CS8C Controller

Instruction manual
© Stäubli Faverges 2006

D28062904A - 01/2006
 Documentation addenda and errata can be found in the "readme.pdf" document delivered with
the controller's CdRom.

2 D28062904A - 01/2006
 TABLE OF CONTENTS

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

1.2 DEFINITION OF THE ELEMENTS INTERVENING AROUND THE ROBOTIZED CELL . . . . . . . 12

2 DESCRIPTION OF THE CONTROLLER

2.1 IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2 LOCATION AND DESCRIPTION OF THE MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 16

3 SAFETY
3.1 REMINDER CONCERNING THE SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.2 SAFETY DIRECTIVES LINKED TO THE WORK ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . 22

3.3 SAFETY DIRECTIVES LINKED TO STAFF PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.4 SAFETY DIRECTIVES LINKED TO PROTECTION OF THE EQUIPMENT . . . . . . . . . . . . . . . . . 25

4 INSTALLATION
4.1 ROBOTIZED CELL ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.2 ON-SITE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.3 UNPACKING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.4 FIXING THE MCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.5 CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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5 INTEGRATION
5.1 EMERGENCY AND SAFETY STOP CHANNELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.2 BASIC INPUTS / OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.3 DIGITAL BIO INPUT/OUTPUT BOARD (OPTIONAL EXTRA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.4 FIELD BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

5.5 PROGRAMMABLE LOGIC CONTROLLER (PLC OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

5.6 ETHERNET LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

5.7 SERIAL PORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

5.8 SOFTWARE CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

6 OPERATION
6.1 POWERING UP THE CONTROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

6.2 PRESENTATION OF THE MCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

6.3 ARM POWER-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

6.4 EMERGENCY STOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

6.5 CALIBRATION, ADJUSTMENT, RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

6.6 OPERATING MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

6.7 JOG INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

6.8 STARTING AN APPLICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

6.9 STOPPING MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

6.10 VAL3 APPLICATION MANAGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

6.11 TEACHING FRAMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

6.12 TEACHING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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 -

7 PC UTILITIES
7.1 STÄUBLI ROBOTICS STUDIO (SRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

7.2 FTP ACCESS FROM A PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

7.3 FTP ACCESS TO A PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

8 MAINTENANCE
8.1 COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

8.2 SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

8.3 PROCESSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

8.4 POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

8.5 RSI BOARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

8.6 LIST OF SYSTEM EVENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

8.7 VENTILATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

8.8 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

APPENDIX
8.9 PROTECTION OF THE POWER LINE FOR THE CS8C CONTROLLER . . . . . . . . . . . . . . . . . . 179

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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 GIVING 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 INTERVENING AROUND THE ROBOTIZED
CELL

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

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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).

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 block, 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 operations 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 on 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 support in manual or test modes, 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.

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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 robotized cell. It has been designed and built to
enable the "robotized cell" unit to comply with regulatory provisions. Compliance of the robotized 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
robotized cell are correctly trained and show the skills necessary to carry out these tasks in full safety"
(extract from standard NF EN 775).
In France, for example, posters isued by the CRAM are available to remind operators of the safety rules
applicable in the vicinity of robotized stations.
The electrical equipment of the robot and the robotized cell must comply with standard EN 60204-1.
The characteristics of the power supply and the grounding terminals must comply with the manufacturers'
specifications.
Standards applicable
Installation of the robot must be planned in accordance with the standard instructions.

• ISO 10218, 1992 International standards

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

• Standard EN 775 Industrial handling robots - Safety

• 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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3.2. SAFETY DIRECTIVES LINKED TO THE WORK ENVIRONMENT

3.2.1. ANALYSIS OF SAFETY AROUND THE ROBOTIZED CELL

Safety must be taken into account for the robotized cell from the design and development stage on.
Before envisaging installation of the robotized cell, it is necessary to study the following points:
• Envisage 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 robotized 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, and especially European standard EN 775.
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 robotized cell
environment must comply with the levels of disturbance set out in the safety
standards.

3.2.2. RULES CONCERNING THE ROBOT'S WORKING 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 working area when the arm is powered up.

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Chapter 3 - Safety

3.3. SAFETY DIRECTIVES LINKED 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 robotized 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.

DANGER:
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 (figure 6.1, item 1).
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.

• 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.
• The arm must not be loaded 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.

DANGER:
All persons are prohibited from remaining in the isolation area in which the robot
arm operates. Certain robot operating modes such as the "release brakes" mode
can lead to unforeseeable arm movements.

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 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. ROBOTIZED CELL SAFETY DEVICES

The safety devices must form an integral part of the design and installation of the robotized 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 robotized 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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Chapter 3 - Safety

3.4. SAFETY DIRECTIVES LINKED 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 up the air inlets and outlets for the controller ventilation circuit.
• Never use the emergency stop to downpower 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. ESD are truly dangerous. It is estimated that they
destroy only 10% of the components that they effect. The other 90% of components fall into the
"deteriorated" category. A component may be damaged with simply 25% of the voltage required to destroy
it.
These hidden faults can lead to problems that appear several days, weeks or even months after the
incident. Components may also undergo a change in their operating characteristics. Initial tests are
successfully passed but an intermittent error occurs under vibration or temperature constraints. The same
components will pass the "on/off" test successfully, as carried out during repairs, but the problem will
reappear again once on site.

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Typical ESD voltages

LOW RELATIVE AVERAGE RELATIVE HIGH RELATIVE

SOURCE HUMIDITY HUMIDITY HUMIDITY
10 - 20% 40% 65 - 90%

Walking on carpet 35 kV 15 kV 1,5 kV

Walking on vinyl 12 kV 5 kV 0,3 kV

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

workstation

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

Polyethylene bags 20 kV 2 kV 1,2 kV

Cellular polyurethane 18 kV 11 kV 1,5 kV

CHARGE SOURCES

Work surfaces Packaging

Floors Handling

Chairs Assembly

Carriages Cleaning

Clothes Repairing

PARTS SENSITIVE TO STATIC CHARGES

Electronic cards
Power supplies
Encoders
etc

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Chapter 3 - Safety

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 4 - Installation

CHAPTER 4

INSTALLATION

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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.

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 19).
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 robotized cell must comply with standard EN60 204-1.
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.

D28062904A - 01/2006 31
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

RS 40, 60, 80 1,7 kVA

Minimum wire dimensions: 14 AWG / 2 mm2

Maximum wire dimensions: 8 AWG / 6 mm2 (flex wire)
Maximum wire dimensions: 7 AWG / 10 mm2 (solid wire)
Maximum 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.

CAUTION:
To comply with the standards concerning electromagnetic disturbances, a ground wire
with a cross-section of at least 6 sq. mm must be connected to the base of the arm.

32 D28062904A - 01/2006
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 60 204-1) 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.
The heat generated by the controller is 400 W.

D28062904A - 01/2006 33
4.2.4. CONTROLLER MEASUREMENTS 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 fitting 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.

4.2.4.1. CS8C FOR TX AND RS ARMS

Detail: A
Scale: 1:1

Figure 4.1

34 D28062904A - 01/2006
Chapter 4 - Installation

4.2.4.2. CS8C FOR RX160 ARM

Detail: A
Scale: 1:1

Figure 4.2

D28062904A - 01/2006 35
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) can 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 ventilation circuit.
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 area, it is necessary to ensure the accessibility of all the mechanical and
electrical elements (robot, sensors, mechanical assemblies, etc.).

