
D49 F5
P4 P1 J101-2 EV2+
Valves

D74

0V1 J101-10 EV2-

0V 5V
D50
P4 P2

Logic

0V 5V-SAUVE
D52
P4 P3

3.3V

J100-11 J100-9 J100-8

J302-11 J302-9 J302-8

STA RC

Figure 8.46

CS8C © Stäubli 2009 – D28070504A 207 / 248

8.8.3.6. CASE 5

Problem:
? RSI display is off, no indication.

Solution:

• If D52 is off: See chapters 8.5, 8.6, 8.7, pages 169, 176, 194.
• If D49, D50 and D52 are On:
• Check that STARC board is operating (see chapter 8.9, page 232).
• Change it if necessary.
• Check wiring between STARC J302 and RSI J100.
• Change the RSI.

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Chapter 8 - Maintenance

8.8.4. ERROR CODES ON 7-SEGMENT DISPLAY

Point on the right

- E flashing (page 211)

- r flashing (page 211)
(0) (page 212)
- 5 + pt left flashing (page 212)
- (i) (page 213)
(0) (page 213)
(1) (page 213)
(2) (page 214)
(3) (page 214)
(4) (page 216)
(5) (page 217)
(6) (page 218)
(7) (page 218)
(8) (page 219)
(9) (page 219)
(A) (page 222)
(a) (page 222)
(b) (page 223)
(C) (page 223)
(c) (page 224)
(d) (page 224)
(e) (page 225)
(E) (page 226)
(F) (page 226)
(H) (page 226)
(h) (page 227)
(U) (page 227)
(y) (page 227)
(i) (page 227)
(J) (page 228)
(L) (page 228)
(n) (page 228)
(o) (page 229)
(P) (page 229)
(r) (page 230)
(t) (page 231)
(u) (page 231)
Figure 8.47

CS8C © Stäubli 2009 – D28070504A 209 / 248

 When switching on controller, the RSI display goes through intermediate steps where the 7-segment and
right point are alternatively flashing.

DISPLAY
STATUS
APPEARANCE

- E flashing The RSI board is waiting to be synchronised with the STARC board

- r flashing The STARC board is waiting to be synchronised with the computer

- 5 + pt left flashing Waiting for the "Safety" task to start

- (i) Waiting for the power supply to be switched on

This sequence lasts approximately 2 minutes.

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Chapter 8 - Maintenance

Trouble shooting when display remains on intermediate error codes with 7-segment and point
alternatively flashing.

8.8.4.1. CASE 1

? Problem:

- E flashing The RSI board is waiting to be synchronised with the STARC

board

Solution:

• If it remains on this status:

• Check STARC board (see chapter 8.9, page 232).
• If STARC is OK:
• Check wiring between STARC J302 and RSI J100.
• Change the RSI.

8.8.4.2. CASE 2

? Problem:

- r flashing The STARC board is waiting to be synchronised with the

computer

Solution:

If it remains on this status, the issue is related to STARC board (see chapter 8.9, page 232).

CS8C © Stäubli 2009 – D28070504A 211 / 248

8.8.4.3. CASE 3

? Problem:

(0) NACK I2C error: Communication problem between the STARC

and RSI boards

Solution:

• Check wiring between STARC J302 and RSI J100. If this error occurs when arm is
powered, pay attention to the correct shielding of this cable.
View of computer card cage:

Figure 8.48
• This error can also be created from external noisy signals coming to the RSI board: E-
Stop lines, I/O signals ...

8.8.4.4. CASE 4

? Problem:

- 5 + pt left flashing Waiting for the "Safety" task to start

Solution:

• If it remains on this status, change CPU board.

Note:
Changing a CPU board requires an intervention level 2 or 3 to set up parameters of
the new CPU (level 2 if CPU is preconfigured, level 3 if not).

