Staubli CS8C Instruction Manual Download Page 229

Page: 229 / 248

CS8C

D28070504A

229 / 248

Chapter 8 - Maintenance

8.8.4.26.

CASE

PS1/PS2

relays are not operating or there is a bad connection in the wiring between

RSI

and

PS1/PS2

The error codes above can be obtained from

MCP

Control Panel.

Figure

8.64

Problem:

(o)

Power up sequence

not effective:

J105-7

: relay

PS1

not activated or faulty contact

(P)

Power up sequence

not effective:

J105-8

: relay

PS2

not activated or faulty contact

Solution:

Controller status

I/O

-SystemIO

Inputs

...
4 HPE2 = On

18 BUS_ON2 = On

Step

: Feedback signals from

PS1

and

PS2

relays
(

RSI

error codes

L, n

)

Step

: Command signals to enable power on

arm
(

RSI

error codes

i, J

)

Outputs

0 HPE1_EN = On
1 HPE2_EN = On
...

Step

: Enable power command applied to

PS1

and

PS2

relays

(

RSI

error codes

o, P

)

5 HPE1 = On

17 BUS_ON1 = On

...

Summary of Contents for CS8C

Page 1: ...CS8C Controller Instruction manual D28070504A 26 03 2009 CS8C St ubli 2009...

Page 2: ...St ubli 2009 D28070504A CS8C 2 248 Documentation addenda and errata can be found in the readme pdf document delivered with the controller s CdRom...

Page 3: ...MAIN COMPONENTS 18 3 SAFETY 3 1 REMINDER CONCERNING THE SAFETY STANDARDS 23 3 2 SAFETY DIRECTIVES CONCERNING TO THE WORK ENVIRONMENT 25 3 3 SAFETY DIRECTIVES CONCERNING TO STAFF PROTECTION 26 3 4 SAF...

Page 4: ...St ubli 2009 D28070504A CS8C 4 248...

Page 5: ...ON 96 5 8 ETHERNET LINK 101 5 9 SERIAL PORT 104 5 10 SOFTWARE CONFIGURATIONS 105 6 OPERATION 6 1 POWERING UP THE CONTROLLER 115 6 2 PRESENTATION OF THE MCP 116 6 3 ARM POWER UP 125 6 4 EMERGENCY STOP...

Page 6: ...St ubli 2009 D28070504A CS8C 6 248...

Page 7: ...IS 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 P...

Page 8: ...St ubli 2009 D28070504A CS8C 8 248...

Page 9: ...CS8C St ubli 2009 D28070504A 9 248 Chapter 1 Introduction CHAPTER 1 INTRODUCTION...

Page 10: ...St ubli 2009 D28070504A CS8C 10 248...

Page 11: ...e necessary knowledge by following a robots training course provided by St ubli The photos are used to make the document easier to understand they cannot be construed as being of a contractual nature...

Page 12: ...ikely to come close to the St ubli robot cell Staff identifies the persons specifically employed and trained to install operate and service the St ubli robot cell User refers to the persons or the com...

Page 13: ...CS8C St ubli 2009 D28070504A 13 248 Chapter 1 Introduction...

Page 14: ...St ubli 2009 D28070504A CS8C 14 248...

Page 15: ...CS8C St ubli 2009 D28070504A 15 248 Chapter 2 Description of the controller CHAPTER 2 DESCRIPTION OF THE CONTROLLER...

Page 16: ...St ubli 2009 D28070504A CS8C 16 248...

Page 17: ...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...

Page 18: ...y 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...

Page 19: ...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...

Page 20: ...St ubli 2009 D28070504A CS8C 20 248...

Page 21: ...CS8C St ubli 2009 D28070504A 21 248 Chapter 3 Safety CHAPTER 3 SAFETY...

Page 22: ...St ubli 2009 D28070504A CS8C 22 248...

Page 23: ...he grounding terminals must comply with the manufacturers specifications The robot and its controller are designed to meet a Category III safety level Standards applicable Installation of the robot mu...

Page 24: ...ment Standard RIA15 06 American National Standard for Industrial Robots and Robot Systems Safety Requirements Standard CSA Z434 03 Industrial Robots and Robot Systems General Safety Requirements Stand...

Page 25: ...e robot cell Select the protective methods use of protective devices installation of signalling means compliance with safe working procedures These points are taken from the standards applicable to ro...

Page 26: ...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...

Page 27: ...in its expected angular range and not more This verification has to be done at slow speed Figure 3 1 Following maintenance work whether it involves mechanical electrical pneumatic or software operatio...

Page 28: ...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 Electr...

Page 29: ...1 5 kV Walking on vinyl 12 kV 5 kV 0 3 kV Working at the workstation 6 kV 2 5 kV 0 1 kV Plastified instructions 7 kV 2 6 kV 0 6 kV Polyethylene bags 20 kV 2 kV 1 2 kV Cellular polyurethane 18 kV 11 k...

Page 30: ...cting equipment static charge generators away from components and boards Use tools providing protection from ESD ST UBLI workstation To handle electronic cards ST UBLI workstations are given a grounde...

Page 31: ...CS8C St ubli 2009 D28070504A 31 248 Chapter 3 Safety...

Page 32: ...St ubli 2009 D28070504A CS8C 32 248...

Page 33: ...CS8C St ubli 2009 D28070504A 33 248 Chapter 4 Installation CHAPTER 4 INSTALLATION...