36 D28062904A - 01/2006
Chapter 4 - Installation

4.3. UNPACKING AND HANDLING

4.3.1. PACKAGING FOR THE CS8C CONTROLLER

7
CS8C FOR RX, 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

1 INSTALLING 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.

D28062904A - 01/2006 37
4.4. FIXING THE MCP

4.4.1. CHARACTERISTICS
Protection index: IP54
Note:
The MCP must not be used in explosive atmospheres.
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.

38 D28062904A - 01/2006
Chapter 4 - Installation

Holder measurements:

Figure 4.5

D28062904A - 01/2006 39
4.5. CONNECTIONS

4.5.1. 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 4.6

4.5.2. 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.
This connection includes optical fibres. When the cable is disconnected, during maintenance for example,
cover the ends to avoid soiling the ends of the optical fibre. 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 fibre when it is lit, in
order to avoid damage to the eyes.

40 D28062904A - 01/2006
Chapter 4 - Installation

4.5.3. CONNECTING THE SIGNALS

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

4 3 2 5 7 12 6

11
7
9

8
8

10
Figure 4.7

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: Encoder input

12: CAN output for Scara robots

The signals must be connected using shielded cables whose shielding braids are grounded at the 2 ends.
This is necessary both for the emergency stop signals (J109) and for the digital links (serial links, Ethernet,
etc.).
The system used to hold the controller in place also provides protection from unwanted outside currents. It
is thus useful for the fastenings (8) to be linked to the ground circuit for the cell as a whole.
Note:
For RS robots, inputs / outputs are also available on the arm.

D28062904A - 01/2006 41
4.5.4. 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.
Note:
Grounded metal backshells provide improved protection from unwanted outside currents.
The cables must comply with minimum curve radii for each type of cable. See the table below:

Minimum curve radius in mm

Interconnection cable 100

hand I / O cable 50

MCP cable 50

Other Depending on the cables

used

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

42 D28062904A - 01/2006
Chapter 5 - Integration

CHAPTER 5

INTEGRATION

D28062904A - 01/2006 43
44 D28062904A - 01/2006
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 CHAIN

(see figure 5.1)
The various elements forming the stop chain are as follows:
• The emergency stop (MCPES 1-2) on the MCP.
• An emergency stop (UESA 1-2) to be wired according to the application.
• If switch SW1 is set to position 2, two parallel channels corresponding to the automatic (COMP) and
manual (MANU) modes (figure 5.1).
Each of these channels is 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 operating mode selected.
• A (UESB 1-2) safety stop to be wired depending on the application.
• The safety stop (BRS) triggered by the manual brake command placed at the foot of the robot.
All the contacts making up these various elements of the emergency stop channels are duplicated.
Note:
The emergency stop is not the normal method for stopping the robot or disabling power on
the arm.
Data on the status of the emergency stop sequence (ESOUT1 and ESOUT2) available for the application
may be taken on two levels in the emergency stop sequence, depending on the position of a selector switch
SW1 (figures 5.1 and 5.4).
The information available is:
• Either the status of MCPES and UESA if the selector switch is in position 1.
• Or the status of MCPES, UESA and (USEREN or DOOR), if the selector switch is in position 2.
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 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 operating mode is only possible if selector switch SW1 is in position 1.
Display on the control panel of the application
The status of the stop chains 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).
D28062904A - 01/2006 45
46
24Vfus

MCPES1+ MCPES2- MANU- MODE

MANU+ RSI-J109
SUBD-37M
MCPES1- MCPES2+ A1 10 UESA1+ J109-1
MANU UESA1- J109-20
UESA1+ UESA2- UESA2+ J109-2
Emergency stop channels

B1 9 UESA2- J109-21
USEREN1+ J109-3
UESA1- UESA2+ MANU-
USEREN1- J109-22
COMP-MODE USEREN2+ J109-4
5 7
COMP+ USEREN2- J109-23
5 7 A1 10 ESOUT1+ J109-5
6 8 ESOUT1- J109-24
COMP ESOUT2+ J109-6
USEREN1+ USEREN2- 8 ESOUT2- J109-25
6 B1 9
COMP+ J109-7
DOOR1+ DOOR2- COMP- COMP- J109-26
USEREN1- USEREN2+
MANU+ J109-8
MANU- J109-27
DOOR1- DOOR2+
DOOR1+ J109-9
UESA2+ DOOR1- J109-28

Figure 5.1
ESOUT2+
UESB1+ UESB2- UESB2- 10 DOOR2+ J109-10
DOOR2- J109-29
UESA1- UES2 UESB1+ J109-14
UESB1- UESB2+ UESB1+ UESB1- J109-33
5
4 9 ESOUT2- UESB2+ J109-15
2 1
UESB2- J109-34
BRS
SW1
8 13 ESOUT1+
10
UES1
A1 B1 A1 B1
5
ESR1 ESR2 UES1 UES2 ESOUT1-

B1 A1 B1 A1

24Vfus 24Vfus
0V1

D28062904A - 01/2006
Chapter 5 - Integration

RSI-J109
24V
SUBD-37M

J109-18

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

J109-19 0 VDC

0V1

Internal External
24VDC 24VDC

Figure 5.2

D28062904A - 01/2006 47
48
24V

RSI-J109

LSW+ 5 8 9 SUBD-37M

USERPS1+ J109-12
LSW- USERPS1- J109-31
10 4 13
USERPS2+ J109-13
A1
USERPS2- J109-32
LSW
DF+
B1 J105-12
delayed delayed J105-11
0V1 ESR1 ESR2
DF- J105-10
J105-9.
PS-ON1+ J105-3
Thermo + PS-ON2+ J105-4

Figure 5.3
PS-ON - J105-5

Thermo - Enable
Pow er

PS-ON1+ PS-ON2+ DF+ J112-3

A1
A1 A1 DF- J112-4
SCR
PS1 PS2 Thermo+ J117-1
B1 Thermo - J117-2
A2 A2
Internal J101-12
PS-ON- LSW+
faults
LSW - J101-5

0V1 0V1

D28062904A - 01/2006
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.

SW1

J111

J109

Figure 5.4

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.

D28062904A - 01/2006 49
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 5.5
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

50 D28062904A - 01/2006
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
equipement

Figure 5.6
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

D28062904A - 01/2006 51
Connection point table

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

UESA 1-2 1 UESA1+ Emergency

20 UESA1- Normal operation
Emergency stop stop
2 UESA2+
21 UESA2-

USER EN1-2 3 USEREN1+ Emergency

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

DOOR1-2 9 DOOR1+ Emergency

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

UESB 1-2 14 UESB1+ Emergency

Emergency stop 33 UESB1- stop
Normal operation
15 UESB2+
34 UESB2-

5 ESOUT1+
ESOUT 1-2
Note (1) 24 ESOUT1- Emergency
Emergency stop Normal operation
Note (3) 6 ESOUT2+ stop
channel status
25 ESOUT2-

Automatic Automatic mode

7 COMP+
mode invalid
COMP/MANU 26 COMP-
Note (3)
Operating mode 8 MANU+
Manual mode
27 MANU- Manual mode
invalid

Note (3) 12 USERPS1+

PS1 PS2 31 USERPS1- Arm not Arm powered
Arm power-up 13 USERPS2+ powered
32 USERPS2-

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

35 USER-IN 1 -

52 D28062904A - 01/2006
Chapter 5 - Integration

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

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

30 USER-IN 0 -

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

Note (2): See figure 5.5.
Note (3): Max. 48V AC/DC/ 0.5A.