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Chapter 8 - Maintenance

8.8.4.5. CASE 5
When initialisation ends up properly, display is:

- (i) Waiting for the power supply to be switched on

Note:
From this step, left point is flashing fast.
8.8.4.6. CASE 6

? Problem:

(0) Regeneration thermoswitch: Contact J1303, 3-4 open

Solution:

• RSI(1) case: Either J117 on RSI or J1303, 3-4 at the back of CS8C are defective (bad
contacts) (the regeneration thermoswitch is not implemented).
• RSI2 case: This input does not exist.
8.8.4.7. CASE 7

? Problem:

(1) RSI board power supply problem: J104, 1-6 or internal power
supplies

Solution:

RSI is powered from ARPS 24V1 output.

• If 24V1 led on ARPS is Off:
• See chapter 8.6, page 176.

• If 24V1 led on ARPS is On:

• Check wiring between ARPS J1102 and RSI J104.

ARPS RSI
24V1 J1102-4 J104-1 24V1

0V1 J1102-12 J104-6 0V1

Figure 8.49

• If wiring is OK, change RSI.

CS8C © Stäubli 2009 – D28070504A 213 / 248

8.8.4.8. CASE 8

? Problem:

(2) Watch Dog open: Computer failure

Solution:

• A major failure has been detected on the CPU:

• Reboot controller.

• If this error code remains:

• Change the CPU.
Note:
Changing a CPU board requires an intervention level 2 or 3 to set up parameters of
the new CPU (level 2 if CPU is preconfigured, level 3 if not).

8.8.4.9. CASE 9

? Problem:

(3) Electric stop activated in the arm: J101, 5-12

Solution:

An open electric limit switch condition has been detected.

Note 1:
The presence and number of electrical limit switches depends on arm type (see
figure 8.51).
Note 2:
With RSI(1) board, limit switch circuit is powered from 24V.
With RSI2 board, limit switch circuit is powered from 24Vfus.

• Check first F2 fuse on front of RSI2 (refer to error code #7).

• Check that arm is inside the defined range through MCP Front Panel information.

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Chapter 8 - Maintenance

- Controller status
...
- Joint position
J1: xx J2: xx J3: xx
J4: xx J5: xx J6: xx
...

Figure 8.50

The maximum angular range is defined in the robot' product characteristics.

• If arm is inside its predefined range, check wiring inside the arm.

RSI IC BRB
24Vf us LSW10+ J101- 12 J1200 M6- 4 J1201 M6- 4 J700- 7 LSW+
LSW10- J101- 5 J1200 M6- 3 J1201 M6- 3 J700- 4 LSW-

J701-15 LSW2+

J701-13 LSW1+
J701-14 LSW1-
J701-16 LSW2-
T X 60 ,
L SW3 L SW2 L SW1
T X 90 ,
1 1 1
R X 1 60
4 4 4

T X 40

Figure 8.51

• Check wiring from RSI to the arm base (mainly the interconnection cable).
• If wiring is OK, change RSI board.

CS8C © Stäubli 2009 – D28070504A 215 / 248

8.8.4.10. CASE 10

? Problem:

(4) Amplifier fault: Contact DF open on J112, 3-4. The events

history can be used to find the number of the amplifier
concerned, and it provides further information on the fault. The
control panel can also be used to display the status of the
various variable speed drives.

Solution:

• Before checking faults on drives, check first that STARC board is operating properly (see
chapter 8.9, page 232).
• Check on MCP Control Panel which drive is faulty and change the drive.

- Controller status
...
- Drives information
Drive 1: Disabled
Drive 2: Error
...
Drive 6: Disabled
Figure 8.52

• If there is no fault on drives, check wiring between drives and RSI.

J921- 3 DF+
D IG 1
J921- 4 DF-
RSI

DF+ J112- 3 J922- 3 DF+

DF- J112- 4 D IG 2
J922- 4 DF-

J923- 3 DF+
D IG 3
J923- 4 DF-

Figure 8.53

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Chapter 8 - Maintenance

8.8.4.11. CASE 11

? Problem:

(5) ShortR-EN command not activated: The safety management

task is not operational (computer). This error is displayed if the
software has detected a blocking fault on start-up. The
controller thus has no working mode, and the events history
provides details on the fault detected (invalid arm configuration,
etc.)

