Toshiba TS2000 User manual

STE 71366-4
INSTRUCTION MANUAL
TS2000 ROBOT CONTROLLER
STARTUP MANUAL
Notice
• Make sure that this instruction manual is delivered to the
final user of Toshiba Machine's industrial robot.
• Before operating the industrial robot, read through and
completely understand this manual.
• After reading through this manual, keep it nearby for future
reference.
TOSHIBA MACHINE CO., LTD.
TOKYO, JAPAN

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Copyright 2002 by Toshiba Machine Co., Ltd.
All rights reserved.
No part of this document may be reproduced in any form without obtaining prior written
permission from Toshiba Machine Co., Ltd.
The information contained in this manual is subject to change without prior notice to
effect improvements.

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Preface
This manual describes the procedures covering from power ON of the robot after
installation to robot operation by manual guide and by programs.
Before reading this manual, install the robot according to the Safety Manual and
Installation & Transport Manual.
When you use the TS2000 robot controller for the first time, be sure to read through this
manual.
Structure of TS2000 robot controller instruction manuals:
These instruction manuals were published in parts according to the application and
purpose, and the name and outline of each manual are as follows:
[Safety Manual]
This manual contains the important information to use the robot safety and correctly.
Be sure to read through and understand this manual before operating the robot.
Also, strictly observe the descriptions made there.
[Installation & Transport Manual]
This manual describes the transport, unpacking and installation of the robot and
controller. Be sure to read through this manual before unpacking the shipment
containing the robot.
[Operator’s Manual]
This manual deals with the TS1000 controller operating procedures. Read through
this manual before operating the robot, and refer to it as necessary.
[Robot Language Manual]
This manual refers to the robot language called "SCOL". When you have to create
a program based on this language, read through the manual.
[Interface Manual]
This manual describes the external signals for the robot. Concerning the interface
conditions between the robot and peripheral equipment, specifications, timing, etc.,
refer to the manual when necessary.

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[Maintenance Manual]
This manual deals with the daily and regular inspections to be made on the robot
and controller. Read through this manual to use the robot safely over long years to
come.
[Communication Manual]
This manual describes the serial communication between the robot controller and
other equipment. Refer to this manual when connecting the robot controller with a
host computer, optical sensor, etc., via a serial cable.

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Cautions on Safety
This manual contains the important information on the robot and controller to prevent
injury to the operators and persons nearby, to prevent damage to assets and to assure
correct use.
Make sure that the following details (indications and symbols) are well understood
before reading this manual. Always observe the information that is noted.
[Explanation of indications]
Indication Meaning of indication
!DANGER
This means that "incorrect handling will lead to fatalities
or serious injuries."
!CAUTION
This means that "incorrect handling may lead to
personal injuries *1) or physical damage *2).
*1) Injuries refer to injuries, burns and electric shocks, etc., which do not require
hospitalization or long-term medical treatment.
*2) Physical damage refers to damages due to destruction of assets or resources.
[Explanation of symbols]
Symbol Meaning of symbol
This means that the action is prohibited (must not be done).
Details of the actions actually prohibited are indicated with
pictures or words in or near the symbol.
!
This means that the action is mandatory (must be done).
Details of the actions that must be done are indicated with
pictures or words in or near the symbol.
!
This means danger.
Details of the actual danger are indicated with pictures or words in
or near the symbol.
!
This means caution.
Details of the actual caution are indicated with pictures or words in
or near the symbol.

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[Operation]
!DANGER
Prohibited
• During operation, NEVER enter the dangerous area of the robot.
Otherwise, you will be injured seriously.
• DO NOT leave in the working range any machinery or materials
which will hinder the operation. If the equipment went wrong, a
person nearby will be injured or involved in an accident.
• Anyone other than the operator MUST NOT approach the
equipment. Should he negligently touch the dangerous part of
the equipment, he will get injured or involved in a serious
accident.
• NEVER perform an inappropriate operation which is not described
in the instruction manual. Otherwise, the equipment will start by
mistake, resulting in personal injury or serious accident.
!
Danger
• If you feel even a little that you are exposed to danger or that the
equipment works abnormally, press the EMERGENCY stop
pushbutton switch to stop the equipment. If the equipment is
used as it is, you will be injured or involved in a serious accident.
When this happens, ask our after-sale service agent for repair.
• During operation, be sure to close the equipment cover. Should
the cover be opened during operation, you will be struck by an
electric shock or get injured.
• Only a well-trained and qualified person is allowed to perform the
operation. Should the equipment be operated improperly, it will
start by mistake, causing a personal injury or serious accident.
• If the equipment has malfunctioned, turn the power off, identify
and remove the cause of the abnormality, maintain the peripheral
equipment and completely restore the malfunctioned equipment.
Then start the equipment at a slow speed. If the equipment
starts, leaving the abnormality, you will be involved in a serious
accident.