D28062904A - 01/2006 53
5.2.3. ENCODER INPUT
A encoder input is provided on J305 on the STARC board. The encoder to be used with this input must be
of the incremental type with 5V differential A, B, Z signals. The 5V power supply is provided by the STARC
board; its level of current is limited to 400mA. The connector used on the STARC board is of the female
Sub D 9 point type.

STARC 5V

10k
J305 SUBD-9F
J305-1 Coder-A
cod-x
J305-6 Coder-A*

120
J305-2 Coder-B
External
encoder J305-7 Coder-B*
J305-3 Coder-Z cod-x*
J305-8 Coder-Z*

10k
J305-4 GND 400mA
J305-9 Coder-5V 5V

(F) 5V-Codeur GND

GND

Figure 5.7
Recovery (preset)
The encoder recovery is used to define the zero position of the joint connected to the coder. It is necessary
to begin by configuring the encoder resolution using the cCounts analogue output (in coder points per
rotation, coded on an unsigned 16-bit integer). The resolution is saved by the system (cell.cfx file).
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:
• Stop the encoder at a reference position defined by the application.
• Write the current encoder position in the cPrstPos output (signed 32-bit integer).
• Activate the cEnPrst output.
The current position cCurrPos then takes the value cPrstPos, and the cEnPrst 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.

Position reading
The position reading is taken via the cCurrPos analogue input. It is a signed 32-bit integer. In the event of
an overshoot, the position sign changes, but no error is reported.
The encoder position is updated electronically after each encoder pulse. The access time for the VAL3
software is less than one microsecond.

54 D28062904A - 01/2006
Chapter 5 - Integration

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 cEnLatch digital output.
• On the next rising or falling signal for the fast input fIn0 (see the chapter on fast input outputs), the encoder
position is recorded in the cLatchPos analogue input and the cLatch digital input is activated to show
that the capture has been executed. The cEnLatch 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 cEnLatch output.

Errors
An encoder reading error is signalled by the cHwErr 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
cOvsErr signal is activated. The maximum encoder speed is 7500 rpm.
To reactivate the encoder after an error, it is necessary to reset it using the cRstErr digital output.

D28062904A - 01/2006 55
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 a certain level, the arm stops
immediately. An excessively high temperature on the DSI board or the castings 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.

56 D28062904A - 01/2006
Chapter 5 - Integration

5.2.5. RS ROBOTS
In the case of RS robots, inputs / outputs are provided on the forearm on the CIO board:
• 8 x 24V digital inputs
• 8 x 24V digital outputs
• 4 x ± 10V analogue inputs
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.

The "Control panel" application enables 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.

D28062904A - 01/2006 57
5.2.5.1. 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 can come out of the forearm cover in two different ways:
• 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.
• To one side by drilling a hole (d = diameter of the cable - 0.2 mm) through the packing. In this
case, the dismantling procedure takes longer.
4) Insert the cable through the connection or through the packing and connect it to the terminals on the CIO
board. Fit the connectors on the CIO 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 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.

58 D28062904A - 01/2006
Chapter 5 - Integration

5.2.5.2. CONNECTING THE INPUTS / OUTPUTS NEXT 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).

D28062904A - 01/2006 59
5.2.5.3. 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
14
external source.

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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 analogue ground
4 cAin2
3 cAin1
2 PE analogue 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
• Analogue inputs:
• Input voltage: ± 10 V
• Resolution: 78 mV
• Accuracy: 5 %
• Response time: 6 ms

D28062904A - 01/2006 61
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
DISPLAY UNIT

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

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5.2.5.4. 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 Gray 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 Gray 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, gray 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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5.3. AS-I DIGITAL INPUTS/OUTPUTS (RS ARMS)

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 5.2.5.3). 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.
• Modify if desired 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 application.

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

BIO 16E / 16S board description

RSI BIO
Figure 5.8

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.

D28062904A - 01/2006 65
Characteristics of the BIO Inputs

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

The connector pin layout is given in the "Electric 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 / creepage distance 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 5.9
Note:
The inputs are numbered from 0 to n on each input/output board.

D28062904A - 01/2006 67
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 layout is given in the "Electric 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 (Vsup - 65) < Vdemag < (Vsup - 45)
= 0,5 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 / creepage distance 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 5.10
Note:
The outputs are numbered from 0 to n on each input/output board.

D28062904A - 01/2006 69
 1

1
Figure 5.11

J601
4 3

J602 4
Figure 5.12

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Chapter 5 - Integration

Installation of the BIO option (figures 5.11 and 5.12):

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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5.5. FIELD BUS

5.5.1. CHARACTERISTICS
There are various types of field bus (DeviceNet, Profibus, CANopen, ModBus).
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° angle connector.

5.5.2. 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 analogue 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 analogue 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 analogue 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).

5.5.3. 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-#nom The #nom item has not been created (wrong name,
already used, or insufficient memory).

Write #Carte #Equip. #Canal #Status Writing error on the field bus.

Read #Carte #Equip. #Canal #Status Reading error on the field bus.

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

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

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

InitBoard #Carte #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 #Carte 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 #Carte #Status Problem with the field bus.

Version Identification of the board version, its BIOS and the

playerIO.

D28062904A - 01/2006 73
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.

45 Non-resident dialogue software

Initialize the applicom interface before using it, by entering the applicom (or PCINIT)
order.

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.

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 STATUS DEFINITION

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.

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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5.6. 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 an run time 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.

5.6.1. 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).

5.6.2. OPERATION IN THE CS8C CONTROLLER

PLC cycle
The PLC program in the CS8C has access to all the digital and analogue inputs and outputs in the system.
It can communicate with a VAL3 program via the analogue 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.

D28062904A - 01/2006 77
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.

5.6.3. 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 5.13

• 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 5.14).

D28062904A - 01/2006 79
 Figure 5.14

• 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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5.7. ETHERNET LINK

5.7.1. 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 another device.
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.

5.7.2. 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 5.9.3).
A free client Ftp is supplied on the CS8C CD-ROM.

5.7.3. 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 "Kit Modbus Tcp" option supplies an Applicom tool that provides access to the Modbus Tcp inputs-
outputs in the PC software (using VisualBasic, Delphi, Visual C++, …). The CS8C CD-ROM provides a trial
version of the software.

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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 #nom The #nom item has not been created (wrong name, already used, or
insufficient memory)
Write #Canal #Status Writing error
Read #Canal #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 5.5).

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5.7.4. 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 character terminating the string.
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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5.8. 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)
• The time lapse prior to triggering of an error message (maximum reading time lapse). A zero value
suppresses the time lapse control
• The character terminating the string
• For J201 (COM2), the RS232/RS422 configuration

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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5.9. 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.