Page 34: ...St ubli 2009 D28070504A CS8C 34 248...

Page 35: ...n the event of a problem the robotized cell must remain in a safe state see chapter 3 page 21 The safety functions include especially Limiting the range of movements The emergency stop and the control...

Page 36: ...olid wire Maximum tightening torque applicable on terminal block screw 1 8 Nm Note The controller is fitted with a filter to limit the induced disturbances disturbances caused by the controller The fi...

Page 37: ...e 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...

Page 38: ...is not kept in a vertical position by its fastening points The length of the Input Output cables must also be taken into account Note In addition to the mechanical fastening of the controller the brac...

Page 39: ...CS8C St ubli 2009 D28070504A 39 248 Chapter 4 Installation 4 2 4 2 CS8C FOR RX160 ARM Figure 4 2 Detail A Scale 1 1...

Page 40: ...2 6 ACCESSIBILITY When designing the safety enclosure it is necessary to ensure the accessibility of all the mechanical and electrical elements robot sensors mechanical assemblies etc CAUTION Make sur...

Page 41: ...ble Take out the box containing the MCP and the upper wedges Take out the documentation and side wedges Take out the box containing the connecting cable CS8C FOR TX RS CS8C FOR RX160 Standard packagin...

Page 42: ...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 easil...

Page 43: ...CS8C St ubli 2009 D28070504A 43 248 Chapter 4 Installation Holder measurements Figure 4 5...

Page 44: ...permanently outside of the cell to be able to change the modes of operation from a safe location outside of the cell To comply with the UL requirements it cannot be provided or modified by the user i...

Page 45: ...ons Figure 4 8 When installed the board side has to be protected against direct contacts and dusty environment The cable between WMS and CS8C has a connector on both sides It has to be connected to J1...

Page 46: ...THE MAINS POWER SUPPLY 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...

Page 47: ...UL type 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 2 200 V 208 V 230 V 400 V 440 V 480 V 7F 8F 9F 7E 8E 9E 7D 8D 9D...

Page 48: ...le has to be attached to the cell s frame to avoid having mechanical constraints on connectors This connection includes optical fibers When the cable is disconnected during maintenance for example cov...

Page 49: ...inal is commercially available from several sources such as Phoenix Contact and others The brackets used to hold the controller in place also provides protection from electrical noise It is thus usefu...

Page 50: ...allation the ends of the interconnection cable should be covered to protect them from dust The only cleaning product that can be used is water Never use alcohol Note 2 Flat interconnection cable requi...

Page 51: ...apter 4 Installation Figure 4 12 The length of the cables must be taken into account to facilitate maintenance Interconnection cable Cable 25 mm Connector passage 90 mm WMS cable Cable 7 mm Connector...

Page 52: ...St ubli 2009 D28070504A CS8C 52 248...

Page 53: ...CS8C St ubli 2009 D28070504A 53 248 Chapter 5 Integration CHAPTER 5 INTEGRATION...

Page 54: ...St ubli 2009 D28070504A CS8C 54 248...

Page 55: ...is not the normal method for stopping the robot or disabling power on the arm Note 2 The robot is delivered with a dummy plug connected to J109 see figure 5 5 When this connector is replaced with the...

Page 56: ...he connection between J109 18 and J109 37 must be removed This mode of operation is only possible if controller is configured with configuration 1 see above Display on the control panel of the MCP The...

Page 57: ...COMP J109 7 COMP J109 26 MANU J109 8 MANU J109 27 DOOR1 J109 9 DOOR1 J109 28 DOOR2 J109 10 DOOR2 J109 29 UESB1 J109 14 UESB1 J109 33 UESB2 J109 15 UESB2 J109 34 UESA2 UESB2 A1 B1 UES2 24Vfus UESB1 UE...

Page 58: ...ubli 2009 D28070504A CS8C 58 248 Figure 5 2 F2 24Vfus 24V 0V1 J109 18 J109 37 J109 19 220uF 24V_In Internal 24VDC 24V 24 VDC 0 VDC 22 26 VDC 50mA 1A External 24VDC for E Stop lines SUBD 37M RSI2 250...

Page 59: ...DF J112 3 DF J112 4 LSW10 J101 12 LSW10 J101 5 B1 A1 RLS10 0V LSW10 LSW10 A1 B1 RLS20 0V LSW20 LSW20 24Vfus 24Vfus 8 9 J114 LSW10 LSW20 option 24V B1 A1 SCR1 Internal faults 0V DF DF Drive Fault Rela...

Page 60: ...S ON 24V A1 PS1 0V1 A2 A1 PS2 A2 PS ON2 USERPS1 J109 12 USERPS1 J109 31 USERPS2 J109 13 USERPS2 J109 32 SUBD 37M RSI2 PS ON1 J105 3 PS ON2 J105 4 PS ON J105 5 J105 12 J105 11 J105 10 J105 9 F3 375mA F...

Page 61: ...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 Figure 5 5 Note If...

Page 62: ...UTS 2 inputs User in 1 and User in 2 are available on the J109 connector Figure 5 6 Characteristics Operational voltage range 0 to 30 VDC Off state voltage range 0 to 1 VDC On state voltage range 4 to...

Page 63: ...0 to 0 5mA On state current range 2 to 9mA Impedance 3 3 k Response time for equipment software 50 s Power supply voltage range 24 V Fast Out 12 to 28 VDC Current consumed 5 5 mA Output voltage range...