Solution:

• Reboot controller.
• If error remains, check events history in the error logger.
This signal can be activated from the CPU in case of malfunction of brakes. If it is the case:
• Check ARPS and RSI, especially the brake command signals (see chapter 8.6,
page 176).

- Controller status
- I/O
-SystemIO
- Inputs
... Arm Off Arm On
26 BRK_REL_EN OFF ON
...
- Outputs
...
5 BRK_EN OFF ON
...

Figure 8.54

• If there is no error related to the brakes, check STARC and CPU boards (see
chapter 8.9, page 232).

CS8C © Stäubli 2009 – D28070504A 217 / 248

8.8.4.12. CASE 12

? Problem:

(6) The ShortR-EN signal is not taken into account by the RSI
board

Solution:

• Change the RSI.

8.8.4.13. CASE 13

? Problem:

(7) Fuse F2 unserviceable or no 24V supply on J109-37

Solution:

Internal voltage (24Vfus) for E-Stop lines is off.

• If E-Stop lines are powered from CS8C:
• Check that there is no short circuit between E-Stop lines.
• Change F2 fuse.
• If E-Stop lines are powered from an external device:
• Check that external 24 V is provided between J109-19 (+24 V) and J109-37 (0 V).
• Check that there is no short circuit between E-Stop lines.
• Change F2 fuse.

R S I2
24V
S U B D- 37 M

J109- 18

F2 24V _In
24Vf us J109- 37 + 24 V DC
250 mA 1A
220uF 22- 26 V DC
24V
50mA

J109- 19 0 V DC

0V 1

Internal External 24 VDC for E-

24 VDC Stop lines

Figure 8.55

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Chapter 8 - Maintenance

8.8.4.14. CASE 14

? Problem:

(8) MCP emergency stop 1 activated: Contact MCPES1, J110

S-J or WMS emergency stop activated: Contact WMSES1,
J113, 1-2

(9) MCP emergency stop 2 activated: Contact MCPES2, J110

T-U or WMS emergency stop activated: Contact WMSES2,
J113, 6-7

Solution:

There is one E-Stop contact open on MCP (Manual Control Pendant) or WMS (Working
Mode Selection) devices.

Manual mode

Comp mode

Figure 8.56

CS8C © Stäubli 2009 – D28070504A 219 / 248

 • MCP is connected on J110:
• Check that MCP connector is properly plugged and screwed on J110.
• Check that MCP E-Stop is released:
• If error remains, disconnect MCP and replace it with J110 dummy plug provided
with CS8C:
• If error disappears, change MCP.
• If error remains, change RSI.

DANGER:
If only one E-Stop contact is operating, the robot will be stopped but unsafely.
It is mandatory to repair the E-Stop line to get both contacts operating: No
error code on RSI and same status on both E-Stop lines on MCP Control
Panel.

Note:
Status of MCP E-Stop push button can be obtained from MCP Control Panel:

- Controller status
- I/O
-SystemIO
- Inputs E-Stop activated E-Stop released
...
20 MCPES1= ON OFF
21 MCPES2= ON OFF

Figure 8.57

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Chapter 8 - Maintenance

• WMS is connected on J113:

• Check that WMS connector is properly plugged on J113.
• Check that WMS E-Stop is released:
• If error remains, disconnect WMS and replace it with J113 dummy plug provided
with CS8C:
• If error disappears, change WMS or its cable.
• If error remains, change RSI.

DANGER:
If only one E-Stop contact is operating, the robot will be stopped but unsafely.
It is mandatory to repair the E-Stop line to get both contacts operating: No
error code on RSI and same status on both E-Stop lines on MCP Control
Panel.