5.9.1. CONFIGURATION OF THE CONTROLLER CHARACTERISTICS

The Control panel application gives the various system characteristics.
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
• The date and time
S5.3 • The address and IP mask of each Ethernet port (fixed or from DHCP)
S5.3 • The list of gateways to reach other Ethernet sub-network
• The current user profile and the user profile when the CS8C is started
• The Ethernet socket connection port for the SRS remote maintenance utility

5.9.2. CONFIGURATION OF THE ARM CHARACTERISTICS

The arm characteristics are displayed in the Control Panel, with the "Arm" version that shows:
• The arm type with its mechanical revision, such as TX90-S1.
• The arm tuning revision, 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 menus of the calibration utility.
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 menu of the calibration utility.
S5.3 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 !

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5.9.3. 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.
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.
Profile password for network connections (Ftp and remote
connectionPassword
maintenance).
Writing access to the VAL3 applications and the CS8C configuration
writeAccess (using 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,
readAccess editing without modification, exporting controller data, connection for the
remote maintenance tool).
Writing access to the specific data for the arm (software limits,
armWriteAccess
adjustment offsets, user marks).
recovery Access to the recovery menu for the calibration utility.
Activation of the "On"/"Off" menus for the inputs-outputs in manual and
ioWriteAccess
test modes. Does not prevent use of keys (1), (2) and (3).
123KeysControl Access to programming for keys (1), (2) and (3).
manualMode Access to manual operating mode.
testMode Access to test operating mode (if the testMode option is activated).
localMode Acces to local operating mode.
remoteMode Access to remote operating mode.
monitorSpeed Access to the MCP monitor speed.
Activation of the power button in remote mode (only power cut-off
powerButton remains 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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5.9.4. 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 Internal signal concerning
emergency stop in manual Digital input 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.
validationKey Signal that the speed limit Digital input No wiring
has been overridden in test
mode (see chapter 6.6.3)

DANGER:
Current standards require that the speed limit must be overridden from
outside the cell. 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 6.6.4)

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] Analogue input
remoteMoveHold Replacement of the Move/Hold Digital input
button

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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 F3
estopMCP Emergency stop signal from the MCP
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
Caution:
The USER EN signal is not valid in local or Digital output
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 or test
mode. Its state is then not updated.
brakeSelect Signal from the joint selector at the base of the arm
brakeRelease Signal requesting release of the brakes at the base
of the arm
deadman Status of the MCP validation button
park Signal concerning detection of the MCP on its
holder
power Arm power status
fastSpeed Speed limit status in test mode
dummyPlug Signal that the MCP is replaced with a shorting plug
temperature Temperature (°C) measured on the RSI board Analogue 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 validation 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 activation button (1/2)
remoteDeadman2 Signal from the activation 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 Analogue input
RX 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

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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
Operating mode selector button (1)
This pushbutton enables you to select one of the 4 operating modes (test mode, manual mode, local mode
and remote mode). The mode selected is displayed around the button opposite the operating mode icons.
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 or test 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 5.9.3).
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 prargraphs 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 6.2.3.

Enable button (11).

This is used in manual mode or in test 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 5.9.3).
Run key
This key enables you to start an application.
Move / Hold key

• In manual or test mode, the arm movements are allowed when the Move / Hold key is pressed. The arm
stops immediately on the progammed 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 5.9.3).

In manual, test 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. INFORMATON 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 5.9.3).
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 5.9.3).

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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).
• Arm movement speed indicator (5). It is applicable to all the movements (manual and programmed).
• Maximum test mode speed indicator (6).
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 working 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:

Press button (1) as many times as necessary to select "manual mode".
(see paragraph 6.2.1)
Press button (3) to switch the arm power on. This action is taken into account if the validation button (2) has
been put into its medium 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 validation button was pushed 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 validation button is released, if the MCP is removed from its holder, or if button
(1) is pressed.

3
2 1

Figure 6.7

D28062904A - 01/2006 103

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, 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 and to comply with the specifications of standard EN 775, 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 in manual and test 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

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, coder) 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 resetting
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 (coder).
• The "zero" resetting offsets
These offsets are stored in the DSI board for the arm. A backup is saved in the arm.cfx file of the controller,
a copy of which is supplied on a floppy disk with each arm.
During start-up, if the zero offsets on the DSI board are different from those in the arm.cfx file (replacement
of the arm linked to the controller, replacement of the DSI board), it is necessary to state which offsets are
correct; this is the recovery operation.
The DSI board also stores a phase offset for each coder-motor pairing. 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 the motor
phase offsets on the DSI board are different from those in the arm.cfx file, it is necessary to state which
offsets are correct, via the recovery operation.

6.5.2. RECOVERY PROCEDURE

The calibration 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 the DSI
board for the arm and the 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.

CAUTION:
The arm.cfx file contains other specific data for the arm (modified mechanical stops,
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).

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• If you have replaced the DSI board for the arm, the recovery menu can be used to reprogram it using the
"zero" and motor phase offsets for the arm.
• If you have replaced a motor or a coder, the maintenance procedure to be followed should normally have
updated the offsets on the DSI board 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 for the arm or the controller, the problem may be due to a faulty DSI
board (data loss) or a corrupt arm.cf file on the controller. Check the contents of the arm.cf 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 must
stem from the DSI board, which can be reprogrammed using the recovery menu.

CAUTION:
The motor phase offsets for the DSI board are critical, and they can make a motor
uncontrollable. Never update a DSI board 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.
Operating mode
• 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 joint has been reset, you will be invited to save the new adjustment offsets for the arm on a
diskette.
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. OPERATING MODE

Each time the operating mode button is pressed, the mode changes in a cyclical way (see
paragraph 6.2.1).

Local mode Remote mode Manual mode Test mode

The operating modes authorized depend on the user profile (see chapter 5.9.3). If a plug connector is
inserted instead of the MCP, the remote mode is imposed.

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.
The operator can only intervene to stop or restart the movement and adjust the speed of
execution using the "+/-" key.

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6.6.3. TEST MODE ("TESTMODE" MODE ONLY)
The test mode is similar to the manual mode. Furthermore, it enables the robot to be moved at full speed
while the operator is present in the cell.

DANGER:
This mode is reserved for persons authorized to carry out adjustments on the
robot cell, who have undergone successful training in handling STÄUBLI robots
and who are thoroughly familiar with the production cell and its dangers.
Take all necessary precautions to avoid accidents.

The maximum speed is displayed in the status bar.

The validationKey system signal must be configured beforehand to enable it to be linked to a digital input
(see chapter 5.9.4).
To increase the speed, it is necessary to:
• Switch the arm power supply on.
• Validate the switchover to test mode by turning on the validationKey signal for 200ms.
• Set the monitor speed to 100% using the "+ / -" speed keys.
• Each time the "+" is pressed, the maximum speed is then increased.
This procedure has to be carried out each time the power is switched off.

DANGER:
Standard EN 775 requires staying in test mode for one cycle only. The integrator
is responsible for compliance with this standard, for example by removing
power on the arm via a VAL3 instruction at the end of the cycle, when the robot
is in test mode.

