Arm - TS2 series

Instruction manual

C.285.043.04-M - 29/04/2024
TS2 - Master
© STÄUBLI 2024
 A "readme.pdf" document may be delivered on the robot DVD. It contains the documentation
addenda and errata.

Stäubli is a trademark of Stäubli International AG, registered in Switzerland and other countries. We reserve the right to modify product specifications without prior
notice.
 Table of contents
1 - INTRODUCTION......................................................................................................................1
1.1 - Foreword......................................................................................................................................... 1
1.1.1 - Objective of this manual..........................................................................................................1
1.1.2 - Special messages concerning safety, dangers, cautions and information............................. 2
1.2 - Definitions and glossary..................................................................................................................2

2 - DESCRIPTION......................................................................................................................... 5
2.1 - Overview......................................................................................................................................... 5
2.2 - Best practices................................................................................................................................. 8
2.3 - Base interface................................................................................................................................. 9
2.4 - Forearm connections.................................................................................................................... 11
2.5 - Flange interface (option)............................................................................................................... 12
2.5.1 - Item identification.................................................................................................................. 12
2.5.2 - Minimum bending radius.......................................................................................................12
2.6 - MPS 010 Tool changer (option).................................................................................................... 13
2.6.1 - General information............................................................................................................... 13
2.6.2 - Automatic MPS 010 version..................................................................................................16
2.6.3 - Manual MPS 010 version...................................................................................................... 20
2.6.4 - Wiring proximity sensors to the MPS station........................................................................ 21
2.7 - Brake release function (option)..................................................................................................... 25
2.7.1 - RBR interface description..................................................................................................... 26
2.7.2 - Releasing joint brake............................................................................................................. 26

3 - MACHINE DESIGN................................................................................................................ 29
3.1 - Safety Requirements.....................................................................................................................29
3.1.1 - Safety regulations..................................................................................................................29
3.1.2 - Essential health and safety requirements..............................................................................30
3.1.3 - Safety functions.....................................................................................................................32
3.1.4 - Safety equipment.................................................................................................................. 33
3.1.5 - Residual risks........................................................................................................................ 34
3.2 - Machinery requirements............................................................................................................... 35
3.2.1 - Work environment................................................................................................................. 35
3.2.2 - Working space and speed.....................................................................................................37
3.2.3 - Arm mounting........................................................................................................................ 44
3.2.4 - End-effector...........................................................................................................................49
3.2.5 - User interface (additional load, camera, harness...).............................................................. 55
3.2.6 - Pneumatic circuit...................................................................................................................57
3.2.7 - Electric circuit........................................................................................................................ 76
3.2.8 - Pressurization unit (Option)................................................................................................... 81
3.2.9 - Controlled space, restricted space and fences.....................................................................81
3.2.10 - Cabling................................................................................................................................ 92
3.3 - Robot simulation........................................................................................................................... 93
Table of contents

4 - STORAGE, TRANSPORT AND INSTALLATION.................................................................. 95

4.1 - Arm packaging.............................................................................................................................. 95
4.2 - Handling of packing...................................................................................................................... 96
4.3 - Unpacking of the arm....................................................................................................................97
4.3.1 - Standard and international packaging.................................................................................. 97
4.3.2 - Compact packaging.............................................................................................................. 98
4.4 - Installation of the arm..................................................................................................................102
4.4.1 - Installation of arm on floor...................................................................................................102
4.4.2 - Installation of arm on ceiling................................................................................................104
4.5 - Installation of the pressurization unit (Option).............................................................................108
4.6 - Installation of the mechanical hard stop (Option)....................................................................... 108
4.7 - Installation of the MPS 010 tool changer (Option)...................................................................... 108
4.7.1 - Docking station................................................................................................................... 108
4.7.2 - Assembly instructions connector for MPS 010................................................................... 109
4.7.3 - Tool sides............................................................................................................................ 115
4.8 - Installation of the UL drive power indicator................................................................................ 115

5 - COMMISSIONING............................................................................................................... 117
5.1 - Verification of the mechanical interfaces.................................................................................... 117
5.2 - Verification of the pneumatic circuits..........................................................................................117
5.3 - Verification of the electric circuits............................................................................................... 117
5.4 - Verification of the robot application............................................................................................ 117
5.5 - Validation of the safety functions................................................................................................117
5.6 - Validation of organizational measures........................................................................................ 118

6 - WARRANTY......................................................................................................................... 119

7 - MAINTENANCE................................................................................................................... 121
7.1 - Rules to be applied for maintenance.......................................................................................... 121
7.1.1 - Mandatory lubricants...........................................................................................................122
7.1.2 - Spare parts.......................................................................................................................... 123
7.1.3 - Tooling.................................................................................................................................123
7.2 - Safety.......................................................................................................................................... 123
7.2.1 - Maintenance mode..............................................................................................................123
7.2.2 - Risks.................................................................................................................................... 124
7.2.3 - Re-commissioning...............................................................................................................124
7.3 - Protection against electrostatic discharges................................................................................125
7.3.1 - Information on electrostatic discharges.............................................................................. 125
7.3.2 - Prevention of damage due to electrostatic discharges.......................................................126
7.4 - Maintenance frequency...............................................................................................................127
7.5 - Paint touch-up procedure for HE and Stericlean robots............................................................ 129
7.6 - Cleaning and disinfecting recommendations..............................................................................130
7.7 - Cover locations and removal...................................................................................................... 133
7.8 - Procedure for replacing the flat seal........................................................................................... 134
7.8.1 - Removing the seal............................................................................................................... 134

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Table of contents

7.8.2 - Fitting a new seal.................................................................................................................134

7.9 - Lubrication.................................................................................................................................. 135
7.9.1 - General information............................................................................................................. 135
7.9.2 - Checking oil levels...............................................................................................................135
7.9.3 - Lubricating the ball screw................................................................................................... 137
7.9.4 - Lubricating the MPS 010 tool changer (Option).................................................................. 137
7.10 - Checking the state of the belts................................................................................................. 138
7.11 - Recommended checks after a robot collision.......................................................................... 139
7.12 - Visual check of the harness condition...................................................................................... 139
7.13 - Orientation of axis 1 after a calibration..................................................................................... 140
7.14 - Maintenance of the mechanical hard stop (option)...................................................................141

Index

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 1 - Introduction

1 - INTRODUCTION

1.1 - FOREWORD M0006390.1

The information contained in the present document is the property of Stäubli and it cannot be repro‐
duced, 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.
Electrical drawings provided in this manual are for information only. The reference for robot electrical
drawings is provided in a separate manual. The photos are used to make the document easier to
understand, they cannot be construed as being of a contractual nature.
Please report errors and omissions to the Stäubli Robotics Customer Support contact for your country,
that can be found at:
■ https://www.staubli.com/contacts
STÄUBLI, UNIMATION, VAL, Stericlean, Stericlean+
Are brands registered by Stäubli INTERNATIONAL AG.

EtherCAT® is a registered trademark and patented technology, licensed by Beckhoff

Automation GmbH, Germany.

Safety over EtherCAT® is a registered trademark and patented technology, licensed by

Beckhoff Automation GmbH, Germany.

1.1.1 - OBJECTIVE OF THIS MANUAL M0006370.1

The objective of this manual is to provide information concerning the installation, operation, and mainte‐
nance of Stäubli TS2. It provides help for people working on the equipment, for reference purposes
only. Stäubli recommends attending training courses for easier understanding of this manual, better use
and robot maintenance.
The CS9 Instruction, CS9 Safety, Electrical diagrams and Spare parts manuals along with the arm man‐
ual, and software manuals (VAL 3, Stäubli Robotics Suite...) are needed to have a complete overview of
the robot.

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 1 - Introduction

1.1.2 - SPECIAL MESSAGES CONCERNING SAFETY, DANGERS, CAUTIONS AND

INFORMATION M0006371.1

In this document, there are several icons for important warnings.

These warnings are as follows (by decreasing order of importance):

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 necessary steps to reduce the
danger. It is essential to comply with the instructions to ensure personal safety.

Safety
SAFETY
Instructions drawing the reader's attention that they are responsible if the steps shown are not
complied with. It is essential to comply with the instructions to maintain the robot safety level.

Instructions directing the reader's attention to the risks of material damage or failure if the
steps shown are not complied with. It is essential to comply with these instructions to ensure
equipment reliability and performance levels.
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 opera‐
tions described.

ESD
This symbol is a reminder of the possible consequences of touching electrostatically sensitive
components.

1.2 - DEFINITIONS AND GLOSSARY M0006409.1

In this manual, a specific vocabulary is used according to our products. This chapter allows an easier
general understanding.
People in contact with the product are designated by different names:
Person: General term identifying all individuals likely to come close to the Stäubli machine.
Staff: Identifies people specifically employed and trained to install, operate, and service the Stäubli ma‐
chine.
User: Refers to people or the company responsible for operating the Stäubli machine.
Operator: Refers to the person who starts or stops the robot, or controls its operation.
Integrator: Refers to people or the company responsible for the design and manufacture of the robot
cell.

Item Definition
AIB Arm interface PCB (arm base)
BACKPLANE Link card between URPS 325 (or RPS 325) power supply and Drive Power Drawer
BRK Brake
COD Arm Encoder
CPT Computer drawer
DP Drive Power drawer
DPM 325 Dual Power Module 325 VDC (Dual drive)
DPMI-CAP Drive Power Module Interface & Capacitors
DPMI-VBus Drive Power Module Interface VBus distribution

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1 - Introduction

Item Definition
DSI9 Dual Sensor Interface Board for CS9 controller (arm base)
EV Solenoid valve
FDI Fast Digital Input
FDO Fast Digital Output
IC Interconnect Cable (between controller and arm)
MMI Human-machine interface PCB
MOT Motor
MPS 010 Stäubli Tool changer
PCIe Digital interface standard for optional peripheral boards
RBR Remote Brake Release
RPS 325 (SP) Robot Power supply 325 VDC single-phase
RSI9 Robot Safety Interface for CS9 controller
S1 Main switch
SBL/CPU Stäubli Bus Link & Central Processing Unit
SDI Safe Digital Input
SDO Safe Digital Output
SP2 Stäubli pendant
SRC The embedded software running on the CS9 Stäubli controllers
SRS The PC software to configure, develop, tune and maintain a robotics application
STARC9 Stäubli Advanced Robot Control for CS9 controller
TDO Digital Output Test signal for Safe Inputs
Th Thermal Sensor
UCB User connection Board
uniVAL A SRC control mode allowing to drive the robot from an external computer through an
industrial fieldbus
URPS 325 (3P) Universal Robot Power supply 325 VDC three phases
USI User Safe Input
USO User Safe Output
VAL 3 The Stäubli robotics programing language for CS9 Stäubli controllers
WMS9 Working Mode Selection control panel for CS9 controller
WMSES Emergency stop button on the operating mode selection panel

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2 - DESCRIPTION

2.1 - OVERVIEW M0007287.1

Figure 2.1:

The arm consists of links interconnected by joints. The different links are: The base (A), the inner link (B),
the forearm (C) and the ball screw (D).
The arm joints movements are generated by servomotors coupled to safe digital absolute encoders.
Motor brakes (on joints 3 and 4) maintain the arm at a fixed position when servomotors are disabled. A
safe digital processor (DSI9) (G) serializes the encoders information to the controller, and controls the
brakes and the electro-valves.
The arm includes electric wiring and pneumatic plumbing for customer use, linking the connectors at
the base to the connectors on the forearm. The forearm also includes points to attach devices to be
connected to the robot tooling.
The arm can be mounted on the floor or on the ceiling, with a horizontal or a vertical cabling connection
to match the specific machine constraints.
Different options for the arm are possible to match end-user appearance or environmental requirements,
such as cleanroom (SCR), food safe oil (H1), UL version, humid (HE) or bio-contaminated environ‐
ments (Stericlean).
For the UL version, a yellow indicator light (I) is fitted on the robot forearm to show that drive power is
available, that motion is possible and that it represents a possible cause of risks for the operator (see
chapter 4.8).
The speed, accuracy, and repeatability of the arm allow for a great variety of applications including
automotive and equipment manufacturers, food, life sciences and pharma, machine tending, plastics,
etc...

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2 - Description

A robot is identified by a plate attached to the controller and to the arm.

Example: Identification plate (H) (see figure 2.1).

Figure 2.2: Standard version

Figure 2.3: UL version

Item Description
1 Arm mass (kg/lb)
2 Manufacture date
3 Manufacturer's address
4 Serial number
5 Machine type and model
6 Nominal payload (kg/lb)
7 Maximum payload (kg/lb)
8 Reach (mm)

The CE mark placed on the identification plate refers to the "Electromagnetic Compatibility" directive.

Safety
SAFETY
The manufacturer's identification plate must remain present and legible throughout the robot
service life.

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2 - Description

Model TS2–40 TS2–60 TS2–80 TS2–100

Characteristics
Limiting load 8.4 kg
Nominal load 2.4 kg
Reach (between axis 1 and 4) 460 mm 620 mm 800 mm 1000 mm
(see chapter 3.2.2)
Number of degrees of freedom 4 4 4 4
Repeatability XY - ISO 9283 ± 0.01 mm ± 0.01 mm ± 0.015 mm ± 0.02 mm
Repeatability Z - ISO 9283 ± 0.004 mm ± 0.004 mm ± 0.004 mm ± 0.004 mm
Repeatability Rz - ISO 9283 ± 0.002 ° ± 0.002 ° ± 0.003 ° ± 0.003 °
Maximum speed at load center of 7.4 m/s 8.9 m/s 12.8 m/s 14.7 m/s
gravity
Typical linear speed 6.2 m/s 6.3 m/s 8.7 m/s 9 m/s
Noise at nominal conditions 76 dBA 76 dBA 72 dBA 72 dBA
25.300.25 mm cycles per minute 240 (0.25 s) 220 (0.27 s) 200 (0.3 s) 170 (0.35 s)
(with 2 kg payload)
Standard cleanliness - ISO Class ISO 6 (With axis 3 cover and bellow)
14644-1
Protection class - EN 60529 IP34/IP54 (with ball screw cover (Option)) /IP65 with ball screw cover
and bellow (Options))
Weight (*Vertical cable outlet) 38 kg 39 kg 40 kg 41 kg
(see chapter 4.1) (*34 kg) (*35 kg) (*36 kg) (*37 kg)
Stäubli Controller CS9
Brakes Joints 3 and 4
RBR (option) (see chapter 2.7) All models
Mounting options (see chap‐ Floor / Ceiling (option)
ter 4.4)
User interface Electrical / Ethernet / Pneumatic
Specific versions (see chapter 3.2.1)
Vertical cable outlet (option) All models
Pressurized version (option) All models
ESD All models
HE version (vertical cable outlet All models
only)
SCR version (cleanliness All models
class ISO 3) (To be confirmed)
Stericlean (vertical cable outlet All models
only)
H1 oil All models
Cylindrical work envelope
Working space can be restricted by different means (software, mechanical stops, …) to match the
available or desired maximum space. See chapter 3.2.2 for detailed information.

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 2 - Description

The arm type and model are defined as specified below:

Item Description
1 TS2 family arm
2 Maximum working radius between joint 1 and joint 4, expressed in decimeters and rounded off to
one significant digit:
+ (see figure 3.1).
3 Number of active axes:
■ 0 = 4 active axes.
4 Letters to indicate an option:
■ SCR, HE, Accesspharma (ACCESS) or Stericlean (STER) = For specific applications (see
chapter 3.2.1).

Figure 2.4:

2.2 - BEST PRACTICES M0006728.1

Stäubli robots are designed to be compact, dynamic and accurate. To have the best performance on
your application please have a look on the following integration best practices.
■ The tool must be as stiff as possible to get the best accuracy performances.
■ The robot support must be as stiff as possible to get the best accuracy performances.
■ If your application needs absolute positioning, please assure a controlled temperature around the
robot and make sure that the robot is at an established temperature.
■ The maximum payload must be respected to prevent any safety issue (see chapter 3.2.4.1).
■ Avoid singularities to get the best accuracy performances.
■ Please take into account the maintenance operations in your design to enhance your robot lifetime
with periodic interventions.
■ Check your screw tightening torques when the temperature varies a lot.
■ If your application needs the best duty cycle, it is possible to overpass the nominal speed up to
maximum speed. Double check the support and tool and verify the temperature and lifetime of your
robot. It will lead to a loss of accuracy along the path (vibrations, …).
■ The path shape and type must be chosen with care when accurate movement is needed. A smooth
path will lead to a better precision.
■ It is also possible to optimize the duty cycle by optimizing the robot position with respect to the
cycle path. A path close to the foot will allow having big accelerations while a path far from the foot
will allow increasing the Cartesian speed.
If your application needs a specific evaluation Stäubli is at your disposal for a custom evaluation.

