Toshiba TS3000 Series User manual

STE 80862-1
INSTRUCTION MANUAL
OPERATOR’S MANUAL
FOR
TS3SFB UNIT
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.

TS3SFB UNIT
series Robot Controller
Copyright 2010 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
Structure of TS series 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 safely and correctly.
Be sure to read through and understand this manual before operating the robot.
Also, strictly observe the descriptions made in the manual.
[Operator’s Manual]
This manual deals with the TS series robot 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.
[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.
[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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[User Parameter Manual]
This manual describes the setting procedures of the robot controller. Refer to this
manual when you perform the setting of communication, I/O, and motion conditions.
[Alarm Manual]
This manual describes the contents, causes, and remedies of alarms. Refer to this
manual when an alarm occurs.
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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, electric shocks, etc., which do not require
hospitalization or long-term medical treatment.
*2) Physical damage refers to damages due to the 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
that will hinder the operation. If the equipment goes wrong, a
person nearby will be injured or involved in an accident.
• Anyone other than the operator MUST NOT approach the
equipment. Should they negligently touch the dangerous part of
the equipment, they will get injured or involved in a serious
accident.
• NEVER perform an inappropriate operation that 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 as is, 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, the teaching operation should be performed outside
the dangerous area of the robot. If it should inevitably be
performed 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,
they should perform the job at a position from which they 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 they can see the entire robot system and operate the
EMERGENCY stop pushbutton switch at the time of an
emergency. Also, they 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 been 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 the after-sale service agent.
• Pushbutton operations of the control 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 the visual appearances of the robot, controller,
peripheral equipment and cables are in 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
1Overview................................................................................................................. 10
2Types of Connection Lines..................................................................................... 10
2.1 Power input/output ACIN2 (See 1. In 2.1 "Outline drawings.")......................... 10
2.2 Signal input/output SAFE (See 2. In 2.1 "Outline drawings.")........................... 11
2.3 Signal input/output RESET (See 3. In 2.1 "Outline drawings.")........................ 12
3Unit Outline Drawings............................................................................................. 13
3.1 Outline drawings............................................................................................... 13
3.2 Detailed internal drawings................................................................................ 14
4Block Diagram of the Internal Circuit ...................................................................... 15
5Operation Timings .................................................................................................. 16
5.1 Activation.......................................................................................................... 16
5.2 Stop.................................................................................................................. 16
5.3 Reactivation...................................................................................................... 16
5.4 Timing diagram................................................................................................. 17
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TS3SFB UNIT
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1 Overview
This manual describes the TS3SFB unit, an optional unit for a TS3000 series
controller. The unit can be used to configure a safety-related block, thereby
allowing the controller to satisfy the requirements of Safety Category 3
(ISO-138491) required for ANSI and the CE marking. The controller with the
standard specification satisfies the requirements of Safety Category 2.
2 Types of Connection Lines
2.1 Power input/output ACIN2 (See 1. In 2.1 "Outline drawings.")
This connector supplies power to the TS3SFB unit, and outputs power through
contactors.
The AC cable for connecting the TS3SFB unit to a TS3000 series controller is
available as an accessory. (The standard length is 3 m.)
AC cable (drawing No.: M249418)
Model No. on the TS3SFB unit side: F32MSP-04V-KX*, manufactured by JST
Model No. on the connection cable side: F32FSS-04V-KX*, manufactured by JST
Connector connected to the AC cable
Pin No. Signal name I/O
1 R2 Input
2 S2 Input
3 R3 Output
4 S3 Output
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2.2 Signal input/output SAFE (See 2. In 2.1 "Outline drawings.")
This connector inputs an emergency stop signal, an enable switch signal for the
teaching pendant, and a safety input switch signal to the TS3SFB unit, and outputs
a feedback signal received from the safety relay module to the TS3000 series
controller.
The signal cable for connecting the TS3SFB unit to the TS3000 series controller is
available as an accessory. (The standard length is 3 m.)
SIG cable (drawing No.: M249419)
Model No. on the TS3SFB unit side: J21DPM-20V-KX*, manufactured by JST
Model No. on the connection cable side: J21DF-20V-KX*, manufactured by JST
Connector connected to the SIG cable
Pin No. Signal name I/O Function
A1 P24V Input Power for the safety relay module
B1 IN-EMG1 Input Emergency stop switch input 1-1
A2 OU-EMG1 Input Emergency stop switch input 1-2
B2 EMS1 Output Emergency stop switch detection 1
A3 P24V Input Power for the safety relay module
B3 IN-EMG2 Input Emergency stop switch input 2-1
A4 OU-EMG2 Input Emergency stop switch input 2-2
B4 EMS2 Output Emergency stop switch detection 2
A5 P24V Input Power for the safety relay module
B5 IN-ENA1 Input Safety switch input 1-1
A6 OU-ENA1 Input Safety switch input 1-2
B6 ENA1 Output Safety switch signal detection 1
A7 P24V Input Power for the safety relay module
B7 IN-ENA2 Input Safety switch input 2-1
A8 OU-ENA2 Input Safety switch input 2-2
B8 ENA2 Output Safety switch signal detection 2
A9 EMG-RM Output Detection of safety relay module for emergency
stop switch
B9 GND Input Ground for safety relay module
A10 ENA-RM Output Detection of safety relay module for safety switch
B10 GND Input Ground for safety relay module
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2.3 Signal input/output RESET (See 3. In 2.1 "Outline drawings.")
This connector inputs a reset signal to each safety module in the TS3SFB unit.
The connector on the connection cable side is available as an accessory.
