Sony CAST-AU4 User manual

OPERATION MANUAL
Sony Desktop Robot
GA
CAST-AU4/B2521E

CAST-AU4/B2521E
This Operation Manual is intended as a guide for users of the Sony Desktop Robot ROBOKIDS.
Before operating this system, you should first throughly read this manual. You may not understand all of the
explanations the first time through, but be on the lookout for any special directions.
It should be used in conjuction with the RK card manual for your specifications.
• This manual may not be replicated in whole or in part without the prior written authorization of Sony
Corporation.
• The information described herein is subject to change without notice.
• The information described herein has been checked for both reliability and accuracy. However, if you
have any questions, or notice any errors or omissions in this manual, please contact the following offices
of Sony Corporation.
[Singapore]
Sony Electronics (Singapore) Pte. Ltd
SPEC, No.52 Tuas Avenue 9, Singapore 639193
TEL : [phone] FAX : [phone]
[Europe]
Sony Wega Produktions GmbH
Production Technology Division Europe
Hedelfinger Str. 61
D-70327 Stuttgart Germany
TEL : [phone] FAX : [phone]
[Japan]
Sony Manufacturing Systems Corporation
FA Service Department
1-10, Kiyoku-cho, Kuki-shi
Saitama, 346-0035 JAPAN
TEL : [phone] FAX : [phone]
About this Operation Manual

CAST-AU4/B2521E
First Time Users
Read this manual form chapter 1 through chapter 4 before starting any operation. The manual describes the
procedures required in setting up ROBOKIDS for users who have little experience with FA (Factory
Automation) equipment.
Routine Assembly
Follow the respective application manuals for routine assembly task operations.
Replacing the Unit or Memory Card
Remove the existing unit. Attach the new unit and replace the memory card. References of the memory card
may be found in this Operation manual or the respective application manuals.
This manual describes the ROBOKIDS base machine. Details for application unit installations may be
found in the operation manuals that are attached when purchasing the application units.
How to Use this Operation Manual

CAST-AU4/B2521E
Manual Configuration
This operation manual describes the procedures required to operate the desktop robot ROBOKIDS Various
types of applications such as dispensing and soldering may be accomplished by exchanging the memory
cards (RK card) which stores the programs required to run an application. The semi-programmable
specification allows the user to modify an operation program and peripheral task program to perform a
specific work. The full open programmable specification enables the use to freely write any program to
perform an unique application. This manual contains the common contents between dispensing, soldering,
semi-programmable and the full open programmable specification. For further details refer to the memory
card (RK Card) operation manual (or the Full Open Programmable operation manual for the full open
programmable specifications.)
Safety Instruction
Describes the safety precautions for user’s safety.
Unpacking
Describes the precautions during unpacking, and lists the supplied accessories.
1. Outline
Outlines features, names and functions of controls, and its specifications.
2. Preparation
Helps you set up the base machine. Beside the supplied accessories, you also may need to purchase the
dispensing unit, soldering unit, air compressor, workpiece fixing tool (including fixing screws)
depending on the configuration.
3. Maintenance
Describes daily maintenance.
4. Troubleshooting
Describes countermeasure (only the contents which are in common in applications) when an error
occurs during operation. The Operation Manual of each memory card (RK card) describes
countermeasures for dispensing errors and soldering errors.
5. Replacement Parts
Shows list of main replacement parts of the base machine.
6. Appendix
Described input and output specifications of each connector.

CAST-AU4/B2521E
Contents
Safety Instruction ............................................................................................................... S-1
Unpacking ........................................................................................................................... U-1
1. Outline
1-1 Nomenclature.................................................................................................................... 1-2
1-2 Outline Drawings .............................................................................................................. 1-4
1-3 Specifications.................................................................................................................... 1-9
1-3-1 Machine Specification ........................................................................................ 1-9
1-3-2 Control Specifications ...................................................................................... 1-10
2. Preparation
2-1 Attaching the Units ........................................................................................................... 2-1
2-1-1 Attaching the Z-unit ........................................................................................... 2-1
2-1-2 Attaching the ZR-unit ......................................................................................... 2-4
2-2 Connecting the External Signal ........................................................................................ 2-7
2-3 Connecting to an Electrical Outlet.................................................................................. 2-12
2-4 Starting Up the Base Machine ........................................................................................ 2-13
2-4-1 Full-open Programmable Specification ............................................................ 2-13
2-4-2 When Using Memory Card “RK card” ............................................................ 2-13
3. Maintenance
3-1 Maintaining the Machine .................................................................................................. 3-1
3-2 Greasing the Machine and Removing Fallen Materials ................................................... 3-1
3-3 Cleaning and Replacing the Air Filter .............................................................................. 3-4
3-4 Replacing the Battery ....................................................................................................... 3-6
4. Troubleshooting
4-1 Common Items.................................................................................................................. 4-1
4-1-1 Stepping Out ....................................................................................................... 4-1
4-1-2 External Noise .................................................................................................... 4-3
4-1-3 Abnormal Sound from Unit’s Motors ................................................................ 4-3
4-2 Full-open Programmable Specifications........................................................................... 4-4
4-3 When Memory Card (RK Card) is Used .......................................................................... 4-7
Trouble Check Sheet ................................................................................................................. 4-10
5. Repair Parts Lists
5-1 ROBOKIDS Body ............................................................................................................ 5-1
5-2 Z-axis Unit ........................................................................................................................ 5-1
5-3 ZR-axis Unit ..................................................................................................................... 5-2
6. Appendix .................................................................................................................................... 6-1