6.6.4. 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 5.9.3).
The enablePower system signal must be configured beforehand to enable it to be linked to a digital input
(see chapter 5.9).
• 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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Chapter 6 - Operation

6.7. JOG INTERFACE

6.7.1. MANUAL MODE

3
2
1

4
Figure 6.8

• To select manual mode, press the operating mode selection button (1). The indicator light corresponding
to the mode selected comes on.

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

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)

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.
• 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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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.

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 figure 6.12 - )
• 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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Chapter 6 - Operation

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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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).

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.
• Apro (Approach) key
This key calls up a window in which it is possible to configure the approach parameters along X, Y and Z.
In this window, the Tog (toggle) menu enables you to switch the approach from active to inactive status
and vice versa.

1 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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Chapter 6 - Operation

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:

• Select the local mode using the operating mode selection button. The indicator light corresponding to the
mode selected comes on.

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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6.8.2. STARTING UP IN MANUAL MODE OR TEST MODE
Once the application has been opened: (see paragraph 6.10.1)
• Select the manual mode or the test mode using the operating mode selection button. The indicator light
corresponding to the mode selected comes on.

Manual mode icon

Test mode icon

• Keep the validaiton 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)
• Select the remote mode using the operating mode selection button. The indicator light corresponding to
the mode selected comes on.

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 or test 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 5.9.3).

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, Manuel and Test 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 operating mode selected (see paragraph 6.3).
Note:
The arm power can be switched off via the MCP in all the operating 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 5.9.3).
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, diskette).
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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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 pull-down 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

Modification keys
• 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(" erreur ")
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 # get()
endwhile and 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 or "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 Inut/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
using the "Run" key, the robot does "Move / Hold" key.
not 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 The information shown for a VAL3 program can
shown on the display unit. only 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.

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 EVENT DIAGNOSIS

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).

Nothing happens when you press the The operating modes are locked (dashes shown
operating mode selection button. in the status bar).
• The operating modes are unlocked by changing
the user profile.

Impossible to calibrate the robot • Check the USBI board display in the controller.
• See the list of system events (see paragraph
8.6).
• Restart the controller and if the problem persists,
contact the maintenance department.

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 There must be a task still being debugged.

using the "Stop" key, the "Run" • Exit the debugging program, and then kill the
indicator light stays on. task in the task manager.

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

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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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6.12. TEACHING POINTS

Teaching pionts, 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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Chapter 7 - PC utilities

CHAPTER 7

PC UTILITIES

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130 D28062904A - 01/2006
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 password 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.
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 5.6
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:
• Operating 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 5.6 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 5.9.3).
• Go to the USR reader using the cd /usr command and then carry out the desired actions.
Note:
The free customer "Ftp surfer"Ftp is supplied with the CS8C 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 adress is in the controller node (see chapter 5.7).

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 (IP address, FTP connection, etc).
• "controller.cf" contains the controller configuration.
• "ep.cf" contains the configuration linked to the (autostart, autoload) applications.
• bio.cfx, bio2.cfx, sio.cfx, can.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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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 SRS 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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136 D28062904A - 01/2006
Chapter 8 - Maintenance

8.1. COMPONENT LAYOUT

The CS8C controller consists of a computer (5), the intelligent part of the installation, which controls the
robot through digital power amplifiers (1) dedicated to each arm axis.
The electrical power is converted by the PSM (6) power block, 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 3 4 5

Figure 8.1

D28062904A - 01/2006 137

8.2. 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 operations 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

8.3. PROCESSING UNIT

The processing unit carries out the application program governing arm control, input/output management,
etc

8.3.1. DESCRIPTION
Main components:
• A CPU board (1) on which a Flash Disk (2) is fitted to store the VAL3 system and the application
programs. The front of the board houses Ethernet (5), USB (3) and serial (4) connections.
The USB "User" ports (J202 and J209) can be used for keys supporting the following protocols:
• #1: Reduce Block Commands (RBC) T10 Project 1240-D.
• #4: UFI.
• #6: SCSI transparent command set.
• A STARC board (6) providing an interface with the variable speed drives in the CS8C and the DSI boards
at the base of the arm, via digital communication. An encoder input (J305) is also available.
• Free spaces (7) for options in PCI format supplied by Stäubli.

2 7

3 4 8 5 6 7
Figure 8.2

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8.3.2. MAINTENANCE
CPU board activity is shown:
• By a beeping tone that sounds about 15 s after powering up (EM02 version only).
• By indicator lights (8) showing activity concerning Ethernet communication.
The STARC board (6) has indicator lights on the front:

o (A) Drive bus Slow : init. Fast : OK

o (B) DSI bus Slow : init. Fast : OK
o (C) DSP1 On: OK
o (D) FPGA prog On: OK.
o (E) Reset OK On: OK.
o (F) 5 Vcodeur On: OK

J305

Figure 8.3

The normal operating status is:

• Led A: Fast flashing (period ~ 0,5 s). STARC - variable speed drive communication.
• Led B: Fast flashing (period ~ 0,5 s). STARC – DSI communication.
• Led C: ON. Correct board programming.
• Led D: ON. Correct board programming.
• Led E: ON. Internal power supply OK.
• Led F: ON. 5V power supply for the external encoder.

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Chapter 8 - Maintenance

8.3.3. REMOVAL
To remove a board or a component

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

(see figure 8.4 - 8.5 - 8.6)

• Set aside the computer after removing the 6 fixing screws (1).
• Remove the 6 screws (2) and open the computer.
• The boards can be removed after taking out the fastening screw (3) for the PCI boards, and after taking
out the 4 fastening screws and the front spacers for the CPU board.

1 1
Figure 8.4

2
Figure 8.5

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Access to the Flash Disk memory
The Flash Disk memory (2) is mounted on a support board (1).

1 2 5

6 6

Figure 8.6

To access the Flash Disk (2):

Extract the CPU board (5) after removing the PCI boards (see chapter 8.3 page 141).
Extract the Flash Disk (2) and its support (1).

2 1

Figure 8.7

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Chapter 8 - Maintenance

3
4

2 5
2 6
1

8 9 10 11

12

3 4

Figure 8.8

D28062904A - 01/2006 143

8.4. POWER

8.4.1. RPS 325 POWER SUPPLY

The RPS325 power supply generates the DC voltage required for the amplifiers from a three-phase AC
voltage. If the motor speed has to be reduced, the power supply is able to absorb the surplus motor power
using a regeneration resistor.
The power supply also generates a signal for the RSI board: power supply status (PWR-OK).

8.4.2. MAINTENANCE
There are 2 indicator lights on the front panel of the power supply:
• When the (3) "ON" indicator light is on, it means that the power supply is working.This happens when
power is applied to the arm. The indicator lamp comes on when the supply voltage output is between 260
and 430 VDC.

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

• The "REGEN" indicator light (4) which comes on to show that the system is in energy dump mode
(deceleration of the robot under load).
Note:
Depending on the robot type, the RPS is operating either single-phase or in three phase.
When operating in three-phase, the loss of one phase (burned fuse, wire disconnected, ...)
is detected or not depending on the robot type, the robot speed, the payload. This has to
be taken into account for maintenance. The effect of one phase loss can be an "envelope
error", or a slower cycle time.
If detected, the "PWR_OK" signal will be affected.

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8.4.2.1. REMOVAL

DANGER:
Heat sinks and power components may be hot, especially in the event of a
ventilation failure.