Page 64: ...on DOOR1 2 Validation in Auto mode 9 28 10 29 DOOR1 DOOR1 DOOR2 DOOR2 Emergency stop in Auto mode Normal operation UESB 1 2 Emergency stop 14 33 15 34 UESB1 UESB1 UESB2 UESB2 Emergency stop Normal ope...

Page 65: ...1 Note 2 See figure 5 6 Note 3 Max 48V AC DC 0 5A Note 4 Refer to chapter 5 1 and figure 5 2 USER IN X 11 30 USER IN 0 USER IN 0 Note 2 Note 4 18 19 37 24 V for EStop lines Note 4 External electrical...

Page 66: ...board has External Encoder Latch signals that can be used for with the encoders The connector used on the DUAL ABZ board is of the female SubD 25 point type These boards are installed in the computer...

Page 67: ...of 4096 pulses per rotation Recovery procedure preset Stop the encoder at a reference position defined by the application Write the current encoder position in the e00PrstPos output Preset position si...

Page 68: ...e if the e00LatchEdgFall digital output is set to True It is possible to filter out bounds on the latch signal by specifying a filter delay in milliseconds using the e00LatchFilter analog output the l...

Page 69: ...sholds Temperature sensors are fitted in the arm to protect the motors and mechanical elements in the event of a temperature rise that is too great If the temperature of a motor rises above 120 C the...

Page 70: ...close as possible to the tool flange through the ball screw An ASI bus can also be supplied as an option on the CIO board not available on ARMIO board The Control panel page allows you to see the sta...

Page 71: ...COMPUTER Refer to 8 9 2 to remove and open CS8C computer module Plug the cable attached to the CAN board to CPU board Figure 5 11 Install the CAN board on B1 location of front plate using the 2 screw...

Page 72: ...d remove the cover 3 The user cable comes out of the forearm cover Towards the top by cutting out an opening d 23 5 mm in the cover and inserting a seal e g PG16 in the opening 4 Insert the cable thro...

Page 73: ...tegration 5 3 1 6 CONNECTING THE INPUTS OUTPUTS TO THE TOOL INTERFACE OPTION Type of connections Molex 2 50 mm SPOX 2 x 8 pin article 22 01 1084 1 x 4 pin article 22 01 10449 These connections are des...

Page 74: ...SPONDENCE 1 ASI 2 ASI 3 cDout0 4 cDout1 5 cDout2 6 cDout3 7 cDout4 8 cDout5 9 cDout6 10 cDout7 11 24 VDC 12 0 V 13 Configuration bridge for the ASI power supply Remove the bridge if the ASI power supp...

Page 75: ...nd 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 Analo...

Page 76: ...3 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 LIGHT EMITTING DIODES LED DISPLAY MEANING LED1 Green Red Logic si...

Page 77: ...CS8C St ubli 2009 D28070504A 77 248 Chapter 5 Integration Figure 5 13 Switches...

Page 78: ...248 5 3 1 8 ARMIO BOARD X11 PIN CORRESPONDENCE 1 cAout 0 2 cAout 1 3 cDout0 4 cDout1 5 cDout2 6 cDout3 7 cDout4 8 cDout5 9 cDout6 10 cDout7 11 24 VDC 12 0 V 13 cAout2 14 cAout3 LED1 LED2 LED3 X11 X21...

Page 79: ...dware 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 maximu...

Page 80: ...1 7 8 9 on 2 3 4 5 6 off see figure 5 13 76 LIGHT EMITTING DIODES LED DISPLAY MEANING LED1 Green Red Logic power supply OK Overload on logic power supply LED2 Green Red Power supply OK Overload on ana...

Page 81: ...CS8C St ubli 2009 D28070504A 81 248 Chapter 5 Integration Figure 5 14 Switches...

Page 82: ...X21 14 Grey X14 1 1 cDin0 13 White green X14 1 2 cDin1 12 White yellow X14 1 3 cDin2 11 White brown X14 1 4 cDin3 10 White orange X14 1 5 cDin4 9 Orange X14 3 1 cDin5 8 Yellow X14 3 2 cDin6 7 Green X...

Page 83: ...ample 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...

Page 84: ...upler 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...

Page 85: ...given for informational purposes only 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 curre...

Page 86: ...d from 0 to n on each Input Output board IN 0 _ 3 9k IN 2 _ 3 9k IN 3 _ 3 9k J601 24 J601 6 IN 4 _ 3 9k J601 25 J601 7 IN 5 _ 3 9k J601 26 J601 8 IN 6 _ 3 9k IN 7 _ 3 9k IN 1 _ 3 9k _ _ _ _ J601 Suppl...

Page 87: ...ven in the Electrical Wiring manual Parameter Value Power supply voltage range 10 VDC Vsup 30 VDC Low voltage stop 5 VDC Vusd 8 VDC Earth current Ig 60 mA Functional current per channel Iout 700 mA pr...

Page 88: ...5 17 Note The outputs are numbered from 0 to n on each input output board OUTRET1 OUT 3 OUTPWR1 OUT 2 OUTPWR1 OUT 1 OUTPWR1 OUT 0 OUTPWR1 _ load load load load J602 Supplied Equipment User Supplied E...

Page 89: ...CS8C St ubli 2009 D28070504A 89 248 Chapter 5 Integration Figure 5 18 Figure 5 19 1 1 J601 J602 2 2 4 3 4...

Page 90: ...acers 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 plac...

Page 91: ...S8C 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 v...