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!CAUTION
Prohibited
• DO NOT change the data of the system structure file.
Otherwise, the robot will move abnormally, resulting in damage or
an accident.
!
Mandatory
• In principle, teaching operation should be performed outside the
dangerous area of the robot. If it should be performed inevitably
within the dangerous area, strictly observe the following matters.
(1) The teaching operation should always be performed by two (2)
persons. One person performs the job and the other person
watches outside the dangerous area. Also, both persons
should try to prevent mis-operation with each other.
(2) The operator should do the job in an attitude ready to press
the EMERGENCY stop pushbutton switch at any time. Also,
he should perform the job at a position from which he can
evacuate immediately at the time of an emergency after
confirming the robot working range and shields nearby.
(3) The supervisor should keep watch on the job at a position
where he can see the entire robot system and operate the
EMERGENCY stop pushbutton switch at the time of an
emergency. Also, he should keep anyone from entering the
dangerous area. Unless the operator or other person follows
the instructions of the supervisor, an accident will be caused.
• If an abnormality has generated or the POWER LED lamp on the
control panel remains off after the main power switch of the
equipment was turned on, turn off the main power immediately
and confirm the wiring. Otherwise, you will be struck by an
electric shock or a fire will break out.
• Unless the robot operates toward a designated direction at
manual guide, turn off the servo power. Otherwise, the robot will
be damaged or you will be involved in an accident. When this
happens, call us at the after-sale service agent.
• Pushbutton operations on the operation panel and teach pendant
should be confirmed visually. Otherwise, you will be involved in
an accident due to mis-operation.
• After the power is turned on, be sure to reset a program to start
an automatic operation. If the program is executed continuously,
the robot will interfere with the peripheral equipment, resulting in
damages or accidents.

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!CAUTION
!
Mandatory
• Before operating the equipment, perform the following inspection.
(1) Make sure that visual appearance of the robot, controller,
peripheral equipment and cables is in the good condition.
(2) Make sure that no obstacle stands in or near the working
range of the robot and peripheral equipment.
(3) Make sure that the emergency stop and other safety devices
operate properly.
(4) Make sure that no abnormal noise or vibration is involved in
the robot operation.
If the above prior inspection is skipped, the equipment will be
damaged or you will be involved in an accident.
!
Caution
• The speed of test operations is initially set at 25 % of the
maximum robot speed.
• The speed of automatic operation is initially set at 100 % of the
maximum robot speed.

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Table of Contents
Page
1. Before Power ON............................................................................................ 9
1.1 Control Panel ....................................................................................... 11
1.2 Teach Pendant..................................................................................... 13
2. Power ON....................................................................................................... 14
2.1 Power ON............................................................................................. 14
2.2 Emergency Stop................................................................................... 15
2.3 Servo ON ............................................................................................. 16
2.4 Main Display......................................................................................... 18
2.5 Power OFF........................................................................................... 20
3. Manual Operation ........................................................................................... 22
3.1 Enable Switch ...................................................................................... 22
3.2 Joint Guide........................................................................................... 23
3.3 Guide in Cartesian Coordinate System................................................ 26
4. Programming .................................................................................................. 28
4.1 Starting Editor ...................................................................................... 28
4.2 Entering Program................................................................................. 32
4.3 Entering Data (Teach Points)............................................................... 33
4.4 Quitting Editor ...................................................................................... 37
5. Starting Program............................................................................................. 38
5.1 Selecting Program................................................................................ 38
5.2 Test Operation ..................................................................................... 41
5.3 Internal Automatic Operation................................................................ 46
6. Input/Output Control........................................................................................ 48
6.1 User's Function Switches..................................................................... 48
6.2 7-Segment User Display ...................................................................... 48
6.3 I/O Control Program............................................................................. 49

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1. Before Power ON
Before turning the power on, confirm the following matters, referring to the
Installation & Transport Manual.
Is the robot secured?
Is the power supply connected?
Single phase,
180 ~ 250 V AC power supply

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Are the cables between the controller and robot connected?
Is the I/P jumper connector connected?
The I/O jumper connector is short-circuited to the external signals required for the
robot operation, such as external emergency stop, servo OFF and stop. The robot
can be moved only when these signals are connected.
Is the teach pendant (TP) connected?
CN5
CN6
CN4
(Brake, hand I/O)
ENC
(Encoder feedback)
Motor power cable
137 18 69 42.2
SERVO
ON
CYCLE
SERVO
OFF
RUN STOP
ALARM
RESET
SELECT
LINE
USER
ALARM
EXT. SIGNAL
EXT. HOST
POWER
MODE
EXT
INT
MANU
EMERGENCY
UF1
UF2

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1.1 Control Panel
The control panel is shown below.
Key switch : Used to select the operation master mode.
MODE : Used to change over the EXT. SIGNAL and HOST
modes while the EXT master mode is selected.
SERVO ON, SERVO OFF : Used to turn on and off the servo power.
RUN : Used to start the internal automatic mode operation.
STOP : Used to stop an operation after the active block of
program has been executed.
CYCLE : Used to select the cycle operation mode in the internal
automatic mode.
SERVO
ON
CYCLE
SERVO
OFF
RUN STOP
ALARM
RESET
SELECT
LINE
USER
ALARM
EXT. SIGNAL
EXT. HOST
POWER
MODE
EXT INT MANU
EMERGENCY
UF1
UF2

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SELECT : Each time this switch is pressed, the display content
changes.
(LINE) No. of execution steps of program.
(USER) Value set in system variable PLCDATAW.
(The value is input by the program.)
(ALARM) Alarm number generated in the controller.
If two (2) or more alarms have generated,
such alarm numbers are displayed at two
(2)-second intervals.
UF1, UF2 : User function switches. This switch input can be
referred to by the DIN command, and the lamp output
by the DOUT command.
ALARM RESET : Used to reset all alarms generated.
EMERGENCY : EMERGENCY stop pushbutton switch.