Note:
Status of WMS E-Stop push button can be obtained from MCP Control Panel:

- Controller status
- I/O
-SystemIO
- Inputs E-Stop activated E-Stop released
...
39 WMSES1= ON OFF
42 WMSES2= ON OFF

Figure 8.58

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8.8.4.15. CASE 15

? Problem:

(A) User emergency stop A1 activated: Contact UESA1, J109, 1-

20

(a) User emergency stop A2 activated: Contact UESA2, J109, 2-

21

Solution:

This E-Stop is coming from the cell and is connected to RSI J109.
• Check wiring from this E-Stop to J109 1-20 and 2-21.

DANGER:
If only one E-Stop contact is operating, the robot will be stopped but unsafely.
It is mandatory to repair the E-Stop line to get both contacts operating: No
error code on RSI and same status on both E-Stop lines on MCP Control
Panel.

Note:
Status of manual brake release switch can be obtained from MCP Control Panel:

- Controller status
- I/O
-SystemIO
- Inputs E-Stop activated E-Stop released
...
22 UESA1= ON OFF
23 UESA2= ON OFF

Figure 8.59

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Chapter 8 - Maintenance

8.8.4.16. CASE 16

? Problem:

(b) User emergency stop UEN1/DOOR1 activated:

Contact USEREN1/DOOR1, J109, 3-22/9-28

(C) User emergency stop UEN2/DOOR2 activated:

Contact USEREN2/DOOR2, J109, 4-23/10-29

Solution:

This E-Stop is coming from the cell and is connected to RSI J109. It is Door contact when
robot is in COMP mode (automatic mode); it is UserEn contact when robot is in Manual
mode.
• Check wiring from these E-Stop to J109 3-22, 4-23, 9-28 and 10-29.

DANGER:
If only one E-Stop contact is operating, the robot will be stopped but unsafely.
It is mandatory to repair the E-Stop line to get both contacts operating: No
error code on RSI and same status on both E-Stop lines on MCP Control
Panel.

Note:
Status of UEN and DOOR can be obtained from MCP Control Panel:

- Controller status
- I/O
-SystemIO Abnormal condition Ready to operate
- Inputs
0 UEN2-DOOR2= ON OFF
1 UEN1-DOOR1= ON OFF
...

Figure 8.60

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8.8.4.17. CASE 17

? Problem:

(c) User emergency stop B1 activated: Contact UESB1, J109, 14-

33

(d) User emergency stop B2 activated: Contact UESB2, J109, 15-

34

Solution:

This E-Stop is coming from the cell and is connected to RSI J109.
• Check wiring from this E-Stop to J109 14-33 and 15-34.

DANGER:
If only one E-Stop contact is operating, the robot will be stopped but unsafely.
It is mandatory to repair the E-Stop line to get both contacts operating: No
error code on RSI and same status on both E-Stop lines on MCP Control
Panel.

Note:
Status of manual brake release switch can be obtained from MCP Control Panel:

- Controller status
- I/O
-SystemIO
- Inputs E-Stop activated E-Stop released
...
24 UESB1= ON OFF
25 UESB2= ON OFF

Figure 8.61

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Chapter 8 - Maintenance

8.8.4.18. CASE 18

? Problem:

(e) Manual brake control selected: The rotary switch at the base of
the arm is not set to 0

Solution:

• Check that rotary switch at the base of the arm is in position 0.

• If error remains, shut-off CS8C, disconnect J1201 plug at the base of the arm and check
arm wiring with an ohm-meter.