S-1
Safety Instruction
CAST-AU4/B2521E
Safety Instruction
Sony Corporation designs and manufactures all its equipment with strict attention to safety. However, if the
machine is operated or maintained without regard to the safety guidelines, damage or injury to the machine
or operator may occur.
To prevent accidents, those in charge of operation and maintenance must follow the safety work rules when
using the machine. Always read the safety precautions carefully before reading the Operation Manual, and
carefully note the following safety rules.
Observe all precautions to ensure safety.
Read the precautions on pages 3 to 6 thoroughly.
Perform regular inspections.
Inspect the machine referring to chapter “3. Maintenance”.
In the event of accidents....
Consult with the dealer that is indicated on warranty card after filling in the trouble check
sheet which is attached to the end of the Operation Manual.

S-2 CAST-AU4/B2521E
Definition of warning symbols
Pay particular attention to the following symbols and conventions shown on the machine and on the
Operation Manual. Fully understand the contents of symbols and conventions before reading the Operation
Manual.
《Machine Symbols》
Indicates a protective terminal of mechanical parts to which an external protective earth wire
is connected.
When the part with this mark is removed, the high voltage appears.
Check the operation manual before using the part with this mark.
Be cautious not to pinch your hands or fingers into the units moving parts.
Before you perform any maintenance and/or check, disconnect the unit from
the main power supply.
《Operation Manual Symbols》
Indicates that mis-operations or mis-handling may result in unexpected danger (fire, etc.,)
and the that operator is at risk (of major injury).
Indicates that mis-handling may result in unexpected danger (electric shock, etc.,) and that
the operator is at risk of injury or the equipment at risk of damage.
Warning
Caution

S-3
Safety Instruction
CAST-AU4/B2521E
Caution
■Important Safeguards
◆ The tool driving mechanism are subject to unexpected movement. Pay attention to safety
measures.
◆ Turn off the main power prior to performing maintenance or inspections. Failure to
observe this may result in severe injury through electric shocks or unexpected movement
of the machine.
◆ Mistakes during maintenance and inspections may result in accidents.
Observe the followings prior to starting maintenance or inspections:
1. Read the Operation Manual thoroughly and following all instructions and warnings closely.
2. Implement inspections on a daily basis to prevent accidents arising from damaged equipment.
3. Pay attention so that the power cord is not pinched by the machine and the peripheral
equipment when installing the machine system.
◆ Ensure to connect the primary power supply to the three-pin AC power outlet using the
power cord (supplied with earth wire) supplied with the equipment. Electrical potential
difference will occur with surrounding equipment if the electrical earth is not connected
and may result in electrical leakage or electrical shocks.
◆ Heavy object. Move and transport with two or more persons, and pay attention to safety measures.
◆ To maintain safety do not make any modifications to the equipment in order.
◆ Be careful so that hands must not be pinched by the movable blocks.
(Movable parts of each axis, tool attachment block, table block, belt beneath the units,
tools, works, etc.)
◆ Avoid installing in the following locations:
○ In places which receive direct sunlight or which experience temperature ranges
exceeding 0 degrees ° C and 40 degrees ° C.
○ In places which experience relative humidity ranges exceeding 35% and 90%, and
places in which condensation is generated by rapidly changing humidity.
○ In places where corrosive gas or inflammable gas exists.
○ In places where the unit will be subject to direct vibrations or impact.
○ Close to machinery which emits electrical noise, such as welders, electric dischargers
or high-frequency generators.
○ In places where any obstacles are anticipated during maintenance and inspection.
◆ Precautions during operation, movement, maintenance and inspection
During operation the machine may look as if it has stopped. Be careful when certain
conditions are met, the machine will resume motion automatically.
◆ Connect the earth wiring (FG) to the tools.
Electrical potential difference will occur with surrounding equipment if the electrical
earth is not connected and may result in electrical shocks.
◆ Be careful that motor gets very hot.
Warning