Case of a CS8C for TX or RS

• Set aside the ARPS power supply (see chapter 8.4.3).
• 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).
• Take out the RPS325 power supply, unplugging the J1001 (7), J1004 (9), J1005 (8), J1003 (10) and
J1002 (11) connectors one after the other.
In the event of replacement of the RPS 325 power supply, make sure the wire (12) is correctly placed, in
the same location as for the original power supply.

Figure 8.9

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Case of a CS8C for RX160

5 4 3

Figure 8.10

• To access the connectors, remove the ARPS (3) power supply wires held in place by 4 screws (4) (see
chapter 8.4.2) and the metal plate (5) holding the socket and kept in place by 4 screws (6).
• Disconnect the connectors J1001 (1), J1002 (2), J1003 (3), J1004 (4), J1005 (5),.

5
4
3
2
1

Figure 8.11

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Chapter 8 - Maintenance

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

Figure 8.12
• Remove the 8 screws (2) holding the PSM (6) power module in place.

3
4
7

2
6
Figure 8.13

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 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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 (1)
(2)
(3)
(4)
(5)

ON
13V
24V1
24V2
24V3

Figure 8.14

5
4
3
2

Figure 8.15

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8.4.3. ARPS POWER SUPPLY

8.4.3.1. DESCRIPTION
The ARPS power supply generates the DC voltage for the logic components of the computer:
• 24 VDC (24V1) voltage for the computer, RSI board, and amplifiers,
• 24 VDC (24V3) voltage for the computer fan,
• 24 VDC (24V2) voltage for the brakes. This voltage is present when a control signal (BRK_REL_EN) for
the RSI board is on.
• 13 VDC (13V) voltage for the DSI boards located in the base of the arm.

The ARPS power supply also generates control signals for the RSI board: status of the power ("ALIM_OK"
signal), presence of mains voltage ("SECTEUR_OK" signal).

8.4.3.2. MAINTENANCE
The power supply is operational if the master switch is in position 1 and if the circuit breaker (3) is in position
1 with its indicator lamp on (see figure 4.6). In this case, LEDs 1, 2, 3 and 5 should be on.
LED 4 will only be on when the brakes are released. This is the case when the arm power is on or when the
manual release of the brakes is engaged.
In the event of a short circuit on one of the outputs, the power supply automatically limits the output current
and the display LEDs go off:
• A short-circuit on one of the 24 V outputs has the immediate effect of inhibiting all the 24 V outputs and
then the 13 V outputs after approximately 500 ms.
• A short-circuit on the 13 V output has the immediate effect of inhibiting all the outputs.
The corresponding LEDs are then off and only LED 1 remains on. When the short circuit has been
eliminated, the power supply returns to normal operation.

24V1 24V2 24V3 13V

Nominal values 25 - 26V 25 - 26V 25 - 26V 13 - 13.5V

If LED 1 is off, make sure that the master switch is in position 1 and that the circuit breaker (3) is in position
1 (figures 4.6 and 8.14). Make sure that the power supply input is 230 VAC voltage. If all these conditions
are fulfilled, the power supply is down.
If the power supply is in fault status ("ALIM_OK" signal = OFF) or if the mains input voltage is less than
200 VAC ("SECTEUR_OK" signal = OFF), the robot is stopped and the computer is switched off.
8.4.3.3. REMOVAL
To extract the ARPS power supply:
• Remove the 4 screws (1) holding the ARPS power supply.
• Pull and switch over to the ARPS power supply.
• Disconnect connectors J1101 (2), J1102 (3), J1103 (4) and J1104 (5).

D28062904A - 01/2006 149

 3 1 2 3
Figure 8.16

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8.4.4. AMPLIFIERS
8.4.4.1. DESCRIPTION
Each amplifier is dedicated to 2 joints and depends on the type of motor controlled and the desired
characteristics. This means that it is possible for two amplifiers to be identical from the mechanical point of
view without being interchangeable.

CAUTION:
The interchangeability of the amplifier boards depends not only on their geometrical
measurements, but also on the references marked on the boards at location (1).

The configuration of an amplifier for a given axis is shown by the reference marked on the amplifier. It takes
the form of both a hardware configuration and a software configuration.
The amplifiers receive their voltage from the RPS325 supply for the high voltage portion and from the ARPS
supply for the logic portion.
The amplifiers are controlled from the STARC board.
Hardware configuration
Each amplifier is made up of 3 electronic boards:
• The DIG (2) board dedicated to the digital section,
• The PWR (3) boards dedicated to the power portion.

Software configuration
The software configuration is controlled on start-up by the controller. The parameters are updated
automatically (after replacement of a amplifier or swapping of amplifiers).

8.4.4.2. MAINTENANCE
There are 2 sources of amplifier operational checks: the information given by the computer and the indicator
lights on the boards.

CAUTION:
All work on the controller must be carried out solely by qualified staff; the installation
must be switched off beforehand.

An amplifier fault can be shown in 2 ways:

• By opening of a relay contact (DRIVE_FAULT) that acts on RSI board (removing power on the arm, and
applying the brakes).
• By an error message sent to the computer by the amplifiers.
The main errors detected are:
• "OverVoltage" if the voltage supplied by RPS is too high.
• "IPM fault" in the event of a short-circuit, an overcurrent or too high a temperature in the amplifiers.
• "Thermal sensor fault" if the temperature of the cooling fins is too high.

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 2

13

Figure 8.17

6
7

Figure 8.18

10

14

11

9 9

12 10
Figure 8.19

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Chapter 8 - Maintenance

8.4.4.3. REMOVAL
Extracting an amplifier:

DANGER:
The cover (2), the regeneration resistor (13) and the amplifier heat sinks (5) may
be hot, especially in the event of a ventilation failure.

• Remove the rear cover (2) after taking out the 6 fastening screws (1) and removing the connectors from
(3).
Note:
If the CS8C is fitted in a cabinet with rear access, it may be useful to be able to remove the
rear cover without having to extract the CS8C from the frame. To do so, either use a
suitable tool (offset ratchet screwdriver) or replace the 2 existing side screws with CHC
type M4 x 12 screws that can be removed using an offset spanner.
• Set aside the amplifier (5) after removing the 6 fixing screws (4).
• Disconnect the cables plugged into the fan:
• Power current supply (10),
• Motor power supply (9),
• Logic power supply (11),
• Control signals (12).
To insert an amplifier:
• Plug in the connectors, complying with the order given on the back plate (8). The motor connectors are
marked J801 for joint 1, J802 for joint 2, and so on. The routing for the cables in the harness (14) must
be separated from that used for the motor and power cables.
• Put the amplifier into its slot using the stand offs (6) and side positioning holes (7).
• Tighten the 6 cover screws (4).
• Add the rear cover (2).

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 5

1 98 7 6
Figure 8.20

98 7 6
Figure 8.21

1 9 8 7 6
Figure 8.22

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Chapter 8 - Maintenance

D1

ARPS
AC

DC
D2

RPS
DC
AC
PS1-PS2
F1-F3
S1

PSM
Filter

Figure 8.23

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8.4.5. POWER MODULE (PSM)
8.4.5.1. DESCRIPTION
This assembly, made up of a transformer (2) and related protection devices, is located in the bottom of the
controller.
Depending on the type of controller, the connections are made either in single phase or in three-phase
configuration, with or without a transformer. The input fuses (7) are size 10,3 x 38 mm / 500 V.

