Toshiba TS3000 Series User manual

STE 80730-0
INSTRUCTION MANUAL
OPERATOR’S MANUAL
(Vertical Articulated Robot System)
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.
TS3100 6-AXIS system

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Copyright 2008 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 safety and correctly.
Be sure to read through and understand this manual before operating the robot.
Also, strictly observe the descriptions made there.
[Startup Manual]
This manual describes the procedures covering from power ON of the robot after
installation to robot operation by manual guide. When you use the TS series robot
controller for the first time, be sure to read through this 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.

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[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.
[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.
This manual describes how to use various functions of the robot system to manually
guide the robot through the teach pendant, edit programs, compile data and perform
automatic operation.
This manual is intended for the robot operator. Before reading this manual, he or she
should first read the Safety Manual and Startup Manual.

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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 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 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
Section 1 Before Operating Your Robot......................................................... 1-1
1.1 Overview of Operation Functions......................................................... 1-1
1.2 Mode Structure.................................................................................... 1-3
1.2.1 External Automatic Mode ....................................................... 1-4
1.2.2 Internal Automatic Mode......................................................... 1-5
1.2.3 Teaching Mode (Including Test Operation) ............................ 1-6
1.2.4 Edit......................................................................................... 1-7
1.3 General Operation ............................................................................... 1-8
1.3.1 Entry of Alphanumeric Characters and Symbols.................... 1-9
1.3.2 Combined Key Operation....................................................... 1-10
1.3.3 Use of Function Keys ............................................................. 1-11
1.3.4 Repeating an Entry................................................................. 1-12
1.3.5 Correcting Incorrect Entries.................................................... 1-12
1.3.6 Canceling an Entry................................................................. 1-13
1.3.7 Use of Wild Cards (*).............................................................. 1-13
1.3.8 Format for Operating Instructions........................................... 1-14
1.4 Assigning Names................................................................................. 1-15
1.4.1 Assigning a File Name............................................................ 1-15
1.4.2 Assigning a Point Name......................................................... 1-16
1.4.3 Assigning a Name to Coordinate Data ................................... 1-17
1.4.4 Assigning a Name to Load Data............................................. 1-18
1.5 File....................................................................................................... 1-19
1.5.1 Kind of File ............................................................................. 1-19
1.5.2 Batch File ............................................................................... 1-21
1.5.3 Backup ................................................................................... 1-21
Section 2 Basic Operation.............................................................................. 2-1
2.1 Basic Operating Procedures................................................................ 2-1
2.2 Control Panel....................................................................................... 2-2
2.3 Turning ON the Main Power ................................................................ 2-4
2.4 Turning ON the Servo Power............................................................... 2-6
2.5 Turning OFF the Servo Power............................................................. 2-8
2.6 Turning OFF the Main Power............................................................... 2-9

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Section 3 Teaching Operation........................................................................ 3-1
3.1 Selecting the Teaching Mode .............................................................. 3-1
3.2 Guidance Coordinates ....................................................................... 3-3
3.3 Guide Mode......................................................................................... 3-4
3.4 Guide Speed........................................................................................ 3-5
3.5 Guidance ............................................................................................. 3-6
3.6 Servo Free........................................................................................... 3-7
Section 4 Program Editing.............................................................................. 4-1
4.1 Starting Up the Program Editor [EDIT]................................................. 4-1
4.2 Character Input.................................................................................... 4-5
4.2.1 Character Input Mode Selection............................................. 4-5
4.2.2 Insert Mode [INS] ................................................................... 4-6
4.2.3 Replace Mode [Replace]........................................................ 4-9
4.2.4 Input Correction [BS].............................................................. 4-11
4.2.5 Character Deletion [DEL]........................................................ 4-12
4.2.6 Moving the Cursor [↑] [↓] [←] [→]........................................... 4-13
4.3 Edit Command Input............................................................................ 4-14
4.3.1 List of Edit Commands ........................................................... 4-14
4.3.2 Command Menu Selection..................................................... 4-15
4.3.3 Input Correction [BS].............................................................. 4-16
4.3.4 Cancel [ESC].......................................................................... 4-17
4.4 Descriptions on Edit Commands.......................................................... 4-18
4.4.1 Data Editing [DEDIT].............................................................. 4-18
4.4.2 Jump to Specified Line [JUMP] .............................................. 4-18
4.4.3 Deleting Block [CUT].............................................................. 4-20
4.4.4 Copying [COPY]..................................................................... 4-22
4.4.5 Pasting [PASTE]..................................................................... 4-24
4.4.6 Searching Character String [FIND]......................................... 4-26
4.4.7 Replacing Character String [CHANG]..................................... 4-28
4.4.8 Quit [SAVE]............................................................................ 4-32
4.4.9 Aborting and Quitting Edit [NOSAVE]..................................... 4-33
4.5 Automatic Start File.............................................................................. 4-34