Page 92: ...rror on the field bus Read Board Equip Channel Status Reading error on the field bus EquipmentStatus Board Equip Status Problem with an item of equipment on the field bus RefreshIn Board Status Error...

Page 93: ...ceiving 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 ite...

Page 94: ...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 c...

Page 95: ...d 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 Wiri...

Page 96: ...n the CS8C has access to all the digital and analog inputs and outputs in the system It can communicate with a VAL3 program via the analog or digital outputs of the system The PLC cycle is carried out...

Page 97: ...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...

Page 98: ...e usr configs plc cfx file which can be modified by Ftp 5 7 3 PLC PROGRAMMING IN SRS Definition of the Inputs Outputs The Inputs Outputs must be declared in the PLC program as global datas with CS8_IO...

Page 99: ...e CS8C Inputs Outputs emulated are then displayed in the left hand frame Select the desired Inputs Outputs from the CS8C list and drag them to the desired frame outputs or inputs Save the PLC project...

Page 100: ...ary to stop it via the programming environment before downloading the new program The download also copies the PLC program on the CS8C which means that the last program downloaded is executed automati...

Page 101: ...hts depend on the login user profile selected see paragraph 5 10 3 A free client Ftp is supplied on the SRS CD ROM 5 8 3 MODBUS TCP PROTOCOL The CS8C controller can be configured to exchange Inputs Ou...

Page 102: ...n 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 an...

Page 103: ...ven 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...

Page 104: ...J201 COM2 the RS232 RS422 configuration Default configuration is RS232 The flow control none hardware Influences COM1 only The time lapse prior to triggering of an error message maximum reading time...

Page 105: ...sian speed in manual mode up to 250 mm s The status of the emergency stop channels ESOUT1 and ESOUT2 with or without DOOR signal see chapter 5 1 1 Language configuration The controller is delivered wi...

Page 106: ...m the calibration menu If some arm characteristics must be updated you need to edit the arm configuration file usr configs arm cfx that is exported with the Exp export button from the calibration menu...

Page 107: ...cription password Profile password connectionPassword Profile password for network connections Ftp and remote maintenance writeAccess Writing access to the VAL3 applications and the CS8C configuration...

Page 108: ...user signal for which the default wiring can be reprogrammed When the MCP is replaced by its shorting plug it is possible to simulate pressing certain keys using inputs Key word Description Type Defa...

Page 109: ...nal from the MCP estopWMS Emergency stop signal from the WMS estopUser1 2 Emergency stop signal from UESA on the safety system estopUser3 4 Emergency stop signal from UESB on the safety system userEna...

Page 110: ...or activation of the local mode remoteRemoteMode Signal for activation of the remote mode remoteDeadman1 Signal from the enable button 1 2 remoteDeadman2 Signal from the enable button 2 2 remotePark1...

Page 111: ...CS8C St ubli 2009 D28070504A 111 248 Chapter 5 Integration...

Page 112: ...St ubli 2009 D28070504A CS8C 112 248...

Page 113: ...CS8C St ubli 2009 D28070504A 113 248 Chapter 6 Operation CHAPTER 6 OPERATION...

Page 114: ...St ubli 2009 D28070504A CS8C 114 248...

Page 115: ...When the electricity supply to the controller is switched on the MCP screen and all the LEDs flash on and off Next a St ubli CS8 message is displayed on the screen and then the main menu is shown aft...

Page 116: ...en 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 relea...

Page 117: ...nts per axis or using Cartesian coordinates depending on the movement mode selected see paragraph 6 6 LEDs and Luminous indicator keys Figure 6 3 DANGER When the MCP power is on all the LED L flash to...

Page 118: ...emented 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 ent...

Page 119: ...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...

Page 120: ...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 depend...

Page 121: ...t 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 Besi...

Page 122: ...as 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 ass...

Page 123: ...movement status indicator 5 M indicates arm movement S indicates a stop indicates for manual movements that the arm has reached its target position The indicator is blank when there is no pending mov...

Page 124: ...s 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...

Page 125: ...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 a...

Page 126: ...te This operation must be carried out with the MCP on its holder when in manual mode Release the emergency stop button by turning it clockwise 1 4 turn Restore power to the arm in accordance with the...

Page 127: ...different from the one in the arm cfx file f i replacement of the arm linked to the controller it is necessary to determine which offset is correct This is done in the recovery operation The motor en...

Page 128: ...rdinates of the reference position must be determined in advance Sequence of operations Select the reference position press Return and then use the arrows If the reference position has not been entere...

Page 129: ...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 t...

Page 130: ...ConnectMove 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 pr...

Page 131: ...is context is important to avoid unexpected movements Therefore when the jog interface is exited the movement mode is also reset automatically It is however possible to exit the jog interface while ke...

Page 132: ...nts for the joints 5 For joint positions and cartesian points a position marker may preceed the name of the data indicates that the robot is exactly at the position indicates that the robot is near th...

Page 133: ...step mode and step size Here menu This menu is used for teaching points By pressing the key you can modify the position of the point selected A confirmation window is then used to validate the selecti...

Page 134: ...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...

Page 135: ...f keys with the sign The movements can be made in translation and rotation see figures 6 12 6 13 6 14 In Translation X Y Z keys A movement in the direction of the X axis is called X and a movement in...

Page 136: ...St ubli 2009 D28070504A CS8C 136 248 If the Tool key 3 has been pressed the movements are made parallel to the axis of the current tool Flange as default setting 6 13 6 14 Z Y X X Y X Z Z Z X Y Y Z Z...