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2.3 - BASE INTERFACE M0008306.1

Item Description
J1201 Arm/controller interconnect cable connection
J1202 13-contact electrical cable connection to J1203
J1204 RBR interface connection
J1217 Socket for a Cat 5e Ethernet link or an electrical connection for the tooling
P1, P2 Pneumatic connections
P3 Pressurization unit connection
E Pneumatic exhaust muffler
1 Interconnect cable, left outlet
2 Interconnect cable, straight outlet
3 Interconnect cable, right outlet

Figure 2.5:

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2 - Description

Item Description
J1201 Arm/controller interconnect cable connection
J1202 13-contact electrical cable connection to J1203
J1204 RBR interface connection
J1217 Socket for a Cat 5e Ethernet link or an electrical connection for the tooling
P1, P2 Pneumatic connections
P3 Pressurization unit connection
E Pneumatic exhaust muffler
1 Interconnect cable, left outlet
2 Interconnect cable, straight outlet
3 Interconnect cable, right outlet

Figure 2.6:

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2.4 - FOREARM CONNECTIONS M0008551.1

Item Description
J1203 Socket for electrical connection of the tool by the user where applicable
J1218 Socket for a Cat 5e Ethernet link or an electrical connection for the tooling
A1, A2, B1, B2, P2 Pneumatic connections

Figure 2.7:

Tapped holes are available for the user to attach additional load, harness,... (see chap‐
ter 3.2.5).

With the ball screw cover option, the forearm connectors are not present under the cover.

Figure 2.8:

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 2 - Description

2.5 - FLANGE INTERFACE (OPTION) M0009042.1

2.5.1 - ITEM IDENTIFICATION M0009169.1

Item Description
J1203 Electrical connection of the tool by the user where applicable
J1218 Cat 5e Ethernet link or an electrical connection for the tool
A1, A2, B1, B2, P2 Pneumatic connections

Figure 2.9:

2.5.2 - MINIMUM BENDING RADIUS M0007752.1

The minimum bending radius of these 3 different types of I/O wires or tubes, to prevent any damage, are
the following:
■ Power supply (3 wires AWG20): R = 4 minimum
■ Ethernet (2 pairs of shieded wires AWG26): R = 6 minimum
■ Pneumatic tubes (PU tubes): R = 8 minimum
These values are applicable to static conditions only.

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The bending radius R corresponds to the inner radius of the incurved wire or tube, as illustrated in the
following figure:

Figure 2.10:

2.6 - MPS 010 TOOL CHANGER (OPTION)

2.6.1 - GENERAL INFORMATION

2.6.1.1 - Main components M0007969.1

The tool changer system MPS 010 comprises a robot side (1) attached to the robot and one or more
tool sides (2). In option, for the automatic version, one or more docking stations (3) are provided.

Figure 2.11:

2.6.1.2 - Features M0007336.1

■ Connecting and disconnecting tools with automatic connection of media lines.

■ Backlash-free locking mechanism, which is locked and released by twisting the outer ring of the
robot side.
■ Locked state remains intact through pre-tensioning of the pressure springs.
■ Integrated media feedthrough.
■ Tool docking system simultaneously serves as locking actuation.

2.6.1.3 - Technical data M0007600.1

Technical data
Nominal payload 1.8 kg
Maximum payload 7.8 kg
Mass robot side 0.42 kg

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Technical data
Mass tool side 0.11 kg
Mass docking station 0.3 kg
Maximum bending moment 20 Nm
Maximum moment of rotation 15 Nm
Maximum traction 520 N
Maximum pressure force 520 N
Maximum shearing force 290 N
Maximum acceleration 50 m/s2
Joint direction Axial
Total joining distance 20 mm
Position tolerance, radial ± 0.2 mm
Limit value of inclined position ± 0.1°
Limit value of twist ± 0.15°

2.6.1.4 - Dimensions M0009355.1

Figure 2.12: Dimensions of the robot side

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Figure 2.13: Dimensions of the tool side

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Figure 2.14: Dimensions of the docking station

2.6.2 - AUTOMATIC MPS 010 VERSION

2.6.2.1 - Proximity switches M0009181.1

The docking station is equipped with three proximity switches that monitor the positions of the compo‐
nents. A proximity switch give information on the system locked (l1), an other on the system in coupling
position (l2) and the third one detects if a tool is present in the station (l3). The proximity switches are
electrically connected to the robot or the superordinate control system. Their signals must be cyclically
checked and evaluated here.

Figure 2.15: Proximity switches on the docking station

Proximity switches data

Type PNP
Cable box M12 x 1 , 3-pin
Cable length 0.3 m

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Proximity switches data

Rated switching distance Sn 1 mm
Rated operating current 100 mA
Operating voltage 10-30 V DC

2.6.2.2 - Function of automatic tool change

2.6.2.2.1 - Using a teaching aid M0007696.1

Figure 2.16: Teaching aid on the robot side (left) and tool side (right)

■ Fit the respective part of the teaching aid on the robot side and tool side of the MPS 010.
■ Slide tool with fitted tool side of the changing system into the docking station parking device
by hand. When doing so, make sure the clevis pin (1) points forwards and damps the proximity
switch I3.

Figure 2.17: Slide tool side into the docking station

■ Drive the robot with the fitted teaching aid precisely with the counter-piece against the tool side to
combine the 2 and align on the level.
■ Save position.
From this position, it is 25 mm in the z-direction (height of the teaching aid) to the actual
coupling position.

2.6.2.2.2 - Operating principle for connecting a tool M0007828.1

The tool is located in the docking station.

■ I1 = 0
■ I2 = 0
■ I3 = 1

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The robot side is driven to the starting posi‐

tion 8 mm above the tool side (see Library MPS Tool
Changer Manager instruction manual).
■ I1 = 1
■ I2 = 0
■ I3 = 1

The robot side is driven onwards to the coupling posi‐

tion.
■ I1 = 0
■ I2 = 1
■ I3 = 1

The fourth axle of the robot is rotated 20° clockwise.

The clamping ring (1) is held in place by the
docking station. The balls in the robot side are
pressed into the pockets of the clamping ring.
■ I1 = 1
■ I2 = 1
■ I3 = 0

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The tool can be horizontally removed from the docking

station and used.
■ I1 = 0
■ I2 = 0
■ I3 = 0

2.6.2.2.3 - Operating principle for disconnecting a tool M0009123.1

■ The coupled changing system is driven horizontally into the docking station.

Figure 2.18:

Figure 2.19:

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■ Rotating the fourth axle of the robot through 20° anticlockwise unlocks the changing system.

Figure 2.20:
■ The robot side can now move away vertically from the tool side.

Figure 2.21:

2.6.3 - MANUAL MPS 010 VERSION M0008100.1

If it is not necessary to change the tool frequently, it is also possible to perform tool changes on the
robot manually.
This requires a special spanner from Stäubli.

CAUTION
Danger of injury due to falling tool, robot movement and escaping compressed air. The tool
could fall during unscrewing and cause injuries. Robot movement can be started.

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In order to lock/unlock a tool, apply the spanner to the locking contour (1) of the clamping ring at the
bottom on the MPS 010 robot side. Hold the tool tight and turn the clamping ring 20° clockwise to
unclock, 20° antoclokwise to lock.

Figure 2.22: To unlock a tool, turn the clamping ring 20° clokwise

Figure 2.23: To lock a tool, turn the clamping ring 20° anticlockwise

2.6.4 - WIRING PROXIMITY SENSORS TO THE MPS STATION M0007472.1

M12 connector application

The NorComp M12 connector system is used in a vari‐

ety of harsh environments and demanding industrial ap‐
plications. Many include industrial controls and automa‐
tion such as remote process sensors, robotics control
systems, ruggedized networking, and power conditioning
systems.

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Inductive sensor BI1U-EH04-AP6X-0.3-RS4/S1160

■ Smooth barrel: Ø 4 mm.

■ Stainless steel: 1.4427.
■ Factor 1 for all metals.
■ Resistant to magnetic fields.
■ Large switching distance.
■ DC 3-wire: 10…30 VDC.
■ NO contact, PNP output.
■ Pigtail with male end M12 x 1.

Wiring diagrams.

Functional principle:
■ Inductive sensors detect metal objects contactless and wear-free. uprox®3 sensors have significant
advantages due to their patented ferrite-coreless multicoil system. They excel in largest switching
distances, maximum flexibility and operational reliability as well as efficient standardization.

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Features:

Type designation BI1U-EH04-AP6X-0.3-RS4/S1160

Ident no. 4602127

Rated switching distance Sn 1 mm

Mounting conditions Flush
Secured operating distance ≤ (0,81 x Sn) mm
Repeat accuracy ≤ 2 % of full scale
Temperature drift ≤ ± 10 %
≤ ± 20 %, ≤ 0 °C
Hysteresis 3…15 %
Ambient temperature -25…+70 °C

Operating voltage 10…30 VDC

Residual ripple ≤ 10 % Uss
DC rated operational current ≤ 100 mA
No-load current I0 ≤ 15 mA
Residual current ≤ 0.1 mA
Isolation test voltage ≤ 0.5 kV
Short-circuit protection Yes/Cyclic
Voltage drop at Ie ≤ 1.8 V
Wire breakage/Reverse polarity protection Yes/Complete
Output function 3 wires, NO contact, PNP
Switching frequency 2 kHz

Design Smooth barrel, 4 mm

Dimensions 30 mm
Housing material Stainless steel, 1.4427 SO
Active area material Plastic, PA12-GF30
Material coupling nut Metal, CuZn, nickel-plated
Electrical connection Cable with connector, M12 × 1
Cable quality 3 mm, Gray, LIF2X11XFHF, TPU, 0.3m
Flame retardant acc. to VDE 0472, part 804B
Cable cross section 3 x 0.14 mm2
Vibration resistance 55 Hz (1 mm)
Shock resistance 30 g (11 ms)
Protection class IP67
MTTF 874 years acc. to SN 29500 (Ed. 99) 40 °C
Packaging unit 1

Switching state LED yellow

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Distance D 2xB
Distance W 3 x Sn
Distance T 3xB
Distance S 1.5 x B
Distance G 6 x Sn

Diameter active area B Ø 4 mm

Accessories:

Type code Reference Description

BS 540 69475 Fixing clamp, Material mounting
block: Anodized aluminium
Clamp sleeve: Steel

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Type code Reference Description

MBS40 69477 Fixing clamp, Material mounting
block: Anodized aluminium

2.7 - BRAKE RELEASE FUNCTION (OPTION) M0006457.1

The brake release function from SP2 is secured with the enabling device, an electrical braking
of the motor, and a low safe speed limit.
■ Axes 1 and 2 are not equipped with a mechanical brake: the brake release function is
needed only for axes 3 and 4. When arm power is disabled, axes 1 and 2 can be moved
freely by hand.
■ The electrical braking and the speed limit allows only slow movements; the RBR brake
release function must be used when faster movements are required.

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2.7.1 - RBR INTERFACE DESCRIPTION M0006489.1

Item Description
1 RBR mode: Normal/OFF/Reduced safety.
2 6-position turn switch to select the axis to release.
3 Connection cable to the arm (J1204).
4 Enabling device to enable brake release opening.
5 Push button to release the selected brake.
6 Plug for external 24 V ±5% (1.5 A) PELV* power supply.

7 Connector for the arm connection cable.

Figure 2.24:

Only positions 3 and 4 of the 6-position turn switch are effective for TS2 arms. Position 3 con‐
trols the brake of axis 3 only. Position 4 controls the brakes of axes 3 and 4 simultaneously.
The RBR interface is designed to be usable with a single hand, left or right.

2.7.2 - RELEASING JOINT BRAKE M0006898.1

The brake on a joint can be released to move the robot manually, for example to quickly clear the cell
during an emergency stop, or following a failure affecting the controller (amplifiers) or the arm (motor,
coder).
The SP2 includes an interface to control each brake from the pendant. The use of the SP2 interface for
brake release is described in the chapter "Manual Brake Release" of the controller instruction manual.

* PELV according to EN 60204-1 6.4.2

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The RBR interface is an alternate way to release a joint brake, when the SP2 is not operational during
installation or maintenance phases, for example.
The behavior when releasing a brake depends on the brake control mode:
■ Using the SP2 interface, an electrical braking is activated to limit the speed and acceleration of the
axis falling due to gravity.
■ Using the RBR normal mode, no electrical braking is activated, but a safety function engages the
brake when the speed exceeds 250 mm/s.
■ Using the RBR reduced safety mode, neither electrical braking nor speed limit are activated.

Safety
SAFETY
The operator shall be informed of the risks when operating near the arm before using
the RBR interface. Residual risks are listed in chapter 3.1.5.

DANGER
■ Wherever possible, operation near the arm shall be done out of the reach of a falling axis.
■ The arm must be secured before any operation under its mechanical parts.
■ The RBR interface shall be used only with an arm whose base has been fastened to the
mounting surface.
■ Depending on the arm and the axis, releasing the brake may lead to an unexpected move.

2.7.2.1 - Normal mode M0006749.1

■ Connect the RBR interface to the J1204 connector at the arm base.
■ Select the normal mode position on the switch (1).
■ Wait 3 seconds.
■ Select the brake to open with the switch (2).

DANGER
Make sure the selection is correct to prevent an unexpected arm movement.
■ Press the enabling device (4) in its intermediate position.
■ Press the push button (5) to open the brake, release it to close the brake.
There is a delay of 3 seconds until brakes can be opened when coming from mode "OFF" to
"Normal mode".
■ After use, select the OFF position on the switch (1), or remove the RBR interface from connec‐
tor J1204. Press the "Update" button on the controller, or reboot it, to resume operation.

DANGER
Using the RBR normal mode, no electrical braking is activated, but a safety function engages
the brake when the speed exceeds a predefined threshold.
The axis must be supported before opening the brake.

■ The brake is engaged automatically when the speed exceeds a predefined threshold. The
enabling device must be released and pressed again to reopen the brake.
■ If this safety function cannot be activated due to a fault, for example a defective encoder,
the brake release function will not be possible on normal mode position. In that case, the
switch (1) must be placed in reduced safety mode position to enable brake release.

2.7.2.2 - Reduced safety mode M0006700.1

■ Connect the RBR interface to the (J1204) connector at the arm base.
■ Select the normal mode position on the switch (1).
■ Wait 3 seconds.

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■ Select the brake to open with the switch (2).

DANGER
Make sure the selection is correct to prevent an unexpected arm movement.
■ Select the reduced function mode position on the switch (1).
■ Press the enabling device (4) in its intermediate position.
■ Press the push button (5) to open the brake, release it to close the brake.
■ There is a delay of 3 seconds until brakes can be opened when coming from mode "OFF"
to "Normal mode".
■ Before selecting the reduced function mode, it is necessary to stay first 3 seconds in the
normal mode position with switch (1).
■ After use, select the OFF position on the switch (1), or remove the RBR interface from connec‐
tor J1204. Press the "Update" button on the controller, or reboot it, to resume operation.

DANGER
Using the RBR reduced safety mode, neither electrical braking nor speed limit are activated.
The axis must be supported before opening the brake.

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3 - MACHINE DESIGN

3.1 - SAFETY REQUIREMENTS M0006759.1

3.1.1 - SAFETY REGULATIONS M0006877.1

Intended use
A robot is not a ready-to-use product. It is a "partly completed machinery" designed to be integrated
in a "machine": the robot cell. This machine as a whole shall be compliant to the applicable safety
regulations before it can be operated.
The Stäubli robot is designed for industrial applications, where the operator is safely separated from
a moving robot with protective devices. Temporary proximity between the operator and the robot is
possible for collaborative operation, or for tuning and maintenance tasks, with additional risks that shall
be handled by the integrator.

European regulations
In the European Union, the applicable safety regulations for a machine are defined by the Machinery
Directive 2006/42/EC. This directive specifies that a risk assessment shall be carried out in order to
determine the health and safety requirements which apply to the machinery. The machinery must then
be designed and constructed taking into account the results of the risk assessment. The directive
defines essential health and safety requirements that are mandatory.
International standards have been developed to provide a framework for the correct application of the
Machinery Directive. The Machinery Directive, and harmonized standards list, can be found at http://eur-
lex.europa.eu. For robot integration, application of the specifications of the EN ISO 10218-2:2011 stand‐
ard on the basis of the integrator risk assessment confers a presumption of conformity with the essential
health and safety requirements of the Machinery Directive covered by the standard.
The Machinery Directive defines the procedures to evaluate the machinery conformity. For completed
machinery, the CE mark accompanied by the EC conformity declaration confers presumption of com‐
pliance with the Directive. For partly completed machinery, the incorporation declaration defines the
essential health and safety requirements and other applicable Directives that are satisfied.
The robot is delivered with its incorporation declaration. An electronic copy including several transla‐
tions is available on the robot DVD. It can also be requested from the Stäubli Customer Support contact.