S-4 CAST-AU4/B2521E
Precautions on Usage
Operate on the specified voltage
Operate the ROBOKIDS only on AC power voltage as specified on the label of the machine. The power
cord must be directly connected to the electrical output, and grounded. The ROBOKIDS conforms with the
safety requirements of the target country to which it is shipped.
When a machine will not be used for extended period of time
If the machine is not in use for a long period, unplug the power cord from the electrical output. To unplug,
pull on the plug. Never pull on the cord.
Do not drop any foreign material into the machine
Dropping any flammable liquid or metal, object into the machine can cause errors and trouble of the machine.
Should any of them drop into the machine, unplug the power cord and contact your local Sony dealer.
Do not place any obstacles in front of the fans.
Heat dissipation will be insufficient and the accumulated heat can cause malfunctions.
Precautions on Transportation
• Avoid excessive shock. Excessive shock such as dropping the machine may cause damage.
• Do not hit the units or work table during operation. Also be careful so that hands and/or clothes are not
pinched by the machine. It can cause unexpected physical injury.
• Be sure to hold the bottom panel when moving the machine.

S-5
Safety Instruction
CAST-AU4/B2521E
Precaution on memory cards
Before inserting or removing a memory card, always turn the power off.
The data stored in the memory card may be damaged if a memory card is inserted or removed while the
power is on.
Precaution on the teaching pendant
ROBOKIDS uses a teaching pendant for the CAST-PRO or SRX. The CAST-U teaching pendant and
CAST-PRO teaching pendant are not compatible. Do not use the CAST-U teaching pendant with the
ROBOKIDS.
If the CAST-U teaching pendant is used with the ROBOKIDS., the ROBOKIDS cannot exit the
emergency stop state and can be damaged. Do not use the CAST-U teaching pendant with the
ROBOKIDS.
If the SRX teaching pendant (SRX-P006) is used with the ROBOKIDS.
the ROBOKIDS can be damaged. Do not use the SRX teaching pendant
with the ROBOKIDS.
Precaution on maintenance
Periodic inspection of the following items is recommended once every six months.
Operation check of the fan attached to the controller
Be sure to check the operation of the fan attached to the controller before starting operation.
Equipment can be seriously damaged by heat accumulated in ICs in certain operating environments in
which equipment is used without sufficient heat dissipation.
Caution

S-6 CAST-AU4/B2521E
On handling batteries
The following battery is used in the base machine controller.
Lithium battery (primary battery) of type : CR17335SE-CN21 Manufactured by Sanyo Electric Co.
Incorrect handling of the battery may result in dangerous situation.
Do not perform the actions as listed below for safety. Sony Corporation is not responsible for
the troubles related to the operation of the following precautions.
(1) Shorting
Do not short the batteries.
Shorting the battery may damage the equipment or may result in thermal injury due to
overheating.
(2) Disassembling
Do not disassemble the batteries.
Gas will be generated irritating the throat. Lithium metal may be generated. The batteries
can be heated internally resulting in explosion or fire if the batteries are subject to shock.
(3) Throwing into fire or water
The battery may explode, generate fire due to liquid leakage or internal shorting if the
battery is heated. Never throw the battery into fire. The batteries can explode if they are
thrown into fire. Throwing the batteries into water may lose the battery function.
(4) Soldering
Do not make any soldering directly to the batteries. The batteries can explode or generate
fire due to liquid leakage or internal shorting inside the batteries caused by heat.
(5) Do not connect the batteries with reverse polarities between (+) and (-)
(6) Using the batteries for other applications
Do not use the batteries for other applications. The batteries may be damaged or the
equipment can be damaged due to specification differences.
(7) Charging
Do not charge the lithium battery (primary battery). Gas will be generated inside causing
explosion and fire.
Life and replacement of batteries
The nominal life of the lithium battery (primary battery) used in the controller is 3 to 5 years. Replace it
every 3 years as a guide line. (Refer to section “3-4 Replacing the Battery” for the replacement procedure.)
Life, however, can be shorter than the nominal life depending upon the ambient environments.
The front POWER indicator changes from green to red when a battery runs out.
Caution

U-1
Unpacking
CAST-AU4/B2521E
Unpacking
Transport it to the installation position while taking care not to drop or fall. Pay extra
attention not to give any vibration or shock because the controller contains precision
electronic parts.
Be sure to use the packaging material specified by Sony Corporation when transporting the
machine.
Caution
NOTE
Accsesorybox
Removebyholdinghan
ds
atthebottomasshown
bythearrows.