Page 137: ...2 The approach can be inactive OFF or active ON The current step mode 3 and if enabled the current step size When the step mode is active each manual movement is a step of the specified size in mm or...

Page 138: ...dation 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 b...

Page 139: ...er 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 a...

Page 140: ...estarting 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...

Page 141: ...ished 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...

Page 142: ...he system when the application stops These two programs do not have any parameters and they cannot be deleted or renamed Figure 6 16 Opening an existing application Press the Open key in the pop up me...

Page 143: ...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 valu...

Page 144: ...ble 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 Th...

Page 145: ...ntained between a while and an endWhile all that has to be done is to mark While twice Example There is a clipboard enabling you to copy instructions Make sure that the instructions are valid in the p...

Page 146: ...tered 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 c...

Page 147: ...hat 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 acce...

Page 148: ...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 fo...

Page 149: ...se the robot moves to the last point selected for a jog interface To return to the programmed movements exit the Point mode see paragraph 6 6 When an application is stopped using the Stop key the Run...

Page 150: ...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 poin...

Page 151: ...ing 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 Configura...

Page 152: ...locity of 120 1 2 is best adapted with accel and decel of 1 2 x 1 2 1 44 144 Higher values for accel and decel give a more aggressive but shakier arm behaviour When the accel and decel parameters are...

Page 153: ...CS8C St ubli 2009 D28070504A 153 248 Chapter 6 Operation...

Page 154: ...St ubli 2009 D28070504A CS8C 154 248...

Page 155: ...CS8C St ubli 2009 D28070504A 155 248 Chapter 7 PC utilities CHAPTER 7 PC UTILITIES...

Page 156: ...St ubli 2009 D28070504A CS8C 156 248...

Page 157: ...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 check...

Page 158: ...the main menu The IP address is in the controller node see chapter 5 8 7 2 3 FUNCTIONS VIA FTP All the information available for the user is on the disk called usr Updating the configuration file Usi...

Page 159: ...he 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...

Page 160: ...robot CD ROM and follow the installation instructions Once the software has been installed create a new user In the user creation window add the sharing of the directory containing the VAL3 applicati...

Page 161: ...CS8C St ubli 2009 D28070504A 161 248 Chapter 7 PC utilities...

Page 162: ...St ubli 2009 D28070504A CS8C 162 248...

Page 163: ...CS8C St ubli 2009 D28070504A 163 248 Chapter 8 Maintenance CHAPTER 8 MAINTENANCE...

Page 164: ...St ubli 2009 D28070504A CS8C 164 248...

Page 165: ...tions Refer to the regulations currently in force in the country concerned 8 1 3 INTERVENTION LEVELS The different troubleshooting steps represented below use 3 intervention levels Level 1 by default...

Page 166: ...e LSW Limit Switch Limit Switch MCP Manual Control Pendant Manual Control Pendant MCPES Manual Control Pendant Emergency Stop Manual Control Pendant Emergency Stop MOT Motor Motor PSM Power Supply Mod...

Page 167: ...8C St ubli 2009 D28070504A 167 248 Chapter 8 Maintenance 8 3 COMPONENT LOCATION Figure 8 1 PSM CPT S1 CPT PWR DIG Regen CPU S1 F1 F3 D2 T1 D1 PS1 PS2 RSI ARPS RPS Fieldbus Starc ABZ BIO PSM Filter Fan...

Page 168: ...e controller or the arm Wait for at least 1 min before starting to work CAUTION Use an anti static wrist strap and an anti static mat connected to the controller for all work involving handling of boa...

Page 169: ...D C A V 8 0 2 E C A V 0 0 2 F 7 8 9 T 1 L 3 L 2 L T 1 S T 2 1 T 1 1 T 0 1 1 1 1 2 1 3 6 1 5 1 7 1 2 1 2 2 2 3 2 D M 2 1 M 1 1 1 1 1 2 4 1 3 1 2 1 2 2 D1 1 T C A V 0 3 2 3 C A V 0 3 2 C A V 0 8 4 0 0...

Page 170: ...he components of the PSM remove the screws 1 and pull it forward CS8C TX RS CS8C RX160 Figure 8 4 Figure 8 5 CAUTION To remove it completely disconnect connectors 2 and 3 The PSM is heavy take all nec...

Page 171: ...e Note Am means slow acting fuse according to IEC 269 1 2 AT means slow acting fuse and AF quick acting fuse according to IEC 127 2 Check D1 circuit breaker Problem All lights of ARPS are off Solution...

Page 172: ...ers Check voltages at the input of the controller L1 L2 L3 Check voltages after the transformer At this point voltages are 230 VAC 10 for all the input voltages Change D1 circuit breaker To change D1...

Page 173: ...ss the components of the PSM remove the screws 1 and pull it forward CS8C TX RS CS8C RX160 Figure 8 7 Figure 8 8 CAUTION To remove it completely disconnect connectors 2 and 3 The PSM is heavy take all...

Page 174: ...74 248 The frame of circuit breaker can be separated from the front face with a screw driver allowing it to be pulled back Figure 8 9 Push on 1 to separate it from the front face 3 and disconnect the...

Page 175: ...n on position 1 change D2 circuit breaker Check input fuses F1 F2 F3 Fuses are 10 x 38 mm type 500V for standard controllers Check voltages at the input of the controller L1 L2 L3 Check voltages after...