0
1
2
3
4- 5- 6
BRK- S EL+ BRB
BRK- S EL-

BP- B RK

BRK- REL-

RSI
24V . BRK- S EL+ J101- 3 J1200 M6- 1 J1201 M6- 1 J700- 5 BRK- S EL+
BRK- S EL- J101- 11 J1200 M6- 2 J1201 M6- 2 J700- 2 BRK- S EL-
BRK- REL- J101- 4 J1200 M6- 5 J1201 M6- 5 J700- 1 BRK- REL-

IC

Figure 8.62

ROTARY SWITCH
TEST BETWEEN
POSITION 0 OTHER POSITION

M6-1 and M6-2 Close Open

M6-1 and M6-5 Open Closed when push button

pressed

• If the above check-up is not correct, change arm harness.

• If it is correct, repeat the same test from J200 (controller side) with J1201 connected on
the arm.
• If the above check-up is not correct, change controller-to-arm cable.
• If it is correct, change RSI.
Note:
Changing arm harness requires an intervention level 2.

CS8C © Stäubli 2009 – D28070504A 225 / 248

 Note:
Status of manual brake release switch can be obtained from MCP Control Panel.

- Controller status
- I/O
-SystemIO
- Inputs position 0 Other position Brake release
...
10 BRK_SEL = OFF ON ON
...
15 BRK_REL = OFF OFF ON

(RSI display) (i) (e) (E)

Figure 8.63

8.8.4.19. CASE 19

? Problem:

(E) Manual brake control activated: One of the brakes has been
released manually

Solution:

• Refer to the case above.

8.8.4.20. CASE 20

? Problem:

(F) Manual brake control channel 1: The BRS 4-8 contact is not
closed

(H) Manual brake control channel 2: The BRS 9-13 contact is not
closed

Solution:

• If manual brake release circuit is correct (see above), change RSI.

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Chapter 8 - Maintenance

8.8.4.21. CASE 21

? Problem:

(h) MCP: Enable button or parking contact not activated

Solution:

• Check that enable button on MCP is correctly pressed or that MCP is properly inserted
on its cradle.
• If OK, change MCP.

8.8.4.22. CASE 22

? Problem:

(U) E-Stop 1 order memorised: An emergency stop on line 1 has

been recorded by the RSI board. This fault is reset the next
time the arm is powered up

(y) E-Stop 2 order memorised: An emergency stop on line 2 has

been recorded by the RSI board. This fault is reset the next
time the arm is powered up

Solution:

• If this error code remains when next enable power sequence is initiated, change RSI.

DANGER:
To ensure that the system is operating properly after this error has occurred,
it is necessary to perform several E-Stop sequences with arm power enabled
and robot stopped.

8.8.4.23. CASE 23
When the robot is waiting for an enable power sequence, the display is:

(i)

The following error codes are related to an enable power sequence.

CS8C © Stäubli 2009 – D28070504A 227 / 248

8.8.4.24. CASE 24

? Problem:

(i) Power-up command 1 not activated by the computer

(J) Power-up command 2 not activated by the computer

Solution:

• Change the RSI.

8.8.4.25. CASE 25

? Problem:

(L) Power up sequence 1 not activated: No PS-ON1+ signal on

J105-3

(n) Power up sequence 2 not activated: No PS-ON2+ signal on

J105-4

Solution:

• Change the RSI.

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Chapter 8 - Maintenance

8.8.4.26. CASE 26

? Problem:

(o) Power up sequence 1 not effective: OV on J105-7: relay PS1

not activated or faulty contact

(P) Power up sequence 2 not effective: OV on J105-8: relay PS2

not activated or faulty contact

Solution:

PS1/PS2 relays are not operating or there is a bad connection in the wiring between RSI
and PS1/PS2.
The error codes above can be obtained from MCP Control Panel.

- Controller status
- I/O
-SystemIO
- Inputs
...
4 HPE2 = On Step 2: Enable power command applied to
5 HPE1 = On PS1 and PS2 relays
... (RSI error codes o, P)
17 BUS_ON1 = On
18 BUS_ON2 = On Step 3: Feedback signals from PS1 and PS2
relays
- Outputs (RSI error codes L, n)
0 HPE1_EN = On
Step 1: Command signals to enable power on
1 HPE2_EN = On
arm
... (RSI error codes i, J)
Figure 8.64

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.