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The robot incorporation declaration is based on the applicable requirements implementation of the
following harmonized standards:

■ EN ISO 10218-1:2011 Robots and robotic devices - Safety requirements for industrial robots -
Part 1
■ EN ISO 13849-1:2015 Safety of machinery - Safety-related parts of control systems - Part 1
■ EN 60204-1:2018 Safety of machinery - Electrical equipment
■ EN 61000-6-4:2007 / Electromagnetic compatibility - Generic emissions standard
A1:2011
■ EN 61000-6-2:2019 Electromagnetic compatibility - Generic immunity standard
■ IEC/EN 62061:2021 Safety of machinery: Functional safety of electrical, electronic and pro‐
grammable electronic control systems
■ EN 61000-6-7:2015 Electromagnetic compatibility - Immunity requirements for functional safe‐
ty in industrial locations
■ EN 61800-5-2:2017 Power drive systems - Functional safety requirements
■ EN 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use - Elec‐
tromagnetic compatibility - Immunity requirements for functional safety in
industrial locations

In the United States, there are no standardized Occupational Safety and Health Administration regula‐
tory standards for robots. However, standard ANSI/RIA R15.06-2012 is referenced as the standard
applicable to robot systems. That standard is harmonized to make it basically identical to stand‐
ards ISO 10218-1:2011 and ISO 10218-2:2011. These ISO standards for industrial robots have also
been adopted in Korea.
Each country can draw up further safety standards, and implement specific local rules. For example,
the UL standard for robots and robot equipment UL 1740 sets out further requirements covering the
robot and electrical safety.
For relative information about REACH 1907/2006 regulation (CE) consult the following internet address:
https://www.staubli.com/en/robotics-reach/

3.1.2 - ESSENTIAL HEALTH AND SAFETY REQUIREMENTS M0006891.1

Safety
SAFETY
When addressing the essential health and safety requirements defined by the Machinery Di‐
rective, the integrator shall address the requirements related to the robot that could not, or
only partially, be addressed by Stäubli. These requirements are noted throughout the robot
instruction manuals.

General-purpose requirements related to the robot are highlighted hereafter:

Principles of safety integration

The completed machinery shall be designed so that the robot is used according to its specifications,
and can be used, adjusted and maintained without risk.

Ergonomics
Robot tuning conditions (point teaching, motion tuning) shall be addressed when designing the robot
end-effector and cell environment.

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Control & information devices

The interaction means between the robot and the operator shall be compliant to the Machinery Directive
requirements.
When there is more than one robot control position in automatic mode, the control system shall be
designed so that the use of one of them precludes the use of the others, except for stop controls and
emergency stops.

Risks related to moving parts

Contacts between the robot and the operator shall be prevented by designing adequate guards or
protective devices.

Instructions
The integrator may have to translate the robot instructions if the completed machinery is put into service
in a country differing from the country where the robot was delivered.
The instructions for the completed machinery shall include the robot manuals, or manuals parts that are
needed to use, adjust, and maintain the robot.
The sales literature of the completed machinery shall be compliant with the robot instructions.

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3.1.3 - SAFETY FUNCTIONS

3.1.3.1 - Performance of safety functions M0006660.1

Function ISO IEC PFH Description

13849-1 62061 (h-1)
5/2-way solenoid 61.6 million - - B10d (number of
valve control commutation cycles
5/3-way solenoid 61.6 million - - reached by 90% of the
valve control devices without dan‐
gerous failure).
3/2-way solenoid 36 million - - See also "Safe control
valve control of external actuators"
chapter of the Safety
manual.
Brakes 6 million - - B10d (number of
(Axes 3, 4) commutation cycles
reached by 90% of the
devices without dan‐
gerous failure).
See also "Brake test‐
ing" chapter of the
Safety manual.
RBR enabling de‐ Cat4, PLe SIL3, HFT1 <10-7 In remote brake re‐
vice brake lock lease mode:
■ Maintain the brakes
closed when not
activated,
■ Close the brake
immediately when
released with an
open brake. 1
RBR limited speed Cat3, PLd SIL2, HFT1 <10-7 In remote brake re‐
lease mode, the brake
is engaged immediate‐
ly when the axis speed
exceeds a predefined
threshold. 1

1 The RBR enabling device and limited speed safety functions disable the safety brake power. The
brakes must be tested regularly for safe operation.

A SIL2/PLd Category 3 safety function is usually adequate for a temporary protection of the operator. A
frequent protection of the operator may require a higher performance of the safety function.

Safety
SAFETY
■ The required performance and parameters for the use of the robot safety functions shall be
defined from the identified risks in the completed machinery.
■ If regular operator intervention near the robot is planned, the safety functions of the control
system shall be designed with an adequate performance level, and the residual risks near
the robot listed in the manuals shall be addressed.

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3.1.3.2 - Characteristics of the solenoid valves M0006863.1

Test conditions:
■ No lubrication,
■ Dry air,
■ Cycle frequency: 3 Hz (5/3) - 5 Hz (3/2 and 5/2),
■ Pressure: 7 bar (5/2, 5/3, 3/2),
■ Vacuum: -0.8 bar (3/2),
■ Ambient temperature.

3.1.4 - SAFETY EQUIPMENT

3.1.4.1 - Remote Brake Release interface (RBR) M0006690.1

The RBR is equipped with 4 safety devices:

■ A 6-position rotary switch to select the axis to be released,
■ A push button to release the brake selected with the rotary switch,
■ An enabling device to enable brake release opening,
■ A switch to enable use in degraded mode when the RBR safety limited speed function cannot be
activated (encoder fault).
The RBR is also equipped with a plug for an external 24 V PELV power supply.
The RBR is an optional equipment. A brake release interface is also provided on the SP2.
The RBR is needed:
■ During installation or maintenance phases, when the controller is switched off or not connected to
the arm,
■ After a fault in the controller or SP2 hardware/software that prevents the use of the SP2 brake
release interface.

Safety
SAFETY
■ The choice to use the RBR interface shall rely on the risk analysis for the cell (risk of a
trapped person, or of a production stop, when a fault prevents the use of the SP2 to free
the machine from the arm).
■ The location of the RBR in the cell shall be carefully defined to assure access and prevent
misuse. The RBR may remain connected to the arm, or it can be connected only when
needed.
■ The RBR interface shall be tested yearly.

3.1.4.2 - RBR external 24V PELV power supply (24V2 circuit) M0006868.1

When the controller is switched off, the RBR interface requires an external power supply to be activated.

Safety
SAFETY
■ The external 24 V power supply for the safety controller shall be protected extra-low
voltage (PELV) (according to EN 60204-1 6.4.2).
■ The choice to use an external 24 V power supply shall rely on the risk analysis for the
cell (risk of a trapped person, or of a production stop, when a fault in the controller power
supply prevents the use of the RBR to free the machine from the arm).

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3.1.5 - RESIDUAL RISKS M0006600.1

Safety
SAFETY
■ The identified residual risks and foreseeable misuse shall be handled by the integrator,
and completed with specific risks and foreseeable misuse in the context of the completed
machinery. See Safety Programming manual for more information.
■ The residual risks shall be eliminated or reduced as far as possible.
■ Protective measures shall be taken in relation to the risks that cannot be eliminated.
■ Users shall be informed of the residual risks.

3.1.5.1 - Absence of defects M0006578.1

The robot must only be operated in faultless conditions. It is recommended to keep records of all safety
related actions on the robot and on the cell in a "safety book" or the like. Special care must be taken
during maintenance and restarting phases. See Safety Programming manual and maintenance manual.
■ Risks of using the robot under degraded conditions (restarting under conditions of reduced safety,
with damaged parts or safety equipment, etc.).
■ Risks of using unsuitable spare parts (fuses, fixings, inappropriate second-hand parts, etc.).
■ Risks of using the robot with a damage harness: Loss of the earth grounding of on segment of the
arm and/or loss of air pressure in pneumatic hoses used by customer tool.

3.1.5.2 - Adequate conditions of use M0006691.1

Risk-free operation of the robot in its cell does not depend solely on its safety functions.
■ Risks of using the robot with protective equipment disabled (sensors, switches, validation devices,
etc.).
■ Risks of changes in the surrounding conditions (electrical, electromagnetic, temperature, dust, wet,
etc.).
■ Risks of changes in the operating conditions (load, speed, acceleration, etc.).
■ Risks of using the robot as a tool for maintenance operations (part holder, support for personnel,
etc.).
■ Risks occurring when several people are working near the robot, with only one person being protec‐
ted by safety equipment.
■ Risks of inadequate earth grounding: If an external electrical power supply is brought to equipment
added on the robot arm, an adequate earth grounding must be added on this equipment.

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3.1.5.3 - Risk signaling M0007145.1

ISO 10218-1: 2011, 5.7.3 recommends that "wherever possible, the manual mode of operation shall
be performed with all persons outside the safeguarded space". It also reminds that prior to selecting
automatic mode, any suspended safeguards shall be returned to their full functionality.
■ Risks of uncontrolled movements, due to gravity (faulty brake) or an outside force (maintenance
operation on the arm or its tool). It is necessary to ensure that the brakes are operational before
working near the arm. The robot must be secured before working underneath the arm.
■ Risk of being entrapped by a moving part, or crushed when caught between the moving robot and
its environment in the cell.
■ Risks of contact with sharp edges on the moving robot, its tool, or the part held, even at low speed.
■ Risks of contact with hot parts: The arm surface temperature can reach 80°C (176°F) after intense
use.
■ Risk of contact with unprotected power transmission elements such as the ball screw, even if only
minor injury may result.
■ Risks stemming from activation of digital outputs (fall of a part on opening of a gripper, activation of
movement for other parts in the cell, etc.).
■ Risks stemming from reduced levels of attention to other hazards in the cell when concentrating on
the robot (slipping, tripping, falls, contact with moving parts, sharp edges, etc.).
■ Risks of sudden operator reaction to unexpected robot motion, even at low speed (inappropriate
operator command, large joint move induced by a small TCP move, unexpected command from
program...).

3.1.5.4 - Emergency rescue procedure M0006954.1

If, after a hazardous event during a collaborative operation, a tuning or a maintenance task, the operator
may possibly be trapped or injured by the robot or its environment, a rescue procedure shall be
established, and the staff shall be trained to react promptly. The procedure and training shall identify the
means to stop the hazards in the cell (such as emergency stops), and to unblock a possibly defective
robot using the brake release safety function (see chapter 2.7).

3.2 - MACHINERY REQUIREMENTS

3.2.1 - WORK ENVIRONMENT M0006663.1

3.2.1.1 - Standard recommendations M0007033.1

Safety
SAFETY
■ Working temperature: + 5°C to + 45°C (+ 41°F to + 113°F).
■ Humidity: 90% maximum (non-condensing).
■ Storage temperature: - 20°C to + 60°C (- 4°F to + 140°F).
■ Altitude: 2000 m max. (please consult us for higher altitudes).
■ Vibrations: Please consult us.

■ In cold conditions, it may be necessary to perform a warm-up cycle before nominal per‐
formances are obtained.
■ In hot conditions, the robot thermal protections may lead to robot cycle time limitations.
Cleaning and disinfecting recommendations (see chapter 7.6).

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■ Noise at nominal conditions: TS2-40, TS2-60: 76 dBA, TS2-80, TS2-100: 72 dBA (meas‐
ured at 1 m away from movement and at 1.6 m high).
■ Arm ingress protection: IP34/IP54* (*requires ball screw cover) /IP65** (**requires ball screw
cover, bellows, electric or blanking plugs inserted and pressurization unit).
■ Impact protection: The mechanical protection index is IK08 for the arm, except IK07 for the
external connectors on base interface and forearm.

3.2.1.2 - Additional information for cleanroom application M0006943.1

■ SCR: Cleanliness class ISO 3 in accordance with standard ISO 14644-1.

3.2.1.3 - Additional information for Accesspharma version (ACCESS) M0009531.1

TS2 Accesspharma robots are specifically designed for Pharma controlled area, and are suitable for
Cleanliness class ISO 5 in accordance with standard ISO 14644-1.
■ Limits of application:
- Resistance to isopropanol
- Resistance to ethanol

3.2.1.4 - Additional information for humid environment application (HE) M0006528.1

■ Limits of application:
- 4,5 < pH < 8,5 (pH 2 to 12 under condition, please consult us).
- Resistance to salt spray: 300 hours in accordance with standard NS EN 60068-2-11.
- Use of chlorinated products for cleaning is prohibited.
- The arm must be pressurized with the Stäubli pressurization unit.
Stäubli declines its warranty if the arm is pressurized by a pressurization unit which doesn’t
provide exactly the same characteristics.

DANGER
The pressurization unit must be protected from the humid environment.

A separate pressurization unit is needed for each robot.

-The following elements are not qualified for a humid environment (HE) and they must be protec‐
ted from that environment:
- The threaded fasteners on the flange mechanical interface.
- The threaded fasteners on the robot.
- The underside of the base.
- The interconnect plate.
- The equipment on the plate.
This protection is to be provided by the customer, and are their responsibility. The guarantee
does not cover any damage occurring there.
- In the event of use of an optional mechanical hard stop system, depending on the environment,
the system may show limited chemical resistance. Regularly inspect the system to check that
it is in good condition. In the event of deterioration, the system can be replaced. It should be
noted that because of its complex shape, the mechanical hard stop system makes the arm more
difficult to clean and disinfect.
■ Vertical cable outlet only.

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3.2.1.5 - Additional information for bio-contaminated environment application (Stericlean) M0007175.1

■ Limits of application:
- 4,5 < pH < 8,5.
- Resistance to salt spray: 300 hours in accordance with standard NS EN 60068-2-11.
- Bio-decontamination with hydrogen peroxide on a wipe (concentration 50%) or in vapor phase.
- Use of chlorinated products for cleaning is prohibited.
- The following elements are not qualified for a bio-contamination controlled environ‐
ment (Stericlean) and they must be protected from that environment:
- The screw(s) on the flange mechanical interface.
- The underside of the base.
- The interconnect plate.
- The equipment on the plate.
This protection is to be provided by the customer, and are their responsibility. The guarantee
does not cover any damage occurring there.
- In the event of use of an optional mechanical hard stop system, depending on the environment,
the system may show limited chemical resistance. Regularly inspect the system to check that
it is in good condition. In the event of deterioration, the system can be replaced. It should be
noted that because of its complex shape, the mechanical hard stop system makes the arm more
difficult to clean and disinfect.
- There must not be any pressure difference between the inside of the robot and the exterior
environment of the robot.
■ Vertical cable outlet only.