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 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.

In the case of a multi-voltage three-phase transformer, the voltage is selected on the terminal strip (1) of the
transformer (figures 8.20 and 8.22).

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

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

The 230VAC outputs from the transformer are protected by single phase circuit breakers (9) and three-
phase circuit breakers (8).
The three-phase circuit breaker (8) supplies the power part of the controller via contactors (5) and the
RPS325 power supply. The single-phase circuit breaker (9) supplies the logic parts of the controller via the
ARPS power supply.

8.4.5.2. MAINTENANCE
The presence of power at the circuit breakers D1 and D2 is shown by the indicator lights fitted on them. If
an indicator light is off, it means either that the circuit breaker is open, or that there is no power supply:
Master switch (6) set to off, fuses (7) cut off.
If D1 is closed and its indicator light is on, the ARPS power supply must be on.
If D2 is closed and its indicator light is on, the RPS power supply can be switched on by closing the
contactors (5).

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Chapter 8 - Maintenance

8.4.5.3. REMOVAL
To access the components of the PSM, remove the screws (1) and pull it forward.

CS8C TX/RS CS8C RX160

3 3
2
2

1
Figure 8.24 Figure 8.25

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

D28062904A - 01/2006 157

 J110
A

J100

SW1
J111
J109

J104
J112

J101 F2 - F5 - F6 J105

Figure 8.26

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Chapter 8 - Maintenance

8.5. RSI BOARD

8.5.1. DESCRIPTION
The RSI board includes all the elements required to power-up the arm and for arm emergency stop under
good electrical safety conditions. It is equipped with redundant safety relays. It can also include up to 32
digital inputs and 32 digital outputs ("BIO" options).

The RSI board is connected:

• to its 24V (ARPS) power supply by J104. This link is also used to deal with controlling the power supply
to the brakes from ARPS,
• to the STARC board by J100 for dealing with safety and Inputs/outputs,
• to the amplifiers on J112 to provide their 24V power supply and recover their fault signal,
• to the control of the power contactors by J105,
• to the arm on J101 (solenoids, limit switch, manual brake control). The solenoid outputs are protected by
0.5 A microfuses (F5, F6).

On the front panel of this board, the following are available::

• The connection with the MCP on J110,
• The connection with the cell for connecting the emergency stop signals on J109,
• Fast inputs / outputs on J111.

The RSI board provides continuity for the emergency stop circuits by linking the various emergency stop
contacts together; their status is shown on the display unit (A).
There are two redundant emergency stop channels supplied "in opposition" (one channel supplied between
+24V and 0V and the other between 0V and +24V) in order to be able to detect a short circuit between these
2 channels: if a short circuit occurs, fuse F2 (250mA microfuse) will blow and an emergency stop procedure
will be activated.
The coherence of the emergency stop signals is ensured by a redundant relay setup and is also controlled
by the CPU board. When an emergency stop is triggered, if only one of the contacts opens, the fault is
detected by the CPU board (see the list of error messages that can be displayed). In this case, the origin of
the fault must be found and the fault corrected. There are 3 types of help for finding the origin of the fault:
• The messages displayed on the MCP,
• The display (A) on the RSI board,
• The Inputs/Outputs displayed on the control panel.

When the request is made to put the arm under power, if one or both of the contacts of an emergency stop
remain open, it is not possible to turn on arm power.

D28062904A - 01/2006 159

160
24Vfus

MCPES1+ MCPES2- MANU- MODE

MANU+ RSI-J109
SUBD-37M
MCPES1- MCPES2+ A1 10 UESA1+ J109-1
MANU UESA1- J109-20
UESA1+ UESA2- UESA2+ J109-2
Emergency stop channels

B1 9 UESA2- J109-21
USEREN1+ J109-3
UESA1- UESA2+ MANU-
USEREN1- J109-22
COMP-MODE USEREN2+ J109-4
5 7
COMP+ USEREN2- J109-23
5 7 A1 10 ESOUT1+ J109-5
6 8 ESOUT1- J109-24
COMP ESOUT2+ J109-6
USEREN1+ USEREN2- 8 ESOUT2- J109-25
6 B1 9
COMP+ J109-7
DOOR1+ DOOR2- COMP- COMP- J109-26
USEREN1- USEREN2+
MANU+ J109-8
MANU- J109-27
DOOR1- DOOR2+
DOOR1+ J109-9
UESA2+ DOOR1- J109-28
ESOUT2+

Figure 8.27
UESB1+ UESB2- UESB2- 10 DOOR2+ J109-10
DOOR2- J109-29
UESA1- UES2 UESB1+ J109-14
UESB1- UESB2+ UESB1+ UESB1- J109-33
5
4 9 ESOUT2- UESB2+ J109-15
2 1
UESB2- J109-34
BRS
SW1
8 13 ESOUT1+
10
UES1
A1 B1 A1 B1
5
ESR1 ESR2 UES1 UES2 ESOUT1-

B1 A1 B1 A1

24Vfus 24Vfus
0V1

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Chapter 8 - Maintenance

RSI-J109
24V
SUBD-37M

J109-18

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

J109-19 0 VDC

0V1

Internal External
24VDC 24VDC

Figure 8.28

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162
24V

RSI-J109

LSW+ 5 8 9 SUBD-37M

USERPS1+ J109-12
LSW- USERPS1- J109-31
10 4 13
USERPS2+ J109-13
A1
USERPS2- J109-32
LSW
DF+
B1 J105-12
delayed delayed J105-11
0V1 ESR1 ESR2
DF- J105-10
J105-9.
PS-ON1+ J105-3
Thermo + PS-ON2+ J105-4

Figure 8.29
PS-ON - J105-5

Thermo - Enable
Pow er

PS-ON1+ PS-ON2+ DF+ J112-3

A1
A1 A1 DF- J112-4
SCR
PS1 PS2 Thermo+ J117-1
B1 Thermo - J117-2
A2 A2
Internal J101-12
PS-ON- LSW+
faults
LSW - J101-5

0V1 0V1

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Chapter 8 - Maintenance

Elements making up the emergency stop

The various elements forming the stop chain are as follows:
• The emergency stop (MCPES 1-2) on the MCP.
• An emergency stop (UESA 1-2) to be wired according to the application.
• If switch SW1 is set to position 2, two parallel channels corresponding to the automatic (COMP) and
manual (MANU) modes (figure 8.27).
Each of these channels is 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 operating mode selected.
• A (UESB 1-2) safety stop to be wired depending on the application.
• The safety stop (BRS) triggered by the manual brake command placed at the foot of the robot.
All the contacts making up these various elements of the emergency stop channels are duplicated.
Note:
The emergency stop is not the normal method for stopping the robot or disabling power on
the arm.
Data on the status of the emergency stop sequence (ESOUT1 and ESOUT2) available for the application
may be taken on two levels in the emergency stop sequence, depending on the position of a selector switch
SW1 (figures 8.26 and 8.27).
The information available is:
• Either the status of MCPES and UESA if the selector switch is in position 1.
• Or the status of MCPES, UESA and (USEREN or DOOR), if the selector switch is in position 2.
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 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 operating mode is only possible if selector switch SW1 is in position 1.
Display on the control panel of the application
The status of the stop chains 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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8.5.2. MAINTENANCE
The board status is shown by indicator lights and a display unit.
Meaning of indicator lights and test points

