Staubli CS8C User manual

CS8C Controller
Instruction manual
D28070504A – 26/03/2009
CS8C
© Stäubli 2009

© Stäubli 2009 – D28070504A CS8C2 / 248
Documentation addenda and errata can be found in the "readme.pdf" document delivered with the
controller's CdRom.

CS8C © Stäubli 2009 – D28070504A 3/ 248
TABLE OF CONTENTS
1INTRODUCTION
1.1 FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 DEFINITION OF THE ELEMENTS AROUND THE ROBOT CELL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2DESCRIPTION OF THE CONTROLLER
2.1 IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 LOCATION AND DESCRIPTION OF THE MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3SAFETY
3.1 REMINDER CONCERNING THE SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 SAFETY DIRECTIVES CONCERNING TO THE WORK ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . 25
3.3 SAFETY DIRECTIVES CONCERNING TO STAFF PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4 SAFETY DIRECTIVES CONCERNING TO PROTECTION OF THE EQUIPMENT . . . . . . . . . . . . . . . . 28
4INSTALLATION
4.1 ROBOTIZED CELL ENVIRONMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2 ON-SITE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3 UNPACKING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.4 FIXING THE MCP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.5 FIXING THE WMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.6 CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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5INTEGRATION
5.1 EMERGENCY AND SAFETY STOP CHANNELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2 BASIC INPUTS/OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.3 RS ROBOTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.4 AS-I DIGITAL INPUTS/OUTPUTS (RS ARMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.5 DIGITAL BIO INPUT/OUTPUT BOARD (OPTIONAL EXTRA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.6 FIELD BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.7 PROGRAMMABLE LOGIC CONTROLLER (PLC OPTION). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.8 ETHERNET LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.9 SERIAL PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.10 SOFTWARE CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6OPERATION
6.1 POWERING UP THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.2 PRESENTATION OF THE MCP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.3 ARM POWER-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.4 EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6.5 CALIBRATION, ADJUSTMENT, RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.6 WORKING MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6.7 JOG INTERFACE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6.8 STARTING AN APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
6.9 STOPPING MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.10 VAL3 APPLICATION MANAGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
6.11 TEACHING FRAMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
6.12 TEACHING POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
6.13 MOTION DESCRIPTOR EDITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.14 CONTROLLER BACKUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

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7PCUTILITIES
7.1 STÄUBLI ROBOTICS STUDIO (SRS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.2 FTP ACCESS FROM A PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.3 FTP ACCESS TO A PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
8MAINTENANCE
8.1 HOW TO USE THIS MANUAL ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
8.2 GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
8.3 COMPONENT LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8.4 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8.5 INPUT VOLTAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
8.6 ARPS AUXILIARY ROBOT POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
8.7 RPS POWER SUPPLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
8.8 RSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
8.9 STARC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
8.10 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
APPENDIX: PROTECTION OF THE POWER LINE FOR THE CS8C
CONTROLLER
8.11 CONTROLLER CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
8.12 PROTECTION UPSTREAM FROM THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

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Chapter 1 - Introduction
CHAPTER 1
INTRODUCTION

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Chapter 1 - Introduction
1.1. FOREWORD
The information contained in the present document is the property of STÄUBLI and it cannot be reproduced, in
full or in part, without our prior written approval.
The specifications contained in the present document can be modified without notice. Although all necessary
precautions have been taken to ensure that the information contained in this document is correct, STÄUBLI
cannot be held responsible for any errors or omissions found in the illustrations, drawings and specifications
contained in the said document.
If any difficulties are met with during operation or servicing of the robot that are not referred to in this document,
or if further information is required, please contact the STÄUBLI After Sales Department, "Robot Division".
STÄUBLI, UNIMATION, VAL
are brands registered by STÄUBLI INTERNATIONAL AG.
1.1.1. OBJECTIVE OF THIS MANUAL
The objective of this manual is to provide information concerning the installation, use and maintenance of the
Stäubli CS8C controller. It provides help for the persons working on the equipment, for reference purposes only.
This is because correct understanding of this document and use of the Stäubli CS8C controller imply that the staff
concerned have acquired the necessary knowledge by following a "robots" training course provided by Stäubli.
The photos are used to make the document easier to understand, they cannot be construed as being of a
contractual nature.
1.1.2. SPECIAL MESSAGES CONCERNING WARNINGS, ALERTS, AND INFORMATION
In this document, there are two formats for warnings and alerts. The messages contained in the boxes inform staff
of the potential risks involved in carrying out an action.
These boxes are as follows (they are shown in decreasing order of importance):
Danger message
Warning message
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.
DANGER:
Instructions drawing the reader's attention to the risks of accidents that could lead to
serious bodily harm if the steps shown are not complied with. In general, this type of
indication describes the potential danger, its possible effects and the steps necessary
to reduce the danger. It is essential to comply with the instructions to ensure personal
safety.
CAUTION:
Instructions drawing the reader's attention to the risks of material damage if the steps shown
are not complied with. It is essential to comply with these instructions to ensure equipment
reliability and performance levels.

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

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Chapter 1 - Introduction

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Chapter 2 - Description of the controller
CHAPTER 2
DESCRIPTION OF THE CONTROLLER

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Chapter 2 - Description of the controller
2.1. IDENTIFICATION
Manufacturer's plate on each robot.
A plate is provided on the controller and on the arm (see figure 2.1).
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.
Standard version
UL version

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2.2. LOCATION AND DESCRIPTION OF THE MAIN COMPONENTS
2.2.1. THE CONTROLLER
The CS8C controller is made up of a processor (5), the intelligent part of the installation.
The processor controls the robot via digital power amplifiers (1) dedicated to each axis of the arm.
The electrical power is converted by the PSM (7) power section, the RPS (2) power supply, and the ARPS (3)
power supply which supplies to each of the above elements the voltage required for correct operation from the
mains voltage delivered by the electrical network.
The functions required for electrical safety are grouped together on the RSI (4) board.
Figure 2.2
To disconnect the system from the power supply, set the master switch (6), located on the front panel of the
controller, to 0. Before doing so, you must stop the arm motion and switch off arm power supply.
1
2345
76

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Chapter 2 - Description of the controller
2.2.2. THE MCP
General description
The MCP (Manual Control Pendant) can be used to enable arm power supply and control its movements.
Figure 2.3
Location and handling of the MCP
To power the arm in manual mode, the MCP must be placed on the holder provided for the purpose. The holder
is fixed outside of the cell. It has two functions:
•Making the MCP easily accessible for the operator.
•Detecting the presence of the MCP outside the cell.
In the event that the MCP is used elsewhere than on its holder in manual mode, it is necessary to use the validation
button (#)located under the MCP. The button's location enables it to be used by right-handed or left-handed
persons alike.
2.2.3. WMS FRONT PANEL
Modes of operation are selected from the WMS front panel which has to be installed permanently outside of the
cell. The removable 3-position keyswitch prevents from changing the mode when it is not allowed.
(#)

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