Page 176: ...puts are overload protected which means that output voltages are automatically set to 0 when there is a short circuit in the components it supplies Normal status arm power off GREEN LEDS STATUS Figure...

Page 177: ...aintenance 8 6 2 ACCESS Turn off main switch S1 to position 0 Remove the 4 screws 1 and pull the ARPS Figure 8 12 8 6 3 TEST POINTS Figure 8 13 1 1 2 3 4 5 24V2 24V1 24V1 13V 0 V DC 0 V DC 24V3 24V3 A...

Page 178: ...J1102 3 J1103 4 J1104 5 connector at ARPS outputs see figure 8 12 If the indicator lights remain off change ARPS If the indicator lights come on again there is a short circuit on the corresponding out...

Page 179: ...ws 1 holding the grille and the air filter in place The fan 3 3 for the RPS power supply can be accessed by removing the amplifier for joints 3 6 see pages 181 and 182 To remove it take out the 2 scre...

Page 180: ...St ubli 2009 D28070504A CS8C 180 248 Plug only J1103 24V3 for fan 1 on top of CS8C If 24V3 light goes off check wiring and fans Change the defective part Figure 8 16 Solution Step 3 Fan 1...

Page 181: ...CS8C St ubli 2009 D28070504A 181 248 Chapter 8 Maintenance Figure 8 17 Figure 8 18 Figure 8 19 2 6 1 5 3 4 7 8...

Page 182: ...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...

Page 183: ...re 8 21 Plug only J1102 24V1 for RSI drives and CPT 24V2 for brakes 13V for DSI inside arm If 24V1 light goes off repeat the same operation with powered components disconnected one by one CPU RSI driv...

Page 184: ...1 V 4 2 1 V 0 2 1 2 0 1 1 J 5 2 0 1 1 J K O M I L A K O M I L A 3 1 2 0 1 1 J 6 2 0 1 1 J K O R U E T C E S 4 1 2 0 1 1 J K O R U E T C E S 7 2 0 1 1 J N E L E R K R B 5 1 2 0 1 1 J N E L E R K R B N...

Page 185: ...V2 light goes off whatever is the selected brake check brake release board in the robot base and the wiring from ARPS to the arm Note Changing a brake requires an intervention level 2 or 3 depending i...

Page 186: ...2009 D28070504A CS8C 186 248 8 6 4 4 ADVANCED INFORMATION Figure 8 24 ARPS DSI 24V2 13V BRK_REL_EN RSI 24V1 CPU 24V3 24V3 25 1 VDC 25 6 VDC 25 1 VDC 13 VDC Fan 4 Drives Brakes Arm Voltages 10 Fan 1 Fa...

Page 187: ...8 6 5 3 TROUBLE SHOOTING 1 It can be a short circuit on one output see chapter 8 6 4 page 178 2 Or it is an internal fault Change the ARPS Problem ALIM_OK status OFF There is a fault detected by ARPS...

Page 188: ...here is no fault status in control panel ON ALIM_OK signal is set to 24 V When there is a fault status in control panel OFF ALIM_OK signal is set to 0 V Figure 8 26 RSI ARPS J104 2 J104 7 J1102 13 ALI...

Page 189: ...s maintained for 100 ms 13V output is maintained for 300 ms there is no voltage backup on 24V2 and 24V3 outputs 8 6 6 2 ACCESS See chapter 8 6 2 page 177 8 6 6 3 TROUBLE SHOOTING Check input voltage t...

Page 190: ...is no fault status in control panel ON SECTEUR_OK signal is set to 24 V When there is a fault status in control panel OFF SECTEUR_OK signal is set to 0 V Figure 8 28 RSI ARPS J104 3 J104 8 J1102 14 SE...

Page 191: ...e on when arm power is enabled Note These signals operate the same way in Manual Brake Release mode which is easier to test Figure 8 30 DANGER Refer to safety chapter 3 Pay attention to risks related...

Page 192: ...eck wiring between ARPS and RSI Change the RSI If it off ARPS is not receiving the command from RSI Check wiring between ARPS and RSI Change the ARPS Problem When trying to enable power on arm 24V2 le...

Page 193: ...RK_REL_EN signal is set to 0V In that case BRK_ON feedback signal goes to 24 VDC RSI input ON status in control panel ON Figure 8 31 RSI ARPS BRK_REL_EN BRK_REL_EN J1102 7 J1102 15 J104 4 J104 9 24V B...

Page 194: ...ism called regeneration Figure 8 32 Normal operation 8 7 2 ACCESS STATUS ON LIGHT REGEN LIGHT Arm not powered OFF OFF Arm powered on ON OFF Arm powered motion with high deceleration ON ON CAUTION When...

Page 195: ...S8C FOR TX OR RS ROBOTS Set aside the ARPS power supply see chapter 8 6 2 page 177 Remove the 4 screws 1 holding the RPS325 power supply Remove the 4 screws 2 holding the J1200 5 connector Release the...

Page 196: ...St ubli 2009 D28070504A CS8C 196 248 When replacing the RPS325 power supply make sure the wire 12 is correctly placed in the same position as on the original power supply Figure 8 34 12...

Page 197: ...To access the connectors remove the ARPS 3 power supply wires held in place by 4 screws 4 see chapter 8 6 2 and the metal plate 5 holding the socket and kept in place by 4 screws 6 Figure 8 35 Disconn...