3.2.2 - WORKING SPACE AND SPEED M0007595.1

Figure 3.1: Floor mounting, horizontal outlet

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Figure 3.2: Floor mounting, vertical outlet

Figure 3.3: Ceiling mounting, horizontal outlet

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Figure 3.4: Ceiling mounting, vertical outlet

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Item Description
F Axis 1
G Axis 2
H Axis 4

Figure 3.5: Floor mounting

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Item Description
F Axis 1
G Axis 2
H Axis 4

Figure 3.6: Ceiling mounting

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The dimensions are shown in figures 3.1 and 3.3 (horizontal cable outlet configuration) and in fig‐
ures 3.2 and 3.4 (vertical cable outlet configuration). Work space, Cartesian frames 'Flange' and 'World'
of the arm are shown in figure 3.5. The main dimensions are summarized below:

Working space TS2–40 TS2–60 TS2–80 TS2–100

Distance between axis 1 and 2 A 220 mm 380 mm 380 mm 580 mm
Distance between axis 2 and 4 B 240 mm 240 mm 420 mm 420 mm
R.M max. reach between axis 1 and 4 A+B 460 mm 620 mm 800 mm 1000 mm
R.m min. reach between axis 1 and 4 (Floor - 150 mm 210 mm 161 mm 206 mm
mounting)
R.m min. reach between axis 1 and 4 (Ceiling - 210 mm 210 mm 195 mm 206 mm
mounting)1
Stroke axis 3 Z stroke 200 mm (400 mm is an option)
Position of Floor Standard C2 340 mm
the flange mounting With flange 323 mm
With flange and bel‐ 321 mm
lows 200 mm stroke
With flange and bel‐ 321 mm
lows 400 mm stroke
With MPS 010 278 mm
Ceiling Standard 360 mm
mounting With flange 377 mm
With flange and bel‐ 379 mm
lows
With MPS 010 422 mm
Top of the Floor 200 mm Z stroke D 756 mm
ball screw mounting 400 mm Z stroke 956 mm
Ceiling 200 mm Z stroke 56 mm
mounting 400 mm Z stroke 256 mm
Top of the Floor 200 mm Z stroke E 807 mm
ball screw mounting 400 mm Z stroke 1007 mm
cover
(option) Ceiling 200 mm Z stroke 107 mm
mounting 400 mm Z stroke 307 mm

1 Values can change if flange or bellow option.

2 This measurement may vary from one robot to another.

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Axis TS2-40 TS2-60 TS2-80 TS2-100

Range Axis 1 360°
Axis 2 (Floor 283° 300° 310° 320°
mounting)
Axis 2 (Ceiling 252° 300° 305° 320°
mounting)
Axis 3 200 mm (400 mm is an option)
Axis 4 1000° (720° with IO and pneumatics to the flange option)1
Joint Limits Axis 1 ±180°
Axis 2 (Floor -143° / +141° ±155° ±157.5° ±165°
mounting)
Axis 2 (Ceiling -126° / +126° ±155° ±152.5° ±165°
mounting)
Axis 3 200 mm (400 mm is an option)
Axis 4 ±500° (±360° with IO and pneumatics to the flange option)1
Nominal speed Axis 1 450°/s 385°/s 350°/s 300°/s
Axis 2 630°/s 525°/s 525°/s 525°/s
Axis 3 2100 mm/s 2100 mm/s 1680 mm/s 1680 mm/s
Axis 4 1260°/s 1260°/s 1260°/s 1260°/s
Maximum Axis 1 550°/s 550°/s 550°/s 550°/s
speed Axis 2 720°/s 720°/s 700°/s 700°/s
Axis 3 2500 mm/s 2500 mm/s 2100 mm/s 2100 mm/s
Axis 4 2500°/s 2500°/s 2500°/s 2500°/s
Angular resolu‐ Axis 1 0.008.10-3°
tion
Axis 2 0.011.10-3°
Axis 3 0.031.10-3 mm
Axis 4 0.028.10-3°

1 Can be configured by software up to ± 15 000° (± 41 rotations). To do so, see the "Software

configuration" chapter in the controller instruction manual. Can be configured as a "continuous"
axis under the continuousAxis license.

The base of the robot is part of the working space; the working space with the end-effector
may also include other parts of the robot. Reduce unused axes ranges to prevent risk of
collision with the robot or the environment, in case of misuse or programming fault.
The maximum space can be reduced by different means:
■ Fences,
■ Mechanical hard stop on axis 1 and 2.
A 3D CAD simulation is required for an accurate positioning of the arm in the cell, to check reachabil‐
ity and prevent collisions. Our Stäubli Robotics Suite PC software allows a complete 3D simulation,
as described in chapter 3.3 (Robot simulation). CAD files are available in our CAD library at http://
www.staubli.com/ for other simulation tools.

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3.2.3 - ARM MOUNTING M0006865.1

3.2.3.1 - Working space M0006996.1

The user or integrator is responsible for performing all preparatory work required to complete the on-site
installation of the robot. Working space must be sufficient, installation surface appropriate; the power
supplies must be available (for the electric power supplies, see the controller characteristics).

Safety
SAFETY
■ The cell must be designed in such a way that the robot is used in accordance with its
specifications, and can be used, adjusted, and maintained without risk.
■ The adjustment conditions (teaching points, movement adjustment) must be taken into
account when designing the cell.
■ All contact between the robot and the operator must be prevented by designing suitable
guards or protective devices.
■ When the peripheral protector is used to limit the space that the robot can reach, it must
be designed in such a way that the robot cannot cause hazardous deformation of the
protector (EN ISO 10218-2:2011, 5.4.3) (see chapter 3.2.9).

To enable all maintenance operations to be carried out, it is essential to provide easy access
to the robot (e.g. removable safety barriers, etc.) and anchoring points for easy handling of the
arms, especially those whose weight exceeds 70 kg / 154 lb.

Figure 3.7: Floor mounting

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Figure 3.8: Ceiling mounting

A 150 mm
B 150 mm

To enable all maintenance operations to be carried out, we advice to provide easy access to the robot
(e.g. removable safety barriers, etc.) and anchoring points for easy handling of the arms, especially
those whose weight exceeds 70 kg / 154 lb.
■ The place (1) should be accessible for axis 1 maintenance (see figure 3.8).
■ The place (2) should be accessible for axis 2, 3 and 4 maintenance (see figures 3.7 and 3.8).
■ Leave a free-place of 0.5 m2 and 1300 mm high close to the arm to guarantee access to the robot
elements by an operator.
The non-respect of these dimensions causes the removal of the arm during maintenance
interventions.

3.2.3.2 - Mounting floor quality M0006713.1

Safety
SAFETY
The user has to make sure that the mechanical characteristics of the floor and the means of
attachment will hold up to the maximum forces caused by the moving arm.

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3.2.3.3 - Attachment M0008980.1

Figure 3.9: Horizontal cable outlet

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Item Description
(*) Opening required for the connectors and to allow removal of the interconnect plate
(**) Zone with roughness to be complied with

Figure 3.10: Vertical cable outlet

Vertical cable outlet with minimum opening size to be made or left in the attachment surface to put the
cable through and access the connections. Seal on the inner face of the base on the holder using a
static joint for the he and steri versions.
The arm can be ordered for floor mount or ceiling mount. In all cases, it must be securely attached
by 3 screws M10 class 12.9 (standard or DeltaProtect, according to ISO 4762).
Tightening torque: 59 Nm (with a tool of minimum ±15% accuracy).

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For the vertical cable outlet, add washer and ensure that the minimum length engagement of the screw
(in the foot threaded hole) is 12 mm and the maximum is 16 mm.
Humid environment (HE), pharma controlled area (Accesspharma) or bio-contamination
controlled environment (Stericlean):
■ The following elements are not qualified for a humid (HE) or pharma (Accesspharma) a
bio-contaminated (Stericlean) environment and they must be protected from these environ‐
ments:
- The threaded fasteners on the flange mechanical interface.
- The threaded fasteners on the robot.
- The underside of the base.
- The interconnect plate.
- The equipment on the plate.
This protection is to be provided by the customer, and are their responsibility. The guarantee
does not cover any damage occurring there.
■ Base / holder interface, sealed with the exterior joint supplied:
- The surface of the holder on which the robot base is fixed must have surface character‐
istics that provide static sealing.
- Lubricate and fit the exterior seal.
- The underside of the base must be protected from the humid or bio-contamination
controlled environment.
■ Protection of the power interconnect plate and the equipment fitted to it:
- Protect the complete element from the humid or bio-contamination controlled environ‐
ment.
To facilitate access to the connections during installation and maintenance, it is important
to leave as large of an opening as possible in the robot base for the "Vertical cable outlet"
version, following the dimensions shown in the figure 3.9, and to leave a safe distance in front
of the base interface for both versions (figures 3.9 and 3.10).
Attachment surface shall be flat and metallic. A deformable support will greatly reduce robot perform‐
ance in speed and accuracy.
When calculating the size of the support, it is necessary to take into account the maximum forces
transmitted by the arm in movement at point 0, which are as follows:
Floor or ceiling mounted arm:

FV 1200 N
FG 2500 N
CB 900 Nm
CP 900 Nm

During motion with nominal velocity and acceleration parameters and under following load conditions:

Load 2.4 kg / 5.29 lb

Load position X 0 mm / 0 in
Z 50 mm / 1.97 in

The user can accurately position the robot by means of two 8h8 diameter centering pins (not supplied).

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3.2.4 - END-EFFECTOR M0008553.1

Item Description
M Center of gravity

Figure 3.11: Standard configuration

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Item Description
M Center of gravity

Figure 3.12: With flange (option)

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Item Description
M Center of gravity

Figure 3.13: With flange and bellows - 200 stroke (option)

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Item Description
M Center of gravity

Figure 3.14: With flange and bellows - 400 stroke (option)

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Item Description
M Center of gravity

Figure 3.15: With MPS 010 (option)

The end-effector (2) is not supplied with the arm assembly; its design depends on the robot specific
applications.
The end-effector design should be sufficiently rigid to avoid affecting robot dynamic perform‐
ance and precision levels. All studies can be undertaken in cooperation with Stäubli to obtain
optimum performance without exceeding the robot arm assembly load limits.

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Safety
SAFETY
■ The end-effector must be correctly sized and attached in accordance with specifications.
■ The tool must be designed to hold the load with the programed accelerations and in the
event of a cut-off in the electrical or pneumatic power supply.
■ At high speed, the possibility of load ejection usually requires the installation of protection
fences around the robot.

Tool flange typical accelerations TS2-40 TS2-60 TS2-80 TS2-100

Translation X, Y 100 m.s-2 80 m.s-2 110 m.s-2 110 m.s-2
Z 40 m.s-2 40 m.s-2 20 m.s-2 20 m.s-2
Rotation X, Y 0 rad.s-2 0 rad.s-2 0 rad.s-2 0 rad.s-2
Z 400 rad.s-2 310 rad.s-2 210 rad.s-2 210 rad.s-2

The end-effector (2) is mounted on the ball screw mechanical interface (1) (dimensions given in fig‐
ures 3.11, 3.12, 3.13, 3.14 and 3.15).
Indexing by the Ø6 pin (1) or Ø3 pin (3).
ISO 9409-1-40-4-M6 mechanical interface (except the localization of the 4 M6 threaded holes).

Safety
SAFETY
■ Secured by 4 class 12-9 screws M6 (4), tightening torque 16.7 Nm ± 0.7 Nm.

Humid environment (HE), pharma controlled area (Accesspharma) or bio-contamination

controlled environment (Stericlean):
The ball screw mechanical interface must be protected by assembling the end-effector with
mastic (Loctite Terostat 92) or equivalent (see figures 3.11, 3.12, 3.13, 3.14 and 3.15).
This protection is to be provided by the customer, and are their responsibility. The guarantee
cannot cover any damage occurring there.

3.2.4.1 - Load capacity M0008857.1

Load characteristics (see figures 3.11, 3.12, 3.13, 3.14 and 3.15):

Load capacity Standard Flange option MPS 010 option

At nominal speed 2.4 kg / 5.29 lb 2.2 kg / 4.85 lb 1.8 kg / 3.97 lb
At reduced speed 1 8.4 kg / 18.52 lb 8.2 kg / 18.07 lb 7.8 kg / 17.20 lb

1 Under reduced speed and acceleration conditions.

Generally: VEL = 65%, ACC = 65%, DEC = 65% (consult us)

Load capacity Axis 4

Nominal inertias 0.05 kg.m²
Maximal inertias1 0.1 kg.m²

1 Under reduced speed and acceleration conditions.

Generally: VEL = 65%, ACC = 65%, DEC = 65% (consult us)

The nominal values can be exceeded to a certain extent but imply a limitation to the speed and
the acceleration of the arm. If these limits are to be exceeded, please consult Stäubli.

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The joint velocities and accelerations of the arm can be reduced to safely prevent the exceeding of the
maximum limits on the flange. The tuning of these safety parameters is described in the "Integration"
chapter of the controller instruction manual.

3.2.4.2 - Maximum torque M0008550.1

To limit the temperature of the robot, the following torques must not be exceeded.

Static torques TS2-40 TS2-60 TS2-80 TS2-100

Horizontal force (continuous / maxi‐ 145 N / 290 N 145 N / 290 N 85 N / 170 N 85 N / 170 N
mum)
Vertical force (continuous / maximum) 260 N / 520 N 260 N / 520 N 260 N / 520 N 260 N / 520 N
Joint 4 torque (continuous / maximum) 14 Nm / 21 Nm 14 Nm / 21 Nm 14 Nm / 21 Nm 14 Nm / 21 Nm

These torques are available for a load carried equal to 0 kg.

3.2.5 - USER INTERFACE (ADDITIONAL LOAD, CAMERA, HARNESS...) M0007791.1

Figure 3.16: Forearm user interface for TS2-40, TS2-60, TS2-80 and TS2-100

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Figure 3.17: Arm user interface for TS2-40

Figure 3.18: Arm user interface for TS2-60 and TS2-80

Figure 3.19: Arm user interface for TS2-100

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As user interface, tapped holes are available:

■ TS2-60, TS2-80 and TS2-100 models: 4 M6 holes on the inner link (maximum torque is 7 Nm),
■ TS2-40 model: 2 M6 holes on the inner link (maximum torque is 7 Nm),
■ All models: 4 M4 holes on the forearm (maximum torque is 3 Nm).
The additional load depends on nominal load. In all cases, do not exceed load characteristics.

For humid environment (HE) or bio-contamination controlled environment (Stericlean), in case

of use of the user interface, it must be protected with mastic (Loctite Terostat 92) or equiv‐
alent. This protection is to be provided by the customer, and are their responsibility. The
guarantee cannot cover any damage occurring there.

3.2.6 - PNEUMATIC CIRCUIT M0008094.1

The standard arm cabling system integrates the pneumatic lines that provide 2 pressure sup‐
plies (A1) and (P2) near the tool clamp, and a press in fitting (A2) for the return to the exhaust.
As an option, the harness includes pneumatic hoses which supply air to the solenoid valves
((EV1) and (EV2)).
■ The robot also has a pressure source (P2) close to the tool clamp.
■ The outlets of the solenoid valves (EV1) and (EV2) are on the forearm or at the flange (option):
- (A1) and (B1) for solenoid valve (EV1),
- (A2) and (B2) for solenoid valve (EV2).

Safety
SAFETY
Do not add wires or cables to arm wiring as this may cause premature wear of the arm
electrical wiring and impacts the safety functions of the arm.

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3.2.6.1 - Pneumatic circuit with direct lines (standard) M0008645.1

Item Description
1 Plate attached to base
2 Forearm

Figure 3.20: Forearm connections (standard)

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Item Description
1 Plate attached to base
3 Ball screw
4 Flange

Figure 3.21: Flange interface (option)

CAUTION
Do not pull on the harness.

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Item Description
1 Plate attached to base
3 Ball screw
5 MPS

Figure 3.22: MPS interface (option)

Description:
■ The arm is connected to the compressed air network (7 bar (100 psi) maximum, with or without
lubrication) through 2 press in fittings (for Ø6 hoses) on its base ((P1) and (P2)).
■ There are two direct lines between the base and the forearm.
■ The centralized exhaust (A2) is directed towards the base and its outlet is through a muffler (E).

Safety
SAFETY
Pressure over 7 bar (100 psi) may entail risks for the user and the machine.

■ Cleanliness of air must be equivalent to 5 µm filtered air.

■ Ambient and fluid temperature: Do not exceed 50°C.
■ Compressed air containing a large amount of drainage can cause malfunction of pneumatic
equipment. An air dryer or water separator should be installed upstream from filters.
■ Do not use compressed air that contains chemicals, synthetic oils including organic sol‐
vents, salt or corrosive gases, etc., as it can cause damage or malfunction.

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3.2.6.2 - Pneumatic circuit with 5/2 bistable solenoid valves (option) M0008424.1

Item Description
1 Plate attached to base
2 Forearm

Figure 3.23: Forearm connections (standard)

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Item Description
1 Plate attached to base
3 Ball screw
4 Flange

Figure 3.24: Flange interface (option)

CAUTION
Do not pull on the harness.

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Item Description
1 Plate attached to base
3 Ball screw
5 MPS 010 Tool changer

Figure 3.25: MPS 010 Tool changer interface (option)

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Electric distributors (EV1 and EV2):

■ 5/2-way bistable.
■ Electrically controlled (24 VDC).
■ Max. working pressure: 1 to 7 bar (14.50 to 100 psi).
■ Flow coefficient: Kv = 8.6 [m3.h-1.bar-1/2], S = 3.6 mm2.
■ Clip-on connector.
■ Overvoltage protective circuit and indicator diode.

Description:
■ The arm is connected to the compressed air network (7 bar (100 psi) maximum, with or without
lubrication) via the base fittings (P1) (one-touch fittings for Ø6 hoses).
■ Cleanliness of air must be equivalent to 5 µm filtered air.
■ Ambient and fluid temperature: Do not exceed 50°C.
■ Compressed air containing a large amount of drainage can cause malfunction of pneumatic
equipment. An air dryer or water separator should be installed upstream from filters.
■ Do not use compressed air that contains chemicals, synthetic oils including organic sol‐
vents, salt or corrosive gases, etc., as it can cause damage or malfunction.
■ In the "forearm connection" configuration there is a direct line between the base (press in fittings
for Ø6 hoses) and the forearm (P2).
■ The exhaust from the valve manifold is directed to the base and through a muffler (E).