HPEx_EN HPEx BUS_ONx ACTION

Arm is Off

OFF OFF OFF Normal status when arm is Off

ON OFF - Change the RSI

OFF ON - Change the RSI

OFF OFF ON Bad connection in the wiring between RSI and

PS1/PS2 or PS1/PS2 defective

Arm enable power sequence requested

OFF OFF OFF Change the RSI

ON OFF OFF Change the RSI

ON ON OFF PS1/PS2 relays are not operating or there is a bad

connection in the wiring between RSI and PS1/PS2

Arm is On

ON ON ON Correct status when arm is powered on

8.8.4.27. CASE 27

? Problem:

(r) RPS power supply not activated: Contact J105, 1-2 open

Solution:

In that case, the most common error displayed on MCP popup message is:

Internal error:
DRIVE-BusUnderVoltage

Refer to RPS chapter (8.7) to verify F1-F3 fuses, 3-phase circuit breaker and RPS.

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Chapter 8 - Maintenance

8.8.4.28. CASE 28

? Problem:

(t) Braking command not activated by the computer.

Solution:

The enable arm power sequence has stopped because brake release command is not
activated: Change the RSI.

8.8.4.29. CASE 29

? Problem:

(u) Power supply to the brakes not activated: Contact J104, 5-10
open.

Solution:

Refer to ARPS chapter (8.6) to differentiate between ARPS issue or RSI issue.

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8.9. STARC BOARD

8.9.1. DESCRIPTION
STARC board does motion control, communicating with encoders for axes positions and amplifiers for
motors commands.

(A) Drive bus

(B) DSI bus
(C) DSPI
(D) FPGA
(E) Reset OK

STARC board
Figure 8.65

Leds A and B are blinking slowly (~ 1 s period) during boot sequence of controller.
They are blinking fast (~ 0.5 s period) when ready to operate.

8.9.2. ACCESS
• Turn off main switch S1 to position 0.
• Set aside the computer after removing the 6 fixing screws (1).
• Remove the 6 screws (2) and open the computer card cage.

1 1
Figure 8.66

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Chapter 8 - Maintenance

DANGER:
The heat-sink of the CPU board may be hot, especially in the event of a
ventilation failure.

• The STARC board can be removed after taking out the fastening screw (3).
• The PCI boards are locked on back edge with an adjustable plate. This plate can be re-
ajusted if necessary when board is replaced.

2
Figure 8.67

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8.9.3. TROUBLE SHOOTING
8.9.3.1. CASE 1

Problem:
? No lights at all on STARC.

(A)
(B)
(C)
(D)
(E)

Solution:

• Check first 24V1 on ARPS (see chapter 8.6, page 176).

• Check STARC internal power supplies leds.
• If 5 V or 3.3 V led is off, change the CPU.
• If one of the other leds is off, change the STARC.

1.2 V
Front face

1.4 V Change the STARC

2.5 V
3.3 V Change the CPU
5V

Figure 8.68

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Chapter 8 - Maintenance

8.9.3.2. CASE 2

Problem:
? Led E is on, Led D is off: Initialization of the board is faulty (FPGA programming issue).

(A)
(B)
(C)
(D)
(E)

Solution:

• Reboot controller.
• If problem remains, change STARC board.

8.9.3.3. CASE 3

Problem:
? Led E and D are on, Led C is off: STARC processor was not able to start.

(A)
(B)
(C)
(D)
(E)

Solution:

• Reboot controller.
• If problem remains, change STARC or CPU board.
Note:
Changing a CPU board requires an intervention level 2 or 3 to set up parameters of
the new CPU (level 2 if CPU is preconfigured, level 3 if not).

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8.9.3.4. CASE 4

Problem:
? Leds E, D and C are on, Led B is blinking slowly (~ 1s period) whatever the status is of led
A (blinking slow or fast): There is a communication problem between STARC and the DSI
in the arm base.
In that case, it is not possible to enable power on the arm.