Page 198: ...the PSM 6 forward to take it out To remove it completely disconnect connectors J010 3 and J011 4 To access the RPS 5 power supply lift it up in front to extract it from the fixing point 7 and then pu...

Page 199: ...PS2 Output command signals and feedback information can be checked from MCP Control Panel and RSI 7 segments error codes Figure 8 39 Problem ON indicator light remains off when arm is powered Solution...

Page 200: ...hange the RSI OFF OFF ON Bad connection in the wiring between RSI and PS1 PS2 or PS1 PS2 defective Arm enable power sequence requested OFF OFF OFF Change the RSI ON OFF OFF Change the RSI ON ON OFF PS...

Page 201: ...248 Chapter 8 Maintenance 8 7 3 2 CASE 2 Change RPS and check that regeneration resistor has not been damaged Regeneration resistor is located at the back of CS8C Figure 8 41 Problem REGEN indicator...

Page 202: ...ifications Reduce speed and or acceleration parameters in the application program Check in manual brake release mode that there are no damages to the mechanics Problem Not able to move the arm due to...

Page 203: ...8 8 1 DESCRIPTION RSI board manages all hardware signals for safe operation of the robot RSI2 board front view Figure 8 42 J110 J113 J111 J109 A 7 segment display indicates status of internal signals...

Page 204: ...l the RSI 2 Figure 8 43 8 8 3 TROUBLE SHOOTING 8 8 3 1 CASE 1 Check ARPS see chapter 8 6 page 176 Check wiring between ARPS J1102 and RSI J104 Figure 8 44 Change the RSI Problem D49 remains off 24V1 f...

Page 205: ...C J302 and RSI J100 Change the RSI 8 8 3 3 CASE 3 Refer to STARC chapter 8 9 if there is an error message from STARC STARC has the possibility to shut off 5V on RSI in case of major error Check wiring...

Page 206: ...are blown check that there is no short circuit in the wiring from RSI to the arm and no short circuit in the valves Change the RSI Problem D73 EV1 or D74 EV2 remains Off when corresponding I O on fron...

Page 207: ...e 8 46 0V 24V1 J104 1 J104 6 J112 1 J112 2 ARPS J1102 4 J1102 12 RSI F2 D49 24V P4 P1 D50 5V SAUVE P4 P2 D52 5V P4 P3 0V1 0V1 J101 2 EV2 J101 10 EV2 F5 D74 J101 1 EV1 J101 9 EV1 F6 D73 STARC J302 9 J3...

Page 208: ...f See chapters 8 5 8 6 8 7 pages 169 176 194 If D49 D50 and D52 are On Check that STARC board is operating see chapter 8 9 page 232 Change it if necessary Check wiring between STARC J302 and RSI J100...

Page 209: ...left flashing page 212 i page 213 0 page 213 1 page 213 2 page 214 3 page 214 4 page 216 5 page 217 6 page 218 7 page 218 8 page 219 9 page 219 A page 222 a page 222 b page 223 C page 223 c page 224 d...

Page 210: ...re alternatively flashing This sequence lasts approximately 2 minutes DISPLAY APPEARANCE STATUS E flashing The RSI board is waiting to be synchronised with the STARC board r flashing The STARC board i...

Page 211: ...atus Check STARC board see chapter 8 9 page 232 If STARC is OK Check wiring between STARC J302 and RSI J100 Change the RSI 8 8 4 2 CASE 2 If it remains on this status the issue is related to STARC boa...

Page 212: ...created from external noisy signals coming to the RSI board E Stop lines I O signals 8 8 4 4 CASE 4 If it remains on this status change CPU board Note Changing a CPU board requires an intervention lev...

Page 213: ...mented RSI2 case This input does not exist 8 8 4 7 CASE 7 RSI is powered from ARPS 24V1 output If 24V1 led on ARPS is Off See chapter 8 6 page 176 If 24V1 led on ARPS is On Check wiring between ARPS J...

Page 214: ...n electric limit switch condition has been detected Note 1 The presence and number of electrical limit switches depends on arm type see figure 8 51 Note 2 With RSI 1 board limit switch circuit is powe...

Page 215: ...SI to the arm base mainly the interconnection cable If wiring is OK change RSI board Controller status Joint position J1 xx J2 xx J3 xx J4 xx J5 xx J6 xx W S L 7 0 0 7 J W S L 4 0 0 7 J 4 6 M 1 0 2 1...

Page 216: ...re 8 53 Problem 4 Amplifier fault Contact DF open on J112 3 4 The events history can be used to find the number of the amplifier concerned and it provides further information on the fault The control...

Page 217: ...Figure 8 54 If there is no error related to the brakes check STARC and CPU boards see chapter 8 9 page 232 Problem 5 ShortR EN command not activated The safety management task is not operational comp...

Page 218: ...rnal 24 V is provided between J109 19 24 V and J109 37 0 V Check that there is no short circuit between E Stop lines Change F2 fuse Figure 8 55 Problem 6 The ShortR EN signal is not taken into account...

Page 219: ...rol Pendant or WMS Working Mode Selection devices Figure 8 56 Problem 8 MCP emergency stop 1 activated Contact MCPES1 J110 S J or WMS emergency stop activated Contact WMSES1 J113 1 2 9 MCP emergency s...

Page 220: ...hange MCP If error remains change RSI Note Status of MCP E Stop push button can be obtained from MCP Control Panel Figure 8 57 DANGER If only one E Stop contact is operating the robot will be stopped...