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3.2.6.3 - Pneumatic circuit with 5/3 monostable solenoid valves (option) M0009266.1

Item Description
1 Plate attached to base
2 Forearm

Figure 3.26: Forearm connections (standard)

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Item Description
1 Plate attached to base
3 Ball screw
4 Flange

Figure 3.27: Flange interface (option)

CAUTION
Do not pull on the harness.

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Item Description
1 Plate attached to base
3 Ball screw
5 MPS 010 Tool changer

Figure 3.28: MPS 010 Tool changer interface (option)

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Electric distributors (EV1 and EV2):

■ 5/3-way monostable.
■ Electrically controlled (24 VDC).
■ Max. working pressure: 1 to 7 bar (14.50 to 100 psi).
■ Flow coefficient: Kv = 8.6 [m3.h-1.bar-1/2], S = 3.6 mm2.
■ Clip-on connector.
■ Overvoltage protective circuit and indicator diode.

Description:
■ The arm is connected to the compressed air network (7 bar (100 psi) maximum, with or without
lubrication) via the base fittings (P1) (one-touch fittings for Ø6 hoses).
■ Cleanliness of air must be equivalent to 5 µm filtered air.
■ Ambient and fluid temperature: Do not exceed 50°C.
■ Compressed air containing a large amount of drainage can cause malfunction of pneumatic
equipment. An air dryer or water separator should be installed upstream from filters.
■ Do not use compressed air that contains chemicals, synthetic oils including organic sol‐
vents, salt or corrosive gases, etc., as it can cause damage or malfunction.
■ In the "forearm connection" configuration there is a direct line between the base (press in fittings
for Ø6 hoses) and the forearm (P2).
■ The exhaust from the valve manifold is directed to the base and through a muffler (E).

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3.2.6.4 - Pneumatic circuit with 3/2 monostable solenoid valves (option) M0007989.1

Item Description
1 Plate attached to base
2 Forearm

Figure 3.29: Forearm connections (standard)

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Item Description
1 Plate attached to base
3 Ball screw
4 Flange

Figure 3.30: Flange interface (option)

CAUTION
Do not pull on the harness.

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Item Description
1 Plate attached to base
3 Ball screw
5 MPS 010 Tool changer

Figure 3.31: MPS 010 Tool changer interface (option)

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Electric distributors (EV1 and EV2):

■ 3/2-way monostable.
■ Electrically controlled (24 VDC).
■ Max. working pressure: vacuum only ≈ -0.8 bar (-11.6 psi).
■ Flow coefficient: Kv = 12.6 [m3.h-1.bar-1/2], S = 3.6 mm2.
■ Clip-on connector.
■ Overvoltage protective circuit and indicator diode.

Description:
■ The arm is connected to the vacuum network via the base (P1).
■ Cleanliness of air must be equivalent to 5 µm filtered air.
■ Fluid temperature: Do not exceed 50°C.
■ Compressed air containing a large amount of drainage can cause malfunction of pneumatic
equipment. An air dryer or water separator should be installed upstream from filters.
■ Do not use compressed air that contains chemicals, synthetic oils including organic sol‐
vents, salt or corrosive gases, etc., as it can cause damage or malfunction.
■ There is a direct line between the base (press in fittings for Ø6 hoses) and the forearm (P2).
■ The exhaust from the valve manifold is directed to the base and through a muffler (E).

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3.2.6.5 - Pneumatic circuit vacuum and pressure with 3/2 monostable solenoid valves
(option) M0008078.1

Item Description
1 Plate attached to base
2 Forearm

Figure 3.32: Forearm connections (standard)

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Item Description
1 Plate attached to base
3 Ball screw
4 Flange

Figure 3.33: Flange interface (option)

CAUTION
Do not pull on the harness.

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Item Description
1 Plate attached to base
3 Ball screw
5 MPS 010 Tool changer

Figure 3.34: MPS 010 Tool changer interface (option)

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Electric distributors (EV1 and EV2):

■ 3/2-way monostable.
■ Electrically controlled (24 VDC).
■ Max. working pressure: 1 to 7 bar (14.50 to 100 psi), vacuum ≈ -0.8 bar (-11.6 psi).
■ Flow coefficient: Kv = 12.6 [m3.h-1.bar-1/2], S = 3.6 mm2.
■ Clip-on connector.
■ Overvoltage protective circuit and indicator diode.

Description:
■ The arm is connected to the vacuum network via the base (P1) (2 one-touch fittings for Ø6 hoses)
and to the pressure network via the base (P2).
■ Cleanliness of air must be equivalent to 5 µm filtered air.
■ Fluid temperature: Do not exceed 50°C.
■ Compressed air containing a large amount of drainage can cause malfunction of pneumatic
equipment. An air dryer or water separator should be installed upstream from filters.
■ Do not use compressed air that contains chemicals, synthetic oils including organic sol‐
vents, salt or corrosive gases, etc., as it can cause damage or malfunction.

3.2.7 - ELECTRIC CIRCUIT M0008895.1

Safety
SAFETY
Supply voltage: 60 VDC (14-contact connector) and 50 VDC (Ethernet socket).
Permissible current:
■ 3-wire conductor AWG20: 3 A per contact.
■ Shielded pairs AWG26: 1 A per contact.
■ Pairs AWG24: 2 A per contact.

Do not use the shields as a conductive cable.

Safety
SAFETY
Do not add wires or cables to arm wiring as this may cause premature wear of the arm
electrical wiring and impacts the safety functions of the arm.

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3.2.7.1 - Forearm connections M0008041.1

Item Description
1 Plate attached to base
2 Forearm

Figure 3.35: Forearm connections (standard)

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The electrical circuit consists of:

■ A male 14-contact socket (J1202), with only 13 connected cables, and a male 4-contact sock‐
et (J1217) (M12 Ethernet code D) at the base,
■ A female 14-contact socket (J1203), with only 13 connected cables, and a female 4-contact sock‐
et (J1218) (M12 Ethernet code D) on the forearm.
The 13 signal contacts in each socket are connected in the following way:
■ 3 power contacts in each socket, connected by a 3-wire conductor with cross-section AWG20
(contacts G-R-S),
■ 5 twisted pairs, cross-section AWG24 for the other contacts.
The 4 contacts are connected via a twin shielded pair AWG26 Ethernet cable.
In option:
■ Connection on forearm by elbow male connectors:
- (J1203), M16 (BINDER 99 0451 75 14).
- (J1218), M12 (PHOENIX CONTACT SACC-M12MRD-4Q SH - 1553624).
■ Connection on the base by female cylindrical connectors:
- (J202), M16 (BINDER 09 0452 70 14).
- (J1217), M12 (PHOENIX CONTACT SACC-M12FSD-4Q SH - 1553611).

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3.2.7.2 - Flange interface M0007716.1

Item Description
1 Plate attached to base
3 Ball screw
4 Flange

Figure 3.36: Flange interface (option)

CAUTION
Do not pull on the harness.

The electrical circuit consists of:

■ A male 14-contact socket (J1202), with only 3 connected cables, and a male 4-contact sock‐
et (J1217) (M12 Ethernet code D) at the base,
■ At the Flange side, there is a Twisted Third cable with 3 wires and an Ethernet cable with 4 conduc‐
tors with shield (Ethernet Cat5e cable).
The 3 signal contacts are connected in the following way:
■ 3 power contacts, connected by a 3-wire conductor with cross-section AWG20 (contacts G-R-S).
The 4 contacts are connected via a twin shielded pair AWG26 Ethernet cable.

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3.2.7.3 - MPS 010 Tool changer interface M0007254.1

Item Description
1 Plate attached to base
3 Ball screw
5 MPS 010 Tool changer

Figure 3.37: MPS 010 Tool changer interface (option)

The electrical circuit consists of:

■ A male 14-contact socket (J1202), with only 13 connected cables, and a male 4-contact sock‐
et (J1217) (M12 Ethernet code D) at the base,
■ A female 14-contact socket (J1203), with only 3 connected cables, and a female 4-contact sock‐
et (J1218) (M12 Ethernet code D) on the forearm or at the flange (option).
The 13 signal contacts in each socket are connected in the following way:
■ 3 power contacts in each socket, connected by a 3-wire conductor with cross-section AWG20
(contacts G-R-S),

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3.2.8 - PRESSURIZATION UNIT (OPTION) M0007456.1

3.2.8.1 - Purpose M0006541.1

TS2 arm is up to class IP65. During operation, the tightness of the arm is sufficient to ensure protection
against dust and splashing liquids. Pressurization must be used for cleaning (pressure jet protection)
when arm is at a standstill.
A separate pressurization unit is needed for each robot.

■ The connection (P3) is provided to connect the pressurization unit, if used, to the base of the robot.
Pressurizing only when the arm is stopped for cleaning.

Safety
SAFETY
Do not use this orifice for other purposes.

3.2.8.2 - Installation of the pressurization unit M0007022.1

Available on the DVD, in a specific pressurization unit manual, if option is chosen.

3.2.9 - CONTROLLED SPACE, RESTRICTED SPACE AND FENCES M0007168.1

In classical robotics applications, safety is assured by the separation of the people and the moving
devices; the separation itself is assured by fences and/or safety sensors to stop the robot on operator
approach. They define the controlled space around the robot.
■ The safety sensors must be positioned adequately with a correct separation distance.
■ If the fences are used to reduce the maximum space of the robot, they must be designed adequately
to stop the robot in worse-case situations.

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3.2.9.1 - Separation distance M0008986.1

The rules to compute the separation distance are given in ISO 13855:2010. This standard specifies that
this computation does not need to take into account faulty conditions, as it is unlikely that the robot
fails just as the operator enters the controlled space. Please see the Separation distance chapter of the
safety manual for possible mitigation measures.
The separation distance must be based on the time for the robot to stop, and, possibly, on the robot
distance traveled during the stop.
The tables in figures 3.38, 3.39, 3.40 and 3.41 give the default stop time and stop distance of the 3 main
axes for the 4 versions of the robot.

Safety stopping time

TS2–40 528 ms
TS2–60 528 ms
TS2–80 528 ms
TS2–100 528 ms

The safety stopping time is verified by the safety controller and includes the internal signal transmission
delay. This stopping time shall be used for the computation of a separation distances as specified
in ISO 13855:2010.

Safety
SAFETY
A safe separation distance shall use safe parameters for robot stopping time.

Safety
SAFETY
When the arm is used outside its nominal speed or payload specification, it must be verified
that the robot is able to stop without error in the worst-case conditions.

A controlled stop always stops the axes within their limits: the specified maximum stopping distance is
in practice bounded by the axis limits.

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TS2-40

Item Description
: Default max. stopping time
: Stopping time decel 100%
: Default max. stopping distance
: Stopping distance decel 100%

Figure 3.38:

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The stopping time and distance with decel 100% at nominal speed is:

Test conditions Stopping time Stopping distance

TS2-40 axis 1 0.18 sec 50.2 °
TS2-40 axis 2 0.20 sec 73.5 °
TS2-40 axis 3 0.16 sec 213 mm

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TS2-60

Item Description
: Default max. stopping time
: Stopping time decel 100%
: Default max. stopping distance
: Stopping distance decel 100%

Figure 3.39:

The stopping time and distance with decel 100% at nominal speed is:

Test conditions Stopping time Stopping distance

TS2-60 axis 1 0.19 sec 43.3 °
TS2-60 axis 2 0.27 sec 80.5 °
TS2-60 axis 3 0.16 sec 213 mm

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TS2-80

Item Description
: Default max. stopping time
: Stopping time decel 100%
: Default max. stopping distance
: Stopping distance decel 100%

Figure 3.40:

The stopping time and distance with decel 100% at nominal speed is:

Test conditions Stopping time Stopping distance

TS2-80 axis 1 0.29 sec 56.7 °
TS2-80 axis 2 0.42 sec 119 °
TS2-80 axis 3 0.18 sec 182 mm

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TS2-100

Item Description
: Default max. stopping time
: Stopping time decel 100%
: Default max. stopping distance
: Stopping distance decel 100%

Figure 3.41:

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The stopping time and distance with decel 100% at nominal speed is:

Test conditions Stopping time Stopping distance

TS2-100 axis 1 0.28 sec 48.4 °
TS2-100 axis 2 0.44 sec 125 °
TS2-100 axis 3 0.20 sec 198 mm

3.2.9.2 - Restricted space and fences strength M0007038.1

The maximum space reachable by the robot can be reduced by different means, such as:
■ Fences.
■ Mechanical hard stop on axis 1.
The limits of the restricted space shall however take into account the possible faults of the robot, to
guarantee the safety of the personal after failures such as a defective motor, amplifier, or power supply.
In such worse-case situations, the robot is stopped on its brakes.
ISO 10218-2:2011 (5.4.3) specifies some requirements to define the restricted space, and the mechani‐
cal strength of the fences when they are used to limit it.

CAUTION
The TS2 arms are not equipped with brakes on axes 1 and 2. For most faults, axes 1 and 2 are
stopped with electrical braking instead. Some faults, such as a defective amplifier, may im‐
pact the electrical braking: in such worse-case situations, axes 1 and 2 are stopped by the
surrounding obstacles.

3.2.9.3 - Fence design M0006963.1

The strength of the fencing shall support the maximum energy of the robot with its payload at the
collision point.
The table below gives the energy of the arm at nominal conditions of use.

Safety
SAFETY
The robot shall not be able to cause a hazardous deformation of the fences or perimeter
guards (ISO 10218-2:2011, 5.4.3).

Maximum energy at nominal speed and payload at the flange

Maximum energy
TS2-40 190 J
TS2-60 200 J
TS2-80 310 J
TS2-100 360 J

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3.2.9.4 - Mechanical hard stops (Option) M0009238.1

The workspace of the robot can be restricted with a mechanical hard stop on axis 1 and 2. The
mechanical hard stop is delivered as an option to be fitted on site.
The restricted space must take the stopping distances into account:

Figure 3.42:

■ Work area: Angular range within which the robot moves during normal operation.
■ Stopping zone (abnormal operating zone): Maximum angle necessary to stop the robot. In the event
of use of the optional adjustable mechanical hard stop system, the stopping angle depends on the
energy of the impact.

Safety
SAFETY
The mechanical hard stop is designed to stop the arm with a nominal payload at nominal
speed in less than 15°.

Description of the optional mechanical hard stop (see figure 3.43)

The optional mechanical hard stop system is able to stop the robot at nominal load and nominal speed.
It is sized to absorb the kinetic energy of the axis.
■ The optional mechanical hard stop system is made up of a two-part ring (1) on which one or two
adjustable hard stops (2) can be placed to limit the working range of axis 1.
■ The ring is fitted on the robot base (3).
■ The working range is changed by placing 1 or 2 adjustable hard stops as shown on figure 3.43.
Example of restricted workspace:
■ One hard stop in position "1a":
- Work area is limited at 178° in the positive direction and 117° in the negative direction.
■ One hard stop in position "1a" and another in position "1b":
- Work area is limited at 117° in the positive and negative directions.
■ Further reduction in steps of 25° when positions 2 to 5 are used.

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The mechanical hard stop is compatible with humid (HE) or bio-contamination controlled
environments (Stericlean).
However, depending on the environment, the system may show limited chemical resistance.
Regularly inspect the system to check that it is in good condition. In the event of deterioration,
the system can be replaced. Because of their complex shape, the mechanical hard stops
make the arm more difficult to clean and disinfect.
The installation of the mechanical hard stop is described in chapter 4.6.

Safety
SAFETY
If the robot is stopped by the mechanical hard stop, an inspection procedure must be per‐
formed (see chapters 7.11 and 7.14).

Safety
SAFETY
Check the following points at least once a year:
■ No visible damage.
■ Tightening torque for the 2 screws holding the ring (1) in place.
■ No slippage for the ring (1). The verification is made by checking the alignment of the ring
slot with the axis marker.

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Figure 3.43: Hard stop on axis 1

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Figure 3.44: Hard stop on axis 2

3.2.10 - CABLING M0007180.1

Safety
SAFETY
The cable layout must comply with a minimum bend radius for each type of cable. See the
table below:

Internal bend radius

Standard interconnect cable 100 mm
RBR cable 50 mm

In humid (HE) or bio-contamination controlled environment (Stericlean or Accesspharma), the

cables must be protected from the environment. This protection is to be provided by the
customer, and are their responsibility. The guarantee does not cover any damage occurring
there.