ARPS

J1102- 12 J1102- 4

J401- 6 J401- 1
0V1 24V1 RSI
J112- 1

J112- 2
Drives

External 24V F6
J101- 1 EV1+
J109 F2
D100

0V1 J101- 9 EV1-

0V1 Relays
24V
D45 F5
P5
0V1 Valves J101- 2 EV2+
P3

D99

0V1 J101- 10 EV2-

0V1
5V - SAUVE
D118
P5 P16

0V1
5V Logic
D46
P5 P4

0V - RSI 5V - RSI
D2
P2 P1

J100- 11 J100- 9 J100- 8

J302- 11 J302- 9 J302- 8

STARC

Figure 8.30

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Chapter 8 - Maintenance

SW1 D2

D45
D46
D118
D100
D99 F2
F6
F5

Figure 8.31

If D45 is off, the board is not powered up. The origin of the fault may lie in a short-circuit on the RSI board
or a problem with the 24V1 power supply of the ARPS.
If the RSI board is correctly powered up (D45 = ON) and the STARC board is in operating status, D46 and
D118 must be ON. If D118 is ON and D46 is OFF, the problem lies in the STARC board or the STARC_RSI
cable.
The D99 and D100 indicator lights show that the solenoid valves located in the robot arm are powered up
(6 axis robots only). If these indicator lights stay off when the corresponding outputs are activated, check
the state of fuses F5 and F6. If fuses F5 and F6 have blown, there may be a fault in the solenoid valve or
the cable between the RSI board and the arm.

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Display of the board status on the 7 segment display unit:
The 7-segment display unit is used to show the controller status or the current fault. Most of the faults shown
on the display unit are also detected by the controller software, and so they are displayed more clearly and
in greater detail in the events history, or in the controller status as displayed on the control panel.

Point on the left

Figure 8.32
• Status in normal mode (left point flashing quickly):

DISPLAY
STATUS
APPEARANCE

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

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

(2) Watch Dog open: Computer failure

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

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
(4)
information on the fault. The control panel can also be used to display the
status of the various variable speed drives

ShortR-EN command not activated: The safety management task is not

operational (computer). This error is displayed if the software has detected a
(5) blocking fault on start-up. The controller thus has no operating mode, and the
events history provides details on the fault detected (invalid arm
configuration, etc.)

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

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

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

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

(A) User emergency stop A1 activated: Contact UESA1, J109, 1-20

(a) User emergency stop A2 activated: Contact UESA2, J109, 2-21

(b) User emergency stop UEN1/DOOR1 activated: Contact USEREN1/DOOR1,

J109, 3-22/9-28

User emergency stop UEN2/DOOR2 activated: Contact USEREN2/DOOR2,

(C)
J109, 4-23/10-29

(c) User emergency stop B1 activated: Contact UESB1, J109, 14-33

(d) User emergency stop B2 activated: Contact UESB2, J109, 15-34

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

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Chapter 8 - Maintenance

DISPLAY
STATUS
APPEARANCE

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

(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

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

(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

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

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

(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

(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

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

(t) Braking command not activated by the computer

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

• Status in normal mode (display and left point flashing slowly):

DISPLAY
STATUS
APPEARANCE

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

(E) Waiting for synchronization between the STARC and RSI boards

(r) Waiting for synchronization between the STARC board and the computer

D28062904A - 01/2006 167

• Status at the time of switching on controller power.
The display unit goes through the following statuses:

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 Waiting for the "Safety" task to start

flashing

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

If "i" is not displayed, this means that there is an "abnormal status" (presence of an emergency stop, MCP
not in place on its holder, etc.).
When the request to switch power on is made, the display unit can show:

DISPLAY APPEARANCE STATUS

+ left point flashing Transitional state waiting for brakes to be applied
No display, point flashing fast Sequence switching power on for arm completed
If this is not the case, there is a fault.

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Chapter 8 - Maintenance

8.5.3. REMOVAL
• Remove the 4 screws (1).
• Pull and swivel the RSI (2) board forward.

1
2
Figure 8.33
• Remove the connectors J100, J101, J104, J105, J112, J117 to enable complete removal of the board.

J100

J117

J104
J112

J105

J101

1
Figure 8.34

D28062904A - 01/2006 169

8.6. LIST OF SYSTEM EVENTS

ERROR ANOMALY

STX … Anomaly in communication with the amplifiers

BRAKE-… Anomaly in the brake board signals

MCP-… Anomaly in communication with the manual control pendant

DRIVE-… Anomaly signalled by an amplifier

SAFETY-… Anomaly in the emergency stop channel

POWER-… Anomaly in the powering signals

ROBOT-… Anomaly in the status machines and in the controller software

MOTION-… Anomaly in movement control

FIELDBUS-… Anomaly in the field bus (see chapter 5.5)

MODBUS-… Anomaly in the Modbus ethernet communication (see chapter 5.7)

INTERFACE-… Anomaly in the CS8C software utilities

STARC-… Anomaly reported by the Starc board

SERVO-… Anomaly reported by the software controlling the amplifiers on the

Starc board

SENSOR-… Anomaly reported by the DSI board located in the arm

RSI-… Anomaly on the RSI board

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Chapter 8 - Maintenance

8.7. VENTILATION

8.7.1. DESCRIPTION
The CS8C has 2 airflow path:
• An airflow path for the regeneration resistor and the amplifier radiators (1). This airflow can be directed
upwards or downwards by turning the fans the opposite way round.
• An airflow path (4) for internal components. The inlet is via (2), and the outlet is either at the top (3) or at
the bottom, except for the CS8C controller for RX160.
There are internal fans on the computer and close to the RPS power supply.

8.7.2. MAINTENANCE
In the event of ventilation problems, overheating is detected:
• By the amplifiers that detect the temperature of their radiator and cut off the power supply to the arm. This
type of overheating can be due to the surrounding temperature or incorrect operation of the fans.
• By the RSI board. The temperature of the RSI board can be displayed by the application and by a reading
in the "System Inputs".
• By the ARPS power supply. In this case, the power supply switches to fault status and cuts off the 24 V
and 13 V outputs.

4 3 4

4
1
4

Figure 8.35

D28062904A - 01/2006 171

 6

Figure 8.36

4 3

Figure 8.37

Figure 8.38

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Chapter 8 - Maintenance

8.7.3. REMOVAL
8.7.3.1. EXTERNAL VENTILATION

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).

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8.7.3.2. INTERNAL VENTILATION
The fans (1) are accessed by removing the screws (2) holding the grille and the air filter in place.
The fan (3) for the RPS power supply can be accessed by removing the amplifier for joints 3-6
(see chapter 8.4.4).
To remove it, take out the 2 screws (4).

Figure 8.39

(Axis 3-6)

Figure 8.40

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Chapter 8 - Maintenance

8.8. 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.

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

8.8.2. 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.
• Variable control system: 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 currents on the primary circuit depend 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 = 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
--------- × -------------- + 2ρl
Us Ucc% --------
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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