Page 221: ...nge WMS or its cable If error remains change RSI Note Status of WMS E Stop push button can be obtained from MCP Control Panel Figure 8 58 DANGER If only one E Stop contact is operating the robot will...

Page 222: ...em A User emergency stop A1 activated Contact UESA1 J109 1 20 a User emergency stop A2 activated Contact UESA2 J109 2 21 Solution DANGER If only one E Stop contact is operating the robot will be stopp...

Page 223: ...om MCP Control Panel Figure 8 60 Problem b User emergency stop UEN1 DOOR1 activated Contact USEREN1 DOOR1 J109 3 22 9 28 C User emergency stop UEN2 DOOR2 activated Contact USEREN2 DOOR2 J109 4 23 10 2...

Page 224: ...em c User emergency stop B1 activated Contact UESB1 J109 14 33 d User emergency stop B2 activated Contact UESB2 J109 15 34 Solution DANGER If only one E Stop contact is operating the robot will be sto...

Page 225: ...e controller to arm cable If it is correct change RSI Note Changing arm harness requires an intervention level 2 Problem e Manual brake control selected The rotary switch at the base of the arm is not...

Page 226: ...t is correct see above change RSI Problem E Manual brake control activated One of the brakes has been released manually Solution Problem F Manual brake control channel 1 The BRS 4 8 contact is not clo...

Page 227: ...des are related to an enable power sequence Problem h MCP Enable button or parking contact not activated Solution Problem U E Stop 1 order memorised An emergency stop on line 1 has been recorded by th...

Page 228: ...E 25 Change the RSI Problem i Power up command 1 not activated by the computer J Power up command 2 not activated by the computer Solution Problem L Power up sequence 1 not activated No PS ON1 signal...

Page 229: ...ve OV on J105 7 relay PS1 not activated or faulty contact P Power up sequence 2 not effective OV on J105 8 relay PS2 not activated or faulty contact Solution Controller status I O SystemIO Inputs 4 HP...

Page 230: ...F Change the RSI OFF ON Change the RSI OFF OFF ON Bad connection in the wiring between RSI and PS1 PS2 or PS1 PS2 defective Arm enable power sequence requested OFF OFF OFF Change the RSI ON OFF OFF Ch...

Page 231: ...stopped because brake release command is not activated Change the RSI 8 8 4 29 CASE 29 Refer to ARPS chapter 8 6 to differentiate between ARPS issue or RSI issue Problem t Braking command not activate...

Page 232: ...igure 8 65 Leds A and B are blinking slowly 1 s period during boot sequence of controller They are blinking fast 0 5 s period when ready to operate 8 9 2 ACCESS Turn off main switch S1 to position 0 S...

Page 233: ...ed after taking out the fastening screw 3 The PCI boards are locked on back edge with an adjustable plate This plate can be re ajusted if necessary when board is replaced Figure 8 67 DANGER The heat s...

Page 234: ...RPS see chapter 8 6 page 176 Check STARC internal power supplies leds If 5 V or 3 3 V led is off change the CPU If one of the other leds is off change the STARC Figure 8 68 Problem No lights at all on...

Page 235: ...change STARC or CPU board Note Changing a CPU board requires an intervention level 2 or 3 to set up parameters of the new CPU level 2 if CPU is preconfigured level 3 if not Problem Led E is on Led D i...

Page 236: ...operating Change interconnection cable from CS8C to arm Or the DSI board in the arm base is not operating Change the DSI Note Changing a DSI board requires an intervention level 2 Problem Leds E D an...

Page 237: ...STARC J306 connector If there is not light or if it seems very dim Change STARC board Check that there is not an angle on optical fiber inside CS8C or inside arm Figure 8 70 Check that there is red li...

Page 238: ...8 6 page 176 If ARPS 13 V light is on Open the robot base and check the D1 light on DSI Figure 8 71 If D1 is off Check the 13 V wiring between ARPS and DSI If D1 is on Change the DSI Note Changing a D...

Page 239: ...ply DSI Optical fiber 5 V from DSI to encoders Individual lines DSI to encoder communication Figure 8 72 DSI board s D1 ON Encoder OK D2 ON Thermo OK D3 Slow Init Fast OK D0 ON DSI OK Transmit Receive...

Page 240: ...played on MCP control panel is the following Figure 8 73 Step 1 Check flat cable between STARC board and the drives If cable has some damage Change the cable Problem Led A is blinking slowly 1 s perio...

Page 241: ...41 248 Chapter 8 Maintenance Step 2 Check that each drive is properly powered with 24 V Led On If one drive has a led off check 24 V power supplier cables If power supplies are OK change drive s Figur...

Page 242: ...mA and 500 mA microfuse STARC board Amplifier drive one of each type BIO board RSI board CPU board MCP Air filter DANGER Disconnect all the electrical and pneumatic power supplies before carrying out...

Page 243: ...CS8C St ubli 2009 D28070504A 243 248 Chapter 8 Maintenance...

Page 244: ...St ubli 2009 D28070504A CS8C 244 248...

Page 245: ...CS8C St ubli 2009 D28070504A 245 248 Chapter 8 Maintenance APPENDIX...

Page 246: ...St ubli 2009 D28070504A CS8C 246 248...

Page 247: ...load current in the controller power supply circuit when the arm is operating When the controller is powered on a surge current is generated The current reaches the level of continuous duty after 8 pe...

Page 248: ...t 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 For a breaker type U ln 488 8 61 A the si...

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