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3.3 - ROBOT SIMULATION M0006697.1

Simulation is a required step during the design of the machine around the robot.
Our PC software suite Stäubli Robotics Suite includes the tools that are needed to test and optimize
the placement of the elements of the machine, and to check that arm constraints on base attachment,
end-effector and payload, are satisfied:
■ Import of CAD data (STEP, IGES, STL, VRML),
■ Possibility to build models based on standard primitives (cubes, spheres, etc...),
■ Direct link between 3D scene and program editor (for geometric data creation/edition, etc...),
■ Full multi-robot simulation capabilities (working space, realistic cycle times through the individual
clocking of each controller in the cell),
■ High performance collision detection (highlighting of colliding objects, minimum distance verifica‐
tion).

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4 - STORAGE, TRANSPORT AND INSTALLATION

4.1 - ARM PACKAGING M0007370.1

Type of packaging according to product ordered:

Product ordered Type of packaging

Arm + Controller Compact packaging
Only Arm Standard or international packaging
Only Controller Standard or international packaging
Arm + Controller with Industrial chassis Standard or international packaging

Standard and international packaging position of the arm:

TS2-40 TS2-60 TS2-80 TS2-100

Axis 1 -60° -45° -30° -40°
Axis 2 0° -105° -120° -110°
Axis 3 0 mm 0 mm 0 mm 0 mm
Axis 4 0° 0° 0° 0°

Compact packaging position of the arm:

TS2-40 TS2-60
Axis 1 0° 0°
Axis 2 -90° -90°
Axis 3 0 mm 0 mm
Axis 4 0° 0°

Robot weight:

TS2-40 TS2-60 TS2-80 TS2-100

Robot weight Horizontal cable outlet 38 kg / 84 lb 39 kg / 86 lb 40 kg / 88 lb 41 kg / 90 lb
(approximately) Vertical cable outlet 34 kg / 75 lb 35 kg / 77 lb 36 kg / 79 lb 37 kg / 82 lb

Standard packaging:

TS2-40 TS2-60 TS2-80 TS2-100

LxHxP Floor mounting 1000 x 1080 x 800 mm / 39.4 x 42.5 x 31.5 in
Ceiling mounting
Gross weight Floor mounting 55 kg / 121 Ib 59 kg / 130 Ib
(approximately) Ceiling mounting 71 kg / 156 lb 77 kg / 170 lb

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International packaging:

TS2-40 TS2-60 TS2-80 TS2-100

LxHxP Floor mounting 1080 x 1080 x 800 mm / 42.5 x 42.5 x 32.7 in
Ceiling mounting
Gross weight Ceiling mounting 72 kg / 159 lb 76 kg / 168 lb
(approximately) Ceiling mounting 88 kg / 194 Ib 94 kg / 207 lb

Compact packaging:

TS2-40 TS2-60
LxHxP 1200 x 690 x 800 mm
47.2 x 27.2 x 31.5 in
Gross weight without robot 17 kg
(approximately) 35.5 lb
Handling YxX 610 x 100 mm
24 x 3.9 in

Safety
SAFETY
Temperature for storage and transport: -20°C to +60°C.

4.2 - HANDLING OF PACKING M0007153.1

Handling of the packaging by pallet truck.

Do not stack.

Do not handle an incomplete package as the arm balancing system may cause unexpected
movement.

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4.3 - UNPACKING OF THE ARM

4.3.1 - STANDARD AND INTERNATIONAL PACKAGING M0007955.1

Figure 4.1:

Safety
SAFETY
Sling users must be trained and knowledgeable concerning safe and proper use of slings.

The slings used to lift the robot must comply with the Machinery Directive in Europe or with the
rules in force for other countries.
■ Move the packing case as near as possible to the installation site.
■ Open the box.
■ Take out the packing wedges.
■ Take out the arm and the support assembly. Put its on the floor.

Figure 4.2:

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Figure 4.3: Packaging position of the arm Figure 4.4: Set the robot to 0° on axes 1 and 2

■ Place the fabric sling around joint 3 as shown on figure 4.2.

500 kg (1102 lb) fabric sling.

CAUTION
Axis 1 and 2 have no brakes, they can move during this operation.

■ Remove the arm 3 M10 bolts while holding the arm in position, and remove the support and
protection cover.
If the arm has to be moved to another site, it shall be packed again in a similar way and
protected against mechanical shocks and dust.

4.3.2 - COMPACT PACKAGING M0007709.1

■ Move the packing case as near as possible to the

installation site.
■ Open the box.

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■ Take out the accessories.

■ Take out power supply cable.

■ Open the box.

■ Take out the foam packing pieces.

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■ Take out the CS9 controller.

CAUTION
Sling users must be trained and knowledge‐
able concerning safe and proper use of
slings.

CAUTION
Fit a sling (fabric sling > 80 kg / 177 lb) us‐
ing hooks between the lifting rings on the
controller and the hook on the lifting tackle.
The hooks must also stand up
to 80 kg / 177 lb.
■ Slowly lift the controller using the lifting tackle and
set it down beside the pallet. Each lifting ring has a
maximum authorized load (30 kg / 66 lb) and shall not
be used for another purpose.
■ The lifting rings on the controller are removable.
■ The slings used to lift the controller must comply with
the Machinery Directive in Europe or with the rules in
force for other countries.

■ Take out the box.

■ Take out the foam packing pieces.

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■ Place the fabric slings as shown around the arm be‐

fore to move it.

CAUTION
Sling users must be trained and knowledge‐
able concerning safe and proper use of
slings.
■ The slings used to lift the robot must comply with
the Machinery Directive in Europe or with the rules in
force for other countries.

CAUTION
The robot will swing when raised.

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CAUTION
Axis 1 and 2 have no brakes, they can move
during this operation.

■ Take out the arm slowly. As a safety precaution, keep

the sling fairly taut to make sure that the arm does
not topple over. Put it on the floor.

■ If the arm has to be moved to another site, it shall be

packed again in a similar way and protected against
mechanical shocks and dust.

4.4 - INSTALLATION OF THE ARM M0007776.1

The arm can be fixed with its base facing downwards (floor-mounted version) or upwards
(ceiling-mounted version). However, it is necessary to configure the controller accordingly. To
do so, see the "Software configuration" chapter in the controller instruction manual.
Throughout all handling and installation operations concerning the arm, it is essential to keep
the protection on the main connector at the foot of the robot in place at all times to avoid
damaging and soiling the electrical and optical contacts.
■ For vertical cable outlet, an O-Ring is delivered and needed between arm foot and custom‐
er interface (see figure 3.9).
■ For humid (HE) or bio-contamination controlled environment (Stericlean), please refer to
specifications described in chapter 3.2.3.
It is necessary to configure the controller to suit the robot installation:
■ Arm mounting type (Floor/Ceiling),
■ Software limits to protect against collisions. To do so, see the "Software configuration"
chapter in the controller instruction manual.

4.4.1 - INSTALLATION OF ARM ON FLOOR M0009407.1

CAUTION
For safety reasons, keep the sling slightly tensioned until the arm is securely attached to the
floor.

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Figure 4.5:

■ Position the arm on the support at its final attachment points.

■ Attach the arm with 3 class 12.9 M10 hex. socket head screws, following the recommendations
previously mentioned.
■ Remove the sling.

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4.4.2 - INSTALLATION OF ARM ON CEILING M0008368.1

Figure 4.6: TS2-40

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Figure 4.7: TS2-60

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Figure 4.8: TS2-80

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Figure 4.9: TS2-100

Item Description
1 Plastic washer (paint protection)
2 Check manual tightening of the M6 lifting eye (on contact)

L sling mini
TS2–40 540
TS2–60 400
TS2–80 400
TS2–100 440

CAUTION
Risk of toppling over.

500 kg (1102 lb) fabric sling.

■ Place the slings as shown on figure 4.6, 4.7, 4.8, 4.9 .

■ Position the arm on the support at its final attachment points.
■ Attach the arm with 3 class 12.9 M10 hex. socket head screws, following the recommendations
previously mentioned.

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CAUTION
For safety reasons, hold the sling slightly tensioned until arm is securely attached to the
ceiling.

4.5 - INSTALLATION OF THE PRESSURIZATION UNIT (OPTION) M0006856.1

Available on the DVD, in a specific pressurization unit manual, if option is chosen.

4.6 - INSTALLATION OF THE MECHANICAL HARD STOP (OPTION) M0007918.1

(see figure 3.43)

1. Fit the ring (1) on the robot base (3), resting on the chamfer.
2. Line the ring slot up with the axis marker.
3. Tighten the 2 screws supplied (CHc M10 x 45, class 12-9) holding the ring (1) in place, to a torque
of 50 Nm ± 3.5 Nm.
4. Position the 1 or 2 adjustable hard stops (2), as shown in figure 3.43.
5. Fix the one or 2 hard stops (2) using the screws supplied (CHc M10 x 25, class 12-9) tightened to a
torque of 57 Nm ± 3.5 Nm.
6. Adjust the joint limits in the software configuration of the arm characteristics (see the controller
instruction manual).
7. Check at low speed that collisions against the mechanical hard stop are prevented by the
controller.

Safety
SAFETY
The system performance levels are only guaranteed in the case of correct assembly (compli‐
ance with the required torque values, etc.), with clean, grease free parts. Any failure to comply
with the instructions can lead to incorrect operation of the mechanical hard stop.

Safety
SAFETY
If the robot is stopped by the mechanical hard stop, an inspection procedure must be per‐
formed (see chapters 7.11 and 7.14).

4.7 - INSTALLATION OF THE MPS 010 TOOL CHANGER (OPTION)

4.7.1 - DOCKING STATION M0008250.1

■ Fasten the docking station horizontally to the intended docking location with 3 x M6 (1) screws.
Make sure that no collision between the tool's drive-in contour (2) and the other elements is
done.

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■ Connect the proximity switches to the robot control. We recommend screened sensor cables.

4.7.2 - ASSEMBLY INSTRUCTIONS CONNECTOR FOR MPS 010 M0007992.1

Item Description
1 Pin contact carrier (pre-assembled)
2 Socket set screw (Order-No. 11006079)
3 Pin CT-NET-SP1/0,14-0,75 (Order-No. 33.0548)
4 Contact carrier CT-NET-E/S-21 (Order-No. 33.4087)
5 Clamp ring (Order-No. 33003067)
6 Nut (Order-No. 33003069)
7 Pneumatic couplings (Order-No. K81612989)

Figure 4.10: Pin contact carrier (Tool side) MP43A-1-TS/TS2 Order No. 33003074

Tools required
■ Insulation stripping pincers Weidmüller Mini-Stripax.
Order No. 25.0014.
■ Crimping pliers M-CZ.
Order No. 18.3800.

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■ Locator.
Order No. 18.3801.
Operating instructions MA085.

■ Insertion tool ME-WZ1/1,2.

Order No. 18.3000.
■ Assembly/disassembly tool.
Order No. 33003065.
■ Extraction tool CT-NET-AWZ.
Order No. 33.3048.

Contact carrier marking

■ The pin contact carrier is marked with "TS" (Tool

side).
The contact numbers can be found on the back of the
contact carriers.
Once crimped, the contacts are inserted from the
back.

Cable preparation (Power contacts)

■ Strip the cable insulation to the length of 4 ±1 mm,

without damaging the individual wires.

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■ For power contacts with conductor cross section: 0,5

mm² / AWG: 20 Selector No. 4.

Cable preparation (signal contacts)

■ Slip nut M and clamp ring Z in the indicated se‐

quence onto the cable.
■ Cable diameter:
- Min. 4.5 mm
- Max. 6.5 mm

■ Without damaging the shielding, carefully

strip 17 ±1 mm of outer cable insulation.
Pull the shield wires back over the outer insulation
cable and secure with adhesive tape.

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■ Fan out single wires and strip them to the length

of 4 ±1 mm.

■ Before crimping, make sure that the crimping pliers

are set correctly.
For signal contacts with conductor cross section:
0,16 mm² / AWG: 26 Selector No. 1.

Signal contacts crimping

■ Crimp contacts.
See Tab. for selector position according to conductor
cross section.

Conductor cross section Selector position

mm2 AWG
0.14 26 1
0.25 24 2
0.34 22 3
0.5 20 4
0.75 18 5

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Assembly of the signal contacts in the inserts

■ The female insert is marked with a (B), the pin insert

is marked with an (S).
The contact numbers are on the back side.
The contacts will be inserted from back side.

Contact arrangement (Seen from the termination side)

Ethernet and Profinet

TX+ 1
TX- 2
RX+ 3
RX- 6

■ Push the contacts through the number indicated side

until they lock into place.

Assembly of the contact insert in the contact carrier

■ Connect the clamp ring (Z) to the contact insert (K).

Place the leading part (F) over the flat area of the
insert (K).

■ Remove adhesive tape and cut the screening wires

so that they can be layed approx. 3 mm over the
clamp ring (Z).

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■ Lay the screening wires over the clamp ring.

In the end position, the clamp ring must clamp
the outer cable insulation.

■ Push nut (M) over the clamp ring (Z).

■ Insert the whole unit in the contact carrier.

Ensure that the position of the flat part is correct.
Tighten nut (M) while holding the cable to avoid any
cable rotation.
Tighten the nut only by hand (without tools).
The amount of thread that is visible after tight‐
ening the nut depends on the outside diameter
of the cable.

Assembly of the power contacts into the contact carrier

■ Using the insertion tool ME-WZ1/1, insert contacts in

the contact inserts until they snap into place.

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Assembly of the pneumatic couplings in the contact carrier

■ Insert pneumatic couplings from the rear, in the con‐

tact carrier and secure using the two supplied socket
set screws.
Screw in the set screws up to the stop.
Grub screws must not protrude from the con‐
tact carrier !

4.7.3 - TOOL SIDES M0008578.1

The MPS 010 tool sides are screwed together with the respective tool from below to establish a
threaded joint.
When screwing together, observe the maximum permissible tightening torques MA specified
by the tool manufacturer.
■ Clean and lubricate the flange surfaces of the tool and tool side of the changing system.
■ Fit the tool side of the changing system on the tool and establish a threaded joint from below
with 4 x M6 screws (1).

4.8 - INSTALLATION OF THE UL DRIVE POWER INDICATOR M0007166.1

Standard UL1740, chapter 35.1.1 requires the presence of an indicator in the robotised cell.
If the UL indicator is not supplied on the robot arm (Stericlean + option for example), the integrator has
to install an indicator in the cell, under his own responsibility, in compliance with the recommendations
set out in UL1740 35.1.1.b and 35.1.1d.
There are 2 ways to connect the drive power indicator on the robot:
■ Use the USOC safety outputs J102-9 or J102-10 (see Electrical diagram manual).
The USOC safety configuration should be set to "USOC_power": This is the case by default, and this
is always the case using the Initial safety version (without safety license).
■ Use the controller IOMAP configuration to have the "power" robot status delivered on the digital
output of your choice, on which is wired the drive power indicator.
This is described in the CS9 manual (chapter system inputs/outputs, "power" keyword)
The IOMAP configuration is easily accessible using the SRS IO Map Editor, that is part of
the SRS Physical IOs editing tool.

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5 - COMMISSIONING M0006623.1

Before using the robot for the first time and putting it into production, verification tests must be carried
out to ensure a reliable and safe use of the robot over time.

5.1 - VERIFICATION OF THE MECHANICAL INTERFACES M0006504.1

■ Arm mounting and attachment.

■ End effector attachment and load capacity.
■ Additional load.
■ Hard stop.
■ Access to covers and preventive maintenance positions (oil level check).

5.2 - VERIFICATION OF THE PNEUMATIC CIRCUITS M0006685.1

■ Base plate connections.

■ Forearm connections.
■ Air pressure and cleanliness.
■ Pressurization unit.

5.3 - VERIFICATION OF THE ELECTRIC CIRCUITS M0006968.1

■ Base plate connections.

■ Forearm connections.

5.4 - VERIFICATION OF THE ROBOT APPLICATION M0006594.1

First robot moves and application tests must be done using the manual or the maintenance
working mode.
■ Torque limits.
■ Temperature limits of motors and DSI9 board (at startup, stabilized temperature after continuous
operation).

5.5 - VALIDATION OF THE SAFETY FUNCTIONS M0006686.1

The validation of the safety functions and safety measures is detailed in the Safety Programming
manual:
■ Stopping time and separation distances.
■ Position limits and restricted workspace.
■ Speed limits.
■ Working mode and restart control.
■ Diagnostic functions on brakes and referencing.
■ Safety organizational measures.

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5.6 - VALIDATION OF ORGANIZATIONAL MEASURES M0007149.1

■ Testing of the emergency stops (regularly, after a shock).