(A)
(B) Slow
(C)
(D)
(E)

Solution:

When led B is blinking slowly, all encoders (sensor) and all PTC sensors are not operating.
The information displayed on MCP control panel is the following:

- Controller status
...
- Sensor status
- Sensor 1: Failed
- Sensor 2: Failed
...
- Sensor 6: Failed
- PTC sensor
- PTC sensor 1 = ?
- PTC sensor 2 = ?
...
- PTC sensor 6 = ?

Figure 8.69

It is a generic problem which is not likely due to a specific encoder or a specific PTC sensor.
• Either the communication through optical fibber between STARC and DSI is not
operating:
• Change interconnection cable from CS8C to arm.
• Or the DSI board in the arm base is not operating:
• Change the DSI.
Note:
Changing a DSI board requires an intervention level 2.

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Chapter 8 - Maintenance

Optical fiber
• Check optical fiber between STARC board and arm to ensure that there is no visible
damage and no dust on optical fibber connectors, especially for the interconnection
cable.

DANGER:
Do not stand with your eyes directly opposite the optical fiber when it is lit, in
order to avoid damage to the eyes.

• Check that there is red light coming out from STARC J306 connector. If there is not light
or if it seems very dim:
• Change STARC board.
• Check that there is not an angle on optical fiber inside CS8C or inside arm.

Risk of malfunction

Figure 8.70

• Check that there is red light coming back on STARC optical fiber connector J307.
• Change defective part if necessary.
Note:
Changing arm harness requires an intervention level 3.

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 DSI
If optical fiber looks good:
• Check that the 13 V led on ARPS is On (see chapter 8.6, page 176).
If ARPS 13 V light is on:
• Open the robot base and check the D1 light on DSI.

DSI board's

D0 ON: DSI = OK
D1 ON: Encoder = OK
D2 ON: Thermo = OK
D3 Slow: Init. Fast. = OK

Figure 8.71

If D1 is off:
• Check the 13 V wiring between ARPS and DSI.
If D1 is on:
• Change the DSI.
Note:
Changing a DSI board requires an intervention level 2.

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Chapter 8 - Maintenance

DSI advanced information

Common lines for all encoders:
• 13 V power supply.
• DSI.
• Optical fiber.
• 5 V from DSI to encoders.

Individual lines:
• DSI to encoder communication.

Optical fiber
Transmit Fiber in Encoder
Receive Fiber out 1

Encoder
2

5V encoder

DSI board's
Encoder
6

Common power supply

Individual communication
D0 ON: DSI = OK channels
D1 ON: Encoder = OK
D2 ON: Thermo = OK
D3 Slow: Init. Fast. = OK
Figure 8.72

CS8C © Stäubli 2009 – D28070504A 239 / 248

8.9.3.5. CASE 5

Problem:
? Led A is blinking slowly (~ 1 s period) after the boot sequence: There is a communication
problem with the amplifiers.

(A) Slow
(B) Fast
(C)
(D)
(E)

Note:
If both leds A and B are blinking slowly, check first the led B issue (previous
paragraph).

Solution:

When only led A is blinking slowly the STARC to drives communication is not operating, the
information displayed on MCP control panel is the following:

- Controller status
...
- Drives information
- Drive 1: Error
- Drive 2: Error
...
- Drive 6: Error
- Sensor status
- Sensor 1 = Working
- Sensor 2 = Working
...
- Sensor 6 = Working

Figure 8.73

Step 1
• Check flat cable between STARC board and the drives.
If cable has some damage:
• Change the cable.

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Chapter 8 - Maintenance

Step 2
• Check that each drive is properly powered with 24 V: Led = On.
• If one drive has a led off, check 24 V power supplier cables.
• If power supplies are OK, change drive(s).

Figure 8.74

Step 3
• Change the STARC.