Model No. common to the TS3SFB unit side and connection cable side:
ML-4000-ASV-4PGY*, manufactured by SATO PARTS Co., Ltd.
One pin
Connector for inputting a reset signal to each safety module
Pin No. Signal name
1 RESET1-1 (input to the safety relay module for the emergency stop switch)
2 RESET1-2 (input to the safety relay module for the emergency stop switch)
3 RESET2-1 (input to the safety relay module for the safety switch)
4 RESET2-2 (input to the safety relay module for the safety switch)
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3 Unit Outline Drawings
3.1 Outline drawings
203
240
145
134 11
210
170
SAFE
RESET
ACIN2
Category 3 Safety UNIT
MODEL TS3SFB
SER.No.
TOSHIBA MACHINE CO.,LTD. MADE IN JAPAN
1
3
2
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3.2 Detailed internal drawings
Magnet contactors
(for emergency stop
switch) K1, K2
SRM1 (for emergency stop
switch) safety relay module
SRM2 (for enable switch and safety
input switch) safety relay module Magnet contactors (for enable switch
and safety input switch) K3, K4
Safety relay modules (SRM1, SRM2): G9SA-321-T075 24V DC manufactured by IDEC
Magnet contactors (K1 to K4): SC-4-1/G 24V DC 1b manufactured by Fuji Electric
Holdings Co., Ltd.
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4 Block Diagram of the Internal Circuit
ＭＣＣＢ
ＡＣ２００Ｖ
Ｋ１ Ｋ２ Ｋ３ Ｋ４
Main substrate :
X8GC
ＴＰ１０００
Power for control
Ｋ１ Ｋ２
Ｅ２４
Ｅ２４
Enable switch
Emergency stop switch
Ａ２ Ｔ１１ Ｔ１２ Ｔ２１ Ｔ２２ ４４ ５４ ３４
Ｔ３１ ＡＴ３２Ａ１ ４３ ５３ ３３
ＳＲＹ１
ＬＯＧＩＣ
24 V DC output
ＡＣ
input
Servo AC input
PN output
Servo power supply
substrate
: Ｘ8ＧＨ
Control panel
External emergency stop
switch
Panel emergency stop switch
Enable
detection
Ｅ２４
ＴＰ１０００
Safety input switch
Module
operation
detection
Momentary
interruption
detection circuit
NF
5 V DC output
２４Ｖ
Emergency
stop detection
Ｋ３ Ｋ４
Ｅ２４
２４Ｖ
1
5
17
18
4
8
2
3
6
7
9
13
19
12
16
20
10
11
14
15
Ｂ
Ａ２ Ｔ１１ Ｔ１２ Ｔ２１ Ｔ２２ ４４ ５４ ３４
Ｔ３１ ＡＴ３２Ａ１ ４３ ５３ ３３
ＳＲＹ２
ＬＯＧＩＣ
Ｂ
２４Ｖ
IPM Motor
Module
operation
detection
２４Ｖ
TS3000/TS3100 controller
TEACH
INTERNAL
EXT
ENABLE
Ｅ２４
* Mode selection
switch
* Details of mode selection and enable switch section
To safety
input section To safety
relay
Back check
Back check
２４
２３
１４
１３
２４
２３
１４
１３
SPY2
activation
switch
SPY1
activation
switch
A1
A3
A9
B9
B2
B4
B1
A2
B3
A4
A5
A7
A10
B6
B8
B10
B5
A6
B7
A8
SAFE
ACIN2
RESET-1,2
TS3SFB unit
EMS1*
EMS2*
IN-EMG1
OU-EMG1
IN-EMG2
OU-EMG2
EMG-RM
1
2
3
4
R2
S2
R3
S3
1
2
3
4
43,53 off delay
500 msec
43,53 off delay
500 msec
ENA1*
ENA2*
ENA-RM
Servo driver
substrate: X8G1-3
Pins 43-44 and 53-54 of the safety relay modules SRM1 and SRM2 are used for off
delay output.
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5 Operation Timings
5.1 Activation
When the RESET1 and RESET2 switches are pressed with the emergency stop
switches, enable switches, and safety input switches turned off, the safety relay
module is reset. After this reset, the contacts of the K1 to K4 contactors are closed.
Then, AC power is supplied to the servo power supply section on the X8GH (power
supply module). However, no voltage is charged to the servo driving capacitor.
When the servo ON command signal is input after that, voltage charging starts and
motor excitation becomes possible.
5.2 Stop
When the emergency stop switches, enable switches, and safety input switches are
pressed, a deceleration stop starts, after which a brake signal is input and the motor
excitation is canceled. The contacts of the K1 to K4 contactors are opened with a
delay of 500 ms after an emergency stop signal is input. Then, the AC power of
the servo power supply section can be turned off. The delay time of 500 ms is set
by the safety relay module.
5.3 Reactivation
When the emergency stop switches, enable switches, and safety input switches are
pressed, the safety relay module is placed in a state in which it is not reset and an
error is indicated. When this happens, the servo cannot be turned on.
If both 008-014 Emergency Stop SW ON and 008-281 Emergency SW relay ON are
generated together, the safety relay module for the emergency stop switches is in a
state in which it is not reset. Press RESET1 with all the emergency stop switches
turned off.
If both 008-017 Safety SW ON and 008-280 Safety SW relay ON are generated
together, the safety relay module for the safety switches is in a state in which it is
not reset. Press RESET2 with all the enable switches and safety input sections
turned off.
In the teaching mode, press RESET2 with the enable switches on the teaching
pendant neutralized.
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5.4 Timing diagram
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