■ Spare parts and maintenance equipment.
■ Software and configuration backup.
■ Training and procedures for emergency rescue, preventive maintenance.

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6 - WARRANTY M0007111.1

During the warranty period of the robot, the customer benefits from the replacement of any material,
assembly or manufacturing defects duly notified by the customer and approved by Stäubli on the robot,
as well as the repair of any damage caused to other parts of the robot as a result of this defect. During
this period, and to benefit from Stäubli’s warranty, it is required to have annual preventive maintenance
as defined by the Stäubli manual.
The same conditions apply to the application of the extended warranty contract if the case may be.
Register your robots via MyStaubli portal, your single-entry point to manage your robot information:
https://login.staubli.com/

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7 - MAINTENANCE M0009007.1

7.1 - RULES TO BE APPLIED FOR MAINTENANCE M0006412.1

To ensure high performance of your robot, help prevent equipment failure, and keep production moving,
a Preventive Maintenance must be performed on a yearly basis or 7000 working hours whichever is the
sooner (please refer to chapter 7.4 for more details).
Preventive maintenance must be carried out solely by Stäubli technicians or a certified maintenance
technician who has undergone specific Stäubli training. Failure to comply with this precaution can cause
unexpected risks undermining the robot performance and the component lifetime and may result in loss
of Stäubli's liability and warranty for any subsequent default related to the robot. A routine inspection
must be done by the operator and defined on the chapter 7.4.

Safety
SAFETY
Poor maintenance can lead to premature wear, or even cause safety hazards for production or
maintenance operators.

To ensure a correct seal, it is essential to replace the seal each time a cover is removed (see
chapter 7.8). An inappropriate application may cause premature wear of the flat seal.
Particular case of HE and Stericlean robots
■ In the event of damage to paintwork (HE or Stericlean arm), it is essential to touch up
the paintwork as soon as possible, to protect the part concerned from corrosion (see
chapter 7.5).
■ We strongly recommend contacting the Stäubli after-sales services to ensure that the
repairs are carried out correctly.
■ In the event of damage, any failure to comply with these instructions can affect the
product's technical characteristics, and hence bring into question Stäubli liability as to
guarantee.
■ Stäubli recommends an additional visit 6 months after the yearly Preventive Maintenance.
Customer support information:
Whenever requesting information, ordering spare parts, or requesting intervention, please contact the
customer support by email or by phone. The up-to-date contact information is available via the link:
https://www.staubli.com/global/en/contacts.html

Please have the following information ready before you contact our Customer Support:
■ Robot type
■ Serial number of the machine (as shown on the identification plate)
■ Software version: (Access this information on the teach pendant’s display screen by select‐
ing ROBOT / INFORMATION)
■ Error logger of the robot: (Access this information on the teach pendant’s display screen by select‐
ing ROBOT / LOGGER)

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 7 - Maintenance

Safety
SAFETY
To ensure correct operation of the robot, it is essential to use original Stäubli parts when
making repairs. Failure to comply with this precaution can cause unexpected risks resulting
in severe injury and may result in loss of Stäubli's liability and warranty for the subsequent
defaults related to the robot.

Safety
SAFETY
Stäubli's declaration of conformity with the requirements set out in the Machinery Directive
and other national legislation is lost if some safety-related parts are replaced with older
or incompatible versions. An updated list of compatible spare parts can be obtained at
your Stäubli Customer Support contact.

DANGER
Disconnect all the electrical and pneumatic power supplies to the equipment and its independ‐
ent I/O before carrying out any work on the controller or the arm. Wait for at least 5 minutes
before starting to work.

DANGER
Residual voltages may remain present between motor phases even in "disable power" status.
Before carrying out any work on the motor connections, the controller must be switched off.

DANGER
After a crash, the structure of the robot, the hard stop devices, gripper and tool have to be
checked carefeully. Don't hesitate to call Stäubli customer support for any doubt.
The calibration of the arm has to must be checked carefully at slow speed.

7.1.1 - MANDATORY LUBRICANTS M0006841.1

Only Stäubli-approved lubricants shall be used. Type of lubricants and approximate quantities (the
quantities are given for information purposes only, oil is not fully drainable, please refer to the oil level for
accurate estimation):

Standard lubricant H1 option Quantity

Axis 1 ROBOLUB 68-S ROBOLUB 100-H1 300 ml
Axis 2 ROBOLUB 68-S ROBOLUB 100-H1 140 ml
Ball screw KLÜBER TOPAS NB 52 KLÜBER NH1 94-402 -
Harness MOBIL MOBILITH SHC PM 460 MOBIL MOBILITH SHC PM 460 -
User harness MOBIL MOBILITH SHC PM 460 KLÜBER NH1 94-402 -
Belts LUPROTEC PTFE PROFLON LUPROTEC PTFE PROFLON -
Or Or
COGELSA UTLRAGREASE TF SPRAY (for COGELSA UTLRAGREASE TF
Chinese market only) SPRAY (for Chinese market only)
MPS 010 KLÜBERSYNTH HLR 46-371 - -

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7.1.2 - SPARE PARTS M0006572.1

Failure to comply with these two precautions can cause unexpected risks resulting in severe injury and
may result in loss of Stäubli's liability and warranty for the modified the subsequent defaults related to
the robot.
For a detailed list of spare parts, in accordance with the risk analysis for the application, please connect
yourself to MyStaubli portal and access to our Spare parts Catalogue: https://login.staubli.com/

7.1.3 - TOOLING M0006665.1

■ Maintenance plug .
■ SP2 (if not used in production phase).
■ RBR interface (if required).
■ External 24 V power supply for CPT (RSI9) (if required).
■ External 24 V power supply for RBR (if required).

7.2 - SAFETY
7.2.1 - MAINTENANCE MODE M0006704.1

The maintenance plug resets the safety configuration to a default configuration so that the controller and
the arm can be tested. An external safety PLC can force the maintenance mode by activating the man‐
ual slow, automatic local and automatic remote working modes together, either on the J101 connector,
or using the slave profile FS bus interface. The robot maintenance mode can thus be integrated as part
of a global cell-defined maintenance mode.
■ User safety stops are disabled; personnel safety is assured by keeping the robot motion at reduced
speed and under the control of the enabling device, even in automatic modes. Fast speed in
automatic modes can be activated and controlled in the same way as for the manual fast speed
working mode.
■ Working mode selection and safety restart acknowledge are made from the pendant interface.
The initial safety configuration is recovered just by removing the maintenance plug.
The maintenance plug is meant to prevent the electrical short-circuiting of the user safety stops during
service. After such a short-circuit, the safety of the personnel cannot be assured when an automatic
mode is used (voluntarily or by mistake).

Safety
SAFETY
■ The maintenance plug shall be used only when a temporary change in the safety configura‐
tion is needed for maintenance reasons.
■ Service personnel shall be trained on the risks near the robot and related to the use of the
maintenance plug.

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7.2.2 - RISKS M0007177.1

Safety
SAFETY
The maintenance technician must be informed of the hazards linked to the robot environment,
and especially the risks of concurrent activity on the machine during maintenance. Refer to the
identified residual risk in chapter 3.1.5.

DANGER
■ Make sure that the arm and the load are suitably supported during all work on the robot
arm. The arm brakes alone shall not be considered as a safe protection against axis fall.
■ Residual voltage may remain present between motor phases under "disable power". Before
carrying out any work on the motor connections, cut the controller off from the power
supply (power switch set to and plug removed from the mains power supply socket).
■ Disconnect all the electrical and pneumatic power supplies before carrying out any work on
the controller or the arm. Wait for at least 5 minutes before starting to work.

7.2.3 - RE-COMMISSIONING M0006485.1

Safety
SAFETY
After a change of a safety-related component, the corresponding safety functions must be
validated:

Changed component Function/component to test

DSI9 Power enabling; solenoid valves control.
Brake Brake test; manual brake release.
Brake encoder module Brake test; manual brake release; referencing.
RBR Manual brake release from RBR interface (if available).
External 24 V power supply on RBR Manual brake release from RBR with controller switched off.

For restarting after any maintenance operation:

■ Make sure that the maintenance procedure was followed until its end.
■ Check that the connections of the arm have been restored.
■ Stay away from the arm during the functional tests.
■ Perform first tests at slow speed, using the manual or the maintenance mode.
The DSI9 firmware version shall be consistent with the safety controller (RSI9) firmware ver‐
sion. A new DSI9 board can only replace a DSI9 board with a compatible firmware.

DSI9 firmware RSI9 compatibility

0.1.1.36 1.0.0.10F
1.0.0.4 2.0.0.3
1.1.0.0 2.0.0.3

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7.3 - PROTECTION AGAINST ELECTROSTATIC DISCHARGES

7.3.1 - INFORMATION ON ELECTROSTATIC DISCHARGES M0007008.1

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 cases, the following is true:
■ To feel an ESD, a charge of at least 3 500 V is required.
■ To hear one, a charge of at least 5 000 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-con‐
ductor must be handled carefully to prevent destruction by ESD. It is estimated that ESD destroy
only 10% of the components that they effect. The other 90% of components fall into the "deteriorated"
category. A component may be damaged with simply 25% of the voltage required to destroy it.
These hidden faults can lead to problems that appear several days, weeks or even months after the
incident. Components may also undergo a change in their operating characteristics. Initial tests are
successfully passed but an intermittent error occurs under vibration or temperature constraints. The
same components will pass the "on/off" test successfully, as carried out during repairs, but the problem
will reappear again once on site.

Typical ESD voltages

Source Low relative humidity Average relative humidity High relative humidity
10 - 20% 40% 65 - 90%
Walking on carpet 35 kV 15 kV 1.5 kV
Walking on vinyl 12 kV 5 kV 0.3 kV
Working at the workstation 6 kV 2.5 kV 0.1 kV
Plastified instructions 7 kV 2.6 kV 0.6 kV
Polyethylene bags 20 kV 2 kV 1.2 kV
Cellular polyurethane 18 kV 11 kV 1.5 kV

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Charge sources
■ Work surfaces
■ Packaging
■ Floors
■ Handling
■ Chairs
■ Assembly
■ Carriages
■ Cleaning
■ Clothes
■ Repairing

Parts sensitive to static charges

■ Electronic boards
■ Power supplies
■ Encoders
■ Etc

7.3.2 - PREVENTION OF DAMAGE DUE TO ELECTROSTATIC DISCHARGES M0006861.1

It is essential to guard against electrostatic discharges during an intervention concerning electronic

components, subassemblies and complete systems.
Elimination of the danger due to ESD requires a combined team effort. By complying with the following
instructions, the user 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.

Work zones
An antistatic bracelet is required to handle boards or electronic components.
Remove objects that generate static electrical charges from the work area.
Printed circuits, boards and electronic components must be kept in antistatic bags.

Antistatic wrist strap

The wrist straps are supplied as part of the standard equipment for the robot.
Use an antistatic wrist strap and mat connected to the frame of the controller or to the frame of
the arm and the ground during all handling of electronic boards or electrical components.

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7.4 - MAINTENANCE FREQUENCY M0006718.1

Routine Check Preventive maintenance

inspec‐ up Level A Level B Level C
tion
Monthly Yearly 7000 h or 20 000 h 40 000 h
1 year or 5 years or 8 years
Safety(1)

Mechanical hard stops (option):

Visual check, change if necessary
Remote brake release (option):
Check operation, replace if neces‐
sary
Fastenings (base, tool interface
flange, etc.): Check tightness and
for corrosion
Power light (option): Check,
change if necessary
Check that the motors and brakes
are working properly
General state of the arm

External: Visual check for corro‐

sion and collision damage
Painted parts: Visual check, touch
up the paintwork for small
areas (<2 cm2) without oxidation
Checking of the factory marks
Checking all moving parts
(MPS010, external harness, bel‐
low, belts, internal harness)
Lubrication of moving parts
(MPS010, external harness, bel‐
low, belts, internal harness)
Execution of a robot test program
lasting from 15 minutes to 1 hour
maximum
Control of the general tightening of
the screws
Checking the known reference po‐
sition
Gear boxes

Checking the joints for backlash

and proper operation
Oil level check of all joints
Oil level adjustment of all the joints
Adjustment of backlash
Draining of all axes

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7 - Maintenance

Routine Check Preventive maintenance

inspec‐ up Level A Level B Level C
tion
Monthly Yearly 7000 h or 20 000 h 40 000 h
1 year or 5 years or 8 years
Sealing

Visual check of external leakage

Visual check of internal leakage
Replacement of flat seals
Pressurization unit: Check operat‐
ing pressure on dial
Belt

Checking the condition of the belts

Check of the belt tension (*) (**)
Replacement of belts
Check of pulleys and remplace‐
ment if needed
Electrical and pneumatic harness

Checking the electrical and pneu‐

matic harnesses and connections
Solenoid valves: Check operation
Replacement of solenoid valves

(1): Visual check only - if the part needs to be changed, it will be charged extra
: Recommended operations: To be adapted in the light of the risk analysis for the application.
: Recommended standard operations.
: Recommended operations for applications in harsh environments (such as damp environments) or
clean environments (such as CRs).
(*) Replacement of belt in case of tension exceeding 120% of the maximum manufacturing tolerance, or
simple adjustment in case of too low tension.

TS2 belts Belt of joint 3 Primary belt of joint 4 (motor Secondary belt of
side) joint 4 (screw ball side)
120% of the maxi‐ ■ 214 Hz: ■ 268 Hz: ■ 336 Hz:
mum manufacturing - TS2-40 - TS2-40 - TS2-40
tolerance - TS2-60 - TS2-60 - TS2-60
■ 112 Hz: ■ 115 Hz: - TS2-80
- TS2-80 - TS2-80 - TS2-100
- TS2-100 - TS2-100

(**) Replacement of belt and pulleys in case of tension exceeding 120% of the maximum manufacturing
tolerance a second time at the next preventive maintenance which follows a belt replacement.

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Recommended periodicity:

Level A Level B Level C

Standard robot Every 7 000 h or 1 Every 20 000 h Every 40 000 h
year or 5 years or 8 years
Robot using H1 oil OR robot with Every 7 000 h or 1 Every 10 000 h Every 40 000 h
heavy duty applications year or 5 years or 8 years
Robot using H1 oil AND with - Every 7 000 h or 1 year Every 40 000 h
heavy duty applications or 8 years

The interval depends on the operation cycle of the robot, its working environment and movement pat‐
tern. In case of doubt, please refer to your Stäubli customer support to define the proper maintenance
plan for your robot.
Replacement of dynamic parts such as gearbox, wrist, worm/gear, lip seals, brakes, balancing system,
bellow, ball screw and harness are not replaced during the preventive maintenance. Nevertheless, these
items will be checked during the preventive maintenance visit and a recommendation will be made on
the identified parts to be replaced.
Those dynamic parts have been designed to achieve the statistic lifetimes ISO 281* listed below
under optimal robot operating conditions. Lifetime can be calculated for a dedicated application
with Optimize Lab software.

Spare parts Lifetime estimated for Life time estimated for Details
average applications Robot with heavy duty
applications*
Gearbox 45 000 15 000 Axis 1
Axis 2
Lip seals 40 000 20 000
Bellow 20 000 10 000
Ball screw 60 000 20 000
Harness 60 000 20 000
Motor (without brake) 80 000 40 000
Motor (with brakes) 80 000 40 000

* ISO 281 - L10 = Life span (statistical average) based on 90% reliability, i.e. 90% survival after
testing on the same batch.

For H1 robots, the estimated lifetime of the gearboxes is divided by two.

7.5 - PAINT TOUCH-UP PROCEDURE

FOR HE AND STERICLEAN ROBOTS M0006401.1

To protect the surfaces of painted parts from the environment, it is essential to make all necessary
touch-ups in the event of scratches.
A paint touch-up kit is available. To order one, contact the Stäubli Customer Support.
The kit includes the paint and the procedure to be followed to carry out the touch-up work.
In the event of damage to the paintwork, failure to comply with these instructions may lead to
deterioration in the product's technical characteristics and bring into question Stäubli liability
concerning warranty.

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7.6 - CLEANING AND DISINFECTING RECOMMENDATIONS M0006993.1

Stäubli standard, SCR and Accesspharma external robot surfaces

■ Unpainted metal parts:
- Use wipes wetted with product recommended in the following compatibility chart.
■ Painted metal parts or plastic parts:
- Use wipes soaked with a neutral pH aqueous soap solution (For example, use a product listed in
the following compatibility chart).
- Rinse with wipe wetted with clean water.
- Dry with wipes.
The interval between two cleaning or disinfecting actions depends on robot dirtiness (Typical periodicity:
1 week).