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8.10. PREVENTIVE MAINTENANCE

DANGER:
Disconnect all the electrical and pneumatic power supplies before carrying out
any work on the controller or the arm. Wait for at least 1 mn before starting to
work.

8.10.1. VENTILATION
The air filter on the ventilaton system must be cleaned and/or replaced as and when necessary, depending on its
level of fouling.

8.10.2. RECOMMENDED SPARE PARTS

• 10.3 x 38 fuse, rating depending on the voltage and the type of arm:

THREE-PHASE THREE-PHASE SINGLE PHASE SINGLE PHASE

400-480 V 200-230 V 230 V 115 V

TX40 4Am 6Am 10Am 16Am

TX60 - RS 4Am 8Am 10Am 16Am
TX90 6Am 12Am – –
RX160 8Am 16Am – –

• 250 mA and 500 mA microfuse.

• STARC board.
• Amplifier (drive): one of each type.

TX40 TX60 TX90 RX160 RS

4/9 + 4/9 4/9 + 8/22 4/9 + 8/22 8/22 + 15/45 4/9 + 8/22

• BIO board.
• RSI board.
• CPU board.
• MCP.
• Air filter.

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Chapter 8 - Maintenance

APPENDIX

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Chapter 8 - Maintenance

APPENDIX 1
Protection of the power line for the CS8C
controller

I. CONTROLLER CHARACTERISTICS

The CS8C controller is protected at its input from risks of short-circuits by Am type fuses.
The load on the primary circuit depends on the type of arm installed, the voltage rating of the power supply and
the type of network (single phase or three-phase) (load = current in the controller power supply circuit when the
arm is operating).

Robot Power installed

TX40 1,5 kVA
TX60 1,7 kVA
TX90 2 kVA
RX160 3 kVA
RS 1,7 kVA

When the controller is powered on, a surge current is generated. The current reaches the level of continuous duty
after ª 8 periods, i.e. ≈ 160 ms for a 50 Hz power frequency. The first peak of the surge current is ª 20 x In.

II. PROTECTION UPSTREAM FROM THE CONTROLLER

The protections upstream from the controller are used to protect the secondary circuits of the upstream
transformer from overcurrents and short-circuits.

B
Controller

Upstream transformer

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You need to install one of the following:
• the gl fuses
• a magneto thermic breaker, type U
• a magneto thermic breaker, type D
Choice of the protection: the NF C 15-100 standard provides the calculation method for the protection against
surges and short-circuits.

Summary:
1) Protection against surges:
The degree of protection must be less or equal to secondary surge current of the upstream transformer. This
current depends on the electrical installation of the customer.
2) Protection against short-circuits:
Calculate minimum short-circuit current at the furthest point in the installation (in B) and choose the protection level
so as to get a disconnection time < 5 s for this current.

Us
Icc mini = ---------------------------------------------
2
Us
--------- × Ucc%-------------- + 2ρl --------
P 100 S

Us = secondary voltage of the upstream transformer These characteristics are

P= power of the upstream transformer printed on the identification
Ucc% = short-circuit voltage of the upstream transformer in % plate of the upstream
transformer
I= length of the line (in metres).
S= section of the line (in mm²). The wire sections must be chosen
according to the current demand, the temperature rise, the potential
difference on the line, ...
= 0.027 mm²/m for copper

Size of gl fuse: In<=Icc mini / 4

Breaker, type U: In<=Icc mini / 8
Breaker, type D: In<=Icc mini / 3.5

3) Use the functioning curves of both the breakers and the fuses to check that the power disconnection
happens in less than 5 s for the selected size:
Example:
Us = 400V
P = 10 kVA
Ucc% = 4%
l = 20 m
S = 6 mm²
= 0.027 mm²/m

For a breaker, type U: ln<=488 / 8 = 61 A.

the size immediately lower is 52 A.
At the short-circuit current, the disconnection happens in less than 5 s.

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