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1.2 Teach Pendant
Display
EMERGENCY
STOP switch
SERVO ON
pushbutton switch
Guidance condition
LED lamp
Enable switch
Guide keys

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2. Power ON
2.1 Power ON
!CAUTION
If an error has occurred or if the POWER LED equipped
on the control panel will not illuminate when the main
power switch of the controller was turned on, turn the
power off immediately and check for the wiring.
Otherwise, you will be involved in an electric shock or a
fire.
When the power is turned on, the controller enters a
program reset status.
When the power is turned on, the
POWER lamp is illuminated.
After power ON, the controller
performs self-check. After the
processing of start has finished, both
the STOP and SERVO OFF lamps
are illuminated in red.
Turn on the controller power.
SERVO
ON
CYCLE
SERVO
OFF
RUN STOP
EXT. SIGNAL
EXT. HOST
POWER
MODE
EXT INT MANU

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2.2 Emergency Stop
If a problem related to safety has occurred in the robot or peripheral equipment,
press the EMERGENCY stop pushbutton switch immediately. The robot stops
instantly with the servo power turned off.
[1] EMERGENCY stop switch
Control panel Teach pendant
ηAn EMERGENCY stop switch can be equipped on the peripheral equipment
also. (For details, see the Interface Manual.)
[2] Reset of EMERGENCY stop switch
To reset the EMERGENCY stop switch, turn the top of the switch in the
arrow-marked direction and pull it up.
SERVO
ON
CYCLE
SERVO
OFF
RUN STOP
ALARM
RESET
SELECT
LINE
USER
ALARM
EXT. SIGNAL
EXT. HOST
POWER
MODE
EXT INT MANU EMERGENCY
UF1
UF2

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2.3 Servo ON
!CAUTION
If the robot has operated abnormally when the servo
power was turned on, press the EMERGENCY stop
switch immediately to turn the servo power off.
Before entering the working envelope of the robot, be
sure to turn the servo power off.
[1] Select "TEACHING" by means of the MODE selector switch.
Select "TEACHING" for the master mode by
changing over the key switch.
[2] Make sure that all EMERGENCY stop switches (provided on the control panel,
teach pendant and external equipment) are reset.
SERVO
ON
CYCLE
SERVO
OFF
RUN STOP
ALARM
RESET
SELECT
LINE
USER
ALARM
EXT. SIGNAL
EXT. HOST
POWER
MODE
EXT INT MANU EMERGENCY
UF1
UF2

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[3] Turn the servo power on.
Or
Make sure that the SERVO ON lamp on the control panel or teach pendant is
illuminated.
SERVO
ON
CYCLE
SERVO
OFF
RUN STOP
ALARM
RESET
SELECT
LINE
USER
ALARM
EXT. SIGNAL
EXT. HOST
POWER
MODE
EXT INT MANU EMERGENCY
UF1
UF2

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2.4 Main Display
Turn the power on, select the TEACHING mode by means of the MODE switch and
turn the servo power on.
M O D E : T E A C H I N G / C O N T
L:
O: 20%
M:FREE
S:STOP
RESET
E D I T D E D I T S E L F I L E >
MODE: Indicates the master mode/operation mode.
The master mode comes in the following four (4) types.
TEACHING Teaching mode
INTERNAL Internal automatic mode
EXT. SIGNAL External automatic signal mode
INT. HOST External automatic host mode
For the operation mode, the following four (4) modes are available.
CONT Continuous operation
CYCLE Cycle operation
(The program is executed from the top to the end
command of the main program.)
SEG Segment operation
(The program is executed just before the next
operation command.)
STEP Step operation
(The program is executed line by line.)
L: (Line)
Indicates the active program line number.
O: (Override)
Indicates the speed override value, taking the specified speed as 100 %.

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M: (Machine)
On the TS1000 screen, "FREE" is always indicated.
S: (Status)
Indicates the program run status of the controller.
The run status comes in the following four (4) types.
RUN During program execution
STOP RESET During stop of initialization mode
(When the RUN mode takes effect, the program is
executed from the top.)
STOP RETRY During stop of restart mode
(When the RUN mode takes effect, interrupted motion
command restarts.)
STOP CONT During stop of continuous mode
(When the RUN mode takes effect, the program is
executed from the command next to the finished
command.)
Function: The function menu is displayed by reversed image on the bottom of the
display. The keys correspond to F1 to F5 in turn, when viewed from the
left. If symbol ">" is displayed on the bottom right side of the display,
the next function menu can be displayed by means of the NEXT key.