Stäubli HE external robot surfaces (Humid environment application):

■ Use an aqueous product having a pH between 4.5 to 8.5 (For example, use a product listed in the
following compatibility chart).
■ Rinse with clean water.
■ Dry with wipes.

Stäubli Stericlean external robot surfaces (Bio-contamination controlled environment application):

■ Use an aqueous product having a pH between 4.5 to 8.5 (For example, use a product listed in the
following compatibility chart).
■ Rinse with clean water.
■ Dry with wipes.
Or
■ Use other products recommended in the following compatibility chart (e.g. 70% Isopropyl alco‐
hol (IPA 70), hydrogen peroxide (H2O2) 35% on a wipe or in vapor phase) without any water rinse.
The interval between two cleaning or disinfecting actions depends on robot dirtiness (Typical periodicity:
End of every production).
Information given herein shall not relieve you from checking the cleanliness of the robot after
the cleaning and disinfecting process. Stäubli shall not be liable for any damage arising be‐
cause of persistence of residue after the cleaning process described herein.
Use of chlorinated products for cleaning or disinfecting is prohibited. Use of any other cleaning
or disinfecting product than those specified may damage robot external surfaces. In such case
it is recommended to cover the robot by a protective covering.
In case of cleaning or disinfecting process with liquid splash or low pressure liquid jet, the
robot arm has to be pressurized (see instruction manual).
Nevertheless, the repetitive mechanical action of wiping may damage the brightness of the
paint.
In case of cleaning or disinfecting agents being out of specification, please consult Stäubli.

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Type of product Disinfectant Cleaner

pH Neutral Neutral 2 to 4 - 8.5 Neutral -
Cleaner or disinfect‐ P3 P3 topax Hydrogen 70% Iso‐ P3 ELPON 70% Iso‐
ing product name alcodes 990 perox‐ propyl al‐ aquanta propyl al‐
ide H2O2 cohol (IPA tin cohol (IPA
70) 70)
Manufacturer ECOLAB ECOLAB
http://www.eco‐ http://www.eco‐
lab.com lab.com
Concentration 100% 3% 35% on a 100% 0.2% 3% 100%
wipe or
vapor
phase
Uncoated No No No No
Robot version

Standard

parts
Coated No No No No
parts or
plastic parts
Uncoated No No No No
SCR

parts
Coated No
parts
Uncoated
HE

parts
Coated No No No No
parts
Uncoated No No No No
Stericlean Accesspharma

parts
Coated No
parts

Uncoated
parts
Coated
parts
Usable for food indus‐
try

Please contact the product manufacturer to define cleaning or disinfected process.

: Use only wipes wetted with the product.
: For painted part, it is also possible to use this product with a soft action of wiping and
without too long application. Nevertheless, the repetitive mechanical action of wiping may
damage the brightness of the paint.

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Chemical compatibility table1

Chemical Compound Concentration Accesspharma Stericlean

Hydrogen peroxide 30% N/A ++
Hydrogen peroxide 50% N/A ++
Isopropanol >99% ++ ++
Ethanol >99% ++ ++
Hydrochloric acid 5% N/A --
Sulfuric acid 5% N/A +
Peracetic acid 15% N/A -
Sodium Hydroxyde 5% N/A -
Sodium hypochlorite 5% N/A -
Ammonium 25% N/A +
Cyclohexane Pure N/A ++

2 Chlorine-containing chemicals must be rinsed so as not to damage stainless steel parts.

1 High temperatures will weaken chemical resistance: Maximum temperature recommended 40°C.

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 7 - Maintenance

7.7 - COVER LOCATIONS AND REMOVAL M0008745.1

Tools required:
■ 3 mm Allen key.
■ 2.5 mm Allen key.
Recommended tools:
■ Torque wrench.

Initial position:
■ Not applicable.
Procedure:

■ (A) DSI cover: 2 M4x20 screws (tightening

torque 3.6 Nm).
■ (B) Axis 1 cover: 3 M4x20 screws (tighten‐
ing torque 3.6 Nm).
■ (C) Inner link cover: 3 M4x20 screws (tight‐
ening torque 3.6 Nm).
■ (D) Upper forearm cover: 3 M4x50 screws
(tightening torque 3.6 Nm).
■ (E) Lower forearm cover: 3 x M3x30 ((E.1),
(E.2) and (E.3)) screws inside the forearm
(tightening torque 1.2 Nm). Holes of the
pulley aligned with the 2 bellow forearm
cover fixing screws (may need to release
joint 4 brakes).
■ (F) Ball screw cover (option):
4 x M4x10 screws inside upper forearm cov‐
er (tightening torque 3.6 Nm).
■ The indicated tightening torques
must be within ±7%.
■ To ensure correct compression of
the flat seal, it is preferable to apply
progressive tightening.

■ Sealed screws for specific versions (tighten‐

ing torque 3.6 Nm).

CAUTION
Do not use threadlocker glue on
screws for covers grounding.

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7.8 - PROCEDURE FOR REPLACING THE FLAT SEAL M0006902.1

7.8.1 - REMOVING THE SEAL M0006415.1

The flat seal is made up of 3 sections:

■ A section made of foam (1).
■ An adhesive section (2).
■ Metal inserts (3) (only for DSI cover and inner link
cover).
■ To remove the flat seal, peel off a corner of the seal
and pull it towards you.
If the adhesive section (2) remains stuck to the cover,
use "C" fluid (ethyl acetate) to remove it.
■ Remove the metal inserts (3) if they are still stuck in
place.
■ Clean the surface, and remove any particles present
on the surface, without scratching it.
■ Clean the whole surface using "C" fluid (ethyl ace‐
tate).

7.8.2 - FITTING A NEW SEAL M0006413.1

The new seal is made up of 4 sections:

■ A section made of foam (1).
■ An adhesive section (2).
■ Metal inserts (3) (only for DSI cover and inner link
cover).
■ A protective paper covering the adhesive (4).
■ Remove the cut-out sections such as screw holes.
■ Present the seal.
■ Remove the protective paper (4) and place the metal
inserts (3) in the screw hole recesses.
■ Apply the new seal to the surface. Line the contour of
the seal up with that of the surface.

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7.9 - LUBRICATION M0006376.1

The greasing and lubrication work is carried out by Stäubli in the factory. At the time of
delivery, the robot is ready for use.

7.9.1 - GENERAL INFORMATION M0006373.1

The robot requires very little maintenance, but lubrication and the inspections listed below must be
carried out at regular intervals to ensure its efficiency over time.

DANGER
Read the general safety precautions before carrying out any maintenance operation (see
chapter 3.1). The system must be disconnected from the power supply while maintenance
operations are carried out on the robot: the master switch on the cell controller MUST be set to
OFF.

It is advisable to carry out regular, precise preventive maintenance to ensure that the robot
keeps its original operating characteristics over long periods.

7.9.1.1 - Lubricate M0006377.1

The type and quantity of lubricant for each lubrication sequence are listed in the table in chapter 7.1.1.
Too much or too little oil can prevent the robot from operating correctly.

7.9.1.2 - Precautions for use of lubricants M0006374.1

Safety
SAFETY
During assembly in the Stäubli factory, the robot is filled up with lubricants that are free of
substances harmful to health; however, in some cases, repeated and prolonged exposure to
the product can cause skin irritation, or sickness if swallowed.

DANGER
In the event of contact with the eyes or the skin, wash the affected areas with plenty of water;
if irritation persists, consult a doctor. In the event of swallowing, do not provoke vomiting or
administer any products orally; consult a doctor as soon as possible.

7.9.2 - CHECKING OIL LEVELS M0006445.1

Tools required:
■ Not applicable.
Recommended tools:
■ Not applicable.

Initial position:
■ Not applicable.
Procedure:

Too much or too little oil can prevent the robot from operating correctly.

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7.9.2.1 - Arm in floor-mounted position M0009063.1

Checking the levels for axes 1 and 2 with the arm on the floor

Axis 1 Axis 2 Axis 3 Axis 4

Axis position - - - -

■ Axis 1: Oil level has to be in the middle of sight

glass (1) ± 3 mm.
■ Axis 2: Oil level has to be in the middle of sight
glass (2) ± 4 mm.

7.9.2.2 - Arm in ceiling-mounted position M0007245.1

Checking the levels for axes 1 and 2 with the arm on the ceiling

Axis 1 Axis 2 Axis 3 Axis 4

Axis position - - - -

Axis 1: Oil level has to be in the middle of sight

glass (1) ± 3 mm.
Axis 2: Oil level has to be in the middle of sight
glass (2) ± 4 mm.

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 7 - Maintenance

7.9.3 - LUBRICATING THE BALL SCREW M0009235.1

Tools required:
■ Soft cloth.
■ Grease.
Recommended tools:
■ Not applicable.

Initial position:
■ Ball screw cover removed (If bellows option installed).
■ Lower forearm cover removed (If bellows option installed).
Procedure:

■ Clean the ball screw with a soft cloth.

■ Apply the grease on the upper (1) and lower
parts (2) with a soft cloth.
■ Move the ball screw up and down several
times to spread out the grease.

7.9.4 - LUBRICATING THE MPS 010 TOOL CHANGER (OPTION) M0008750.1

Tools required:
■ Soft cloth.
■ Grease.
Recommended tools:
■ Not applicable.

Initial position:
■ Separate the tool from the docking station.
■ Separate the MPS 010 tool changer from the tool side.

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 7 - Maintenance

Procedure:

■ Clean the MPS 010 tool changer with a soft

cloth.
■ Apply the grease on the pockets (1), the
guide columns (2), the docking station guide
surfaces (3) and the contact surfaces for
clamping ring of the robot side (4).
■ Reassemble the MPS 010 tool changer.

7.10 - CHECKING THE STATE OF THE BELTS M0008855.1

Tools required:
■ Not applicable.
Recommended tools:
■ Not applicable.

Initial position:
■ Upper forearm cover removed.
■ Lower forearm cover removed.
Procedure:

■ Check the condition of the 3 belts without

removing it (do not force or twist the belt).
■ Replace the belt if necessary.

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 7 - Maintenance

7.11 - RECOMMENDED CHECKS AFTER A ROBOT COLLISION M0008552.1

In the event of a handling or programming error, a ro‐

bot movement may result in a crash. To make sure the
collision has not affected the robot's internal mechan‐
ical elements, check the alignment of the marks cali‐
brated during assembly at Stäubli prior to dispatch of
the arm or the references determined by the customer
(UserMarks, RefPos).
Before making any such checks, make sure you
can do so in full safety by ensuring that the
movement speed is set to a suitable level (we
recommend 25% of the nominal speed).
In the event of an offset, carry out a calibration. Consult
the Stäubli Customer Support.

7.12 - VISUAL CHECK OF THE HARNESS CONDITION M0008988.1

Tools required:
■ Not applicable.
Recommended tools:
■ Not applicable.

Initial position:
■ Axis 1 cover removed.
■ Arm cover removed.
■ Upper forearm cover removed.

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 7 - Maintenance

Procedure:

■ Check the general condition of the harness

over its full length and especially at the
points shown.
Attention, axis 1 does not feature an
internal joint limitation system. This
means that during calibration, it is
possible to mistakenly offset the axis
by 360°. This type of calibration error
can lead to harness damage. To check
that axis 1 is correctly oriented, pro‐
ceed as described in chapter 7.13.

7.13 - ORIENTATION OF AXIS 1 AFTER A CALIBRATION M0007598.1

Tools required:
■ Not applicable.
Recommended tools:
■ Not applicable.

Initial position:
■ Axis 1 cover removed.
■ Axis 1 at 0° position.
Procedure:

■ When axis 1 is at 0° position, the harness

must not be twisted.

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 7 - Maintenance

7.14 - MAINTENANCE OF THE MECHANICAL HARD STOP (OPTION) M0006380.1

What should be done if the robot is stopped by an optional mechanical hard stop ?
1. Check that the robot has not suffered any visible damage.
2. Check transmission. Place arm on reference mark. If there is an offset, contact Stäubli.
3. Check that there is no unusual noise or backlash on the various axes during brake release and in
manual mode.
4. Put the ring back in place if it has slipped. Follow the points concerned in the installation chapter (see
chapter 4.6).
5. Check operation at low speed.

DANGER
If any ring damage or slippage is noted (or in the event of doubt following an impact or a
suspected impact), consult the Stäubli Customer Support for an arm diagnostic.

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Index

Index
Numerics Cover 7, 42, 121, 130, 133, 134, J
137–140
24V CPT 2 Joint 5, 26, 43, 55
External 26, 33 Current 17, 76
3D 43
Iges 93
L
Step 93
D
Library 43
Stl 93 Decel 83, 85–87 License 43
Vrml 93 Dimensions 14–16, 45 Location 33, 108, 133
DPM 2 Joint 5
A
ACCESSPHARMA 48, 54, 92
E M
Additional load 11, 55, 57 Editor 93 Motor 3, 5, 25, 26, 88
Air Electrostatic 125 Move 26, 27
Pneumatic circuit 57, 58, 61, 65, 69, ESD 125, 126
73 Emergency stop 31
Pressure 33, 36, 37, 57, 81 Encoder 2, 5, 27, 33
O
Application 8, 29, 36, 37, 130 Environment 35–37, 48, 54, 57, 90, 92, Oil 122
Arm power 25 102, 129, 130 Quantity 122
Axis limit 82 Ethernet 9–12, 76, 78–80, 113 Type 122

B F P
Backlash 141 Fan 112 Packaging 95
Belt 138 Fence 43, 54, 81, 88 Paint 129–131
Box 97 Energy 88, 89 Payload 6, 13, 88, 89
Brakes 7, 26, 27, 88 File 43 Pendant 3, 26
Release 25–27, 32, 33 Flange 12, 36, 37, 48–51, 59, 61, 65, 69, Pneumatic 9, 10, 12, 43, 57, 58, 61, 64,
Safety 25–27 73, 79, 80, 115 69, 72, 73, 76
Stopping distance 82, 89 Flat seal 133, 134 Power supply 2, 3, 26, 33, 44, 54, 126,
135
C G Pressurization 9, 10, 81, 108
Profinet 113
CAD 43 Gear box Programming 43, 139
Calibration 139, 140 Characteristics 7
Certification Grease 137
ISO 7, 29, 32, 35, 36, 44, 54, 82, 88 R
UL 5, 6
Cleaning 130 H Range 43, 89
Reach 6
Pressure 130
Hard stop 89–91, 108, 141 Repeatability 5, 7
Compatibility 6, 29, 130
Harness 139
Connection 9, 12, 48, 58, 61, 65, 69,
Connectors 78
73, 77, 78, 81
Electric 77–80
S
A1 11, 12, 57
Pneumatic 9–12, 43, 57, 58, 61, 65, Safety 1, 2, 29, 30, 32, 33, 76, 81, 88,
A2 11, 12, 57
69, 73 89
B1 11, 12, 57
User 11, 12 Brakes 26, 27, 32, 33
B2 11, 12, 57
HE 7, 8, 36, 48, 54, 57, 90, 92, 121, Configuration 88, 108
Connection
129–131 Reference 139, 141
A2 60
E 9, 10 Separation distance 82
J1201 9, 10 I Speed 83, 85–88
J1202 9, 10, 77, 79, 80 Stopping distance 82, 83, 85–87,
J1203 11, 12, 77, 80 Installation 44, 48, 95–97, 102, 104, 89
J1204 9, 10 108, 109 Stopping time 83, 85–87
J1217 9, 10, 77, 79, 80 Ceiling 38, 40, 42–44, 47, 95, 96, Tool 54
J1218 11, 12, 77, 80 104, 136 Seal 47, 134
P1 9, 10, 60, 64, 68, 72, 76 Controller 102 Software limits 102
P2 9–11 Floor 37, 39, 42–45, 47, 95, 96, Solenoid valves 33, 61, 62, 64–66, 68
P3 9, 10, 81 102, 136 SP2 20
Controller 33 Holes 54, 57 Speed 43, 54, 83, 85–87
Screw 47, 54, 103, 107, 108 STERICLEAN 48, 54, 90, 92, 121,
129–131

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Stroke 42

T
Temperature 34, 35, 55, 64, 68, 72, 76,
96
Terostat 54, 57
Tightening torque 54, 90, 115, 133
Tool 80, 115
Torque 54, 55, 57, 90, 108, 133

U
User interface 55

V
Valve 32, 61, 65, 69, 73
3/2 69
5/2 61
5/3 65
Pressure 33, 64, 68, 72, 76
Version 5, 7, 131
Voltage 17, 33, 76

W
Weight 7, 44, 45, 95, 96
WMS
Emergency stop 3
World 42
Wrist 126