U-2 CAST-AU4/B2521E
When the machine is unpacked, make sure the following items are in the package.
Base machine Power cable Operation box USER I/O connector
(For AC 200V to 240 V) PCR-E68FS (connector)
PCS-E68LA (connector cover)
(Honda Communications Company)
Operation Manual External supply power
connector for USER I/O
MC 1.5/2-ST-3.81
(Phoenix Contact Inc.)

1-1
1. Outline
CAST-AU4/B2521E
1. Outline
ROBOKIDS is a desktop assembly tool designed to automate cell production systems saving a significant
amount of power consumed by assembly lines. It may be used in a variety of applications by simply
exchanging the work unit and memory card. The basic operation procedures are common throughout the
applications enabling a smooth migration from one work to another.
• The programs required for an application are stored in the memory card “RK Card”.
Operation is started by inserting the specific memory card into the base machine and teaching the work
points. The machine may be switched to perform a different application be exchanging the memory card.
• The work points and the working speed may be set by using the simple operation teaching pendant
(option) even by someone who has just purchased ROBOKIDS.
• The power supply and controller are built inside the machine thus making the system transportable to the
place where it is needed.
• The machine is equipped with an external switch connector and also an USER I/O connector allowing
synchronous operation with external equipment. Remote operation is also possible.
The external switch and connector enabling operation of the machine by two operators, must
be prepared by the user.
■Product Configuration
The base machine consists of two axes X-axis and Y-axis. It may be upgraded to three and four axes by
installing the optional Z-unit and ZR-unit respectively.
NOTE

1-2 CAST-AU4/B2521E
1-1 Nomenclature
Front View
* Debug station •••Option
Either the “SRX teaching pendant”or the program transfer cable can be directly connected to the debug
station connector.
* EJECT button •••When inserting or removing the CAST-PRO teaching pendant, insert it or remove it
while pressing the EJECT button.
5-gang LED Display
The following machine conditions are indicated on the 5-gang LED display.
1. ERROR ........Illuminates during the error state.
2. ONLINE.......Illuminates during the on-line state. (Illuminates normally.)
3. ROBOT ........Illuminates while the servo is on. (Illuminates continually after home position is checked.
Turned off during stop.)
4. TASK ...........Illuminates while any of the robot task, or PLC task, or peripheral task is being executed.
5. POWER .......Illuminates in green while power is on. Illuminates in red when a battery runs out.
Work table mounting bracket (Y-axis)
X-axis
Unit or tool mounting bracket
X-axis stand
START button
Operation box
PROGRAM switch
STOP button
Memory card slot
5-gang LED display
(POWER, TASK, ROBOT,
ONLINE, ERROR indications
from the left)
RS 232C program
transfer connector
SRX teaching
pendant connector
*To debug station
Debug station connector
*EJECT button
TECH. PEN. connector
(for teaching pendant of CAST-PRO)

1-3
1. Outline
CAST-AU4/B2521E
Rear View
CAST-PRO Teaching Pendant SRX Teaching pendant
CAST-P06 (option) SRX-P005/S (option)
888
POWER switch
Internal/external selecting switch for I/O
(Upper : OUTSIDE, Lower : INSIDE)
INLET (power)
USER INPUT/OUTPUT connector
(External I/O connector)
RS232C connector
(Used only when the full open programmable specification
is used.)
SAFETY connector
DC24V INPUT (I/O power) connector
(Up to maximum 1.5 A)
OPERATION BOX connector
Z- and ZR-axis connector
Fan

1-4 CAST-AU4/B2521E
1-2 Outline Drawings
■ROBOKIDS
Standard Type (CAST-AU4/B2521E)
320
(35)
(69)
250
(Stroke)
105 40 105
(250)
203
(300)
18
A
2
48
(60)
(6)
26
(40)
4
φ4
4-M4
+ 0.03
0
+ 0.03
0
(7)
A
(52) 210
(Stroke)
(4.5)
210
(360)
10 110 150 90
(6) (78)
Detailed view of "A"

1-5
1. Outline
CAST-AU4/B2521E
Height Adjustable Type (CAST-AU4/BT2521E)
320
(35)
(69)
250
(Stroke)
105 40 105
(250)
203
(300)
18
A
A
(52) 210
(Stroke)
(4.5)
210
10 110 90
(6) (78)
(440)
230

1-6 CAST-AU4/B2521E
■3-Axes Model
Z-unit
■4-Axes Model
ZR-unit
φ12h7
5280
50 Tool attachment position
63
162
97
45
144.5
5
30
57

45
58
11
576 26
97
162
68
10 (13) 179
(202)
70
48
14 26
4-M4

1-7
1. Outline
CAST-AU4/B2521E
Service Tapped-Hole Position
50 50
128
10
50
50
128
10
(120)
6-M3
10 10
(250)
Side A
10 20
6-M3
(Side A only)
(1.6)
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