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Section 5 Data Editing.................................................................................... 5-1
5.1 Starting Up the Data Editor.................................................................. 5-1
5.2 Position Data Directory Display Mode.................................................. 5-3
5.2.1 Editing of Position Data Name................................................ 5-7
5.2.2 Editing of Position Element..................................................... 5-10
5.2.3 Addition of New Position Data (INS)....................................... 5-14
5.2.4 Deletion of Position Data (ALT + BS)..................................... 5-16
5.2.5 Quitting Data Editing [SAVE].................................................. 5-17
5.2.6 Abortion and Quitting Data Editing [NOSAVE] ....................... 5-19
5.2.7 Return to Program Editor [PRG]............................................. 5-21
5.2.8 Call of Detailed Position Data Display [FULL]......................... 5-22
5.2.9 Call of Coordinate Data Directory Display [TRANS]............... 5-23
5.2.10 Call of Load Data Directory Display [PYLD] ........................... 5-24
5.2.11 Search of Position Data [FIND] .............................................. 5-25
5.2.12 Teach of Position Data [TEACH]............................................ 5-26
5.2.13 Move to Teach Point [M–TO].................................................. 5-30
5.2.14 Cut of Position Data [CUT]..................................................... 5-32
5.2.15 Paste of Position Data [PASTE] ............................................. 5-35
5.3 Detailed Position Data Display Mode................................................... 5-36
5.3.1 Editing of Detailed Position Data Name.................................. 5-39
5.3.2 Editing of Detailed Position Element....................................... 5-42
5.3.3 Call of Position Data Directory Display [DIR].......................... 5-45
5.4 Coordinate Data Directory Display Mode............................................. 5-46
5.4.1 Addition of New Coordinate Data (INS).................................. 5-49
5.4.2 Deletion of Coordinate Data (ALT + BS) ................................ 5-51
5.4.3 Call of Detailed Coordinate Data Display ............................... 5-52
5.4.4 Call of Load Data Directory Display [PYLD] ........................... 5-53
5.4.5 Setting of Work Coordinate System
(Call of Position Data Directory Display) [WORK]................... 5-54
5.4.6 Setting and Cancel of Tool Coordinate System [TOOL]......... 5-55
5.4.7 Search of Coordinate Data [FIND].......................................... 5-56
5.4.8 Cut of Coordinate Data [CUT] ................................................ 5-59
5.4.9 Paste of Coordinate Data [PASTE]......................................... 5-62
5.5 Detailed Coordinate Data Display Mode.............................................. 5-63
5.5.1 Editing of Coordinate Data Name........................................... 5-65

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5.5.2 Editing of Coordinate Element................................................ 5-68
5.5.3 Teaching of Coordinate Data [TEACH]................................... 5-71
5.6 Load Data Display Mode...................................................................... 5-77
5.6.1 Editing of Load Data Name .................................................... 5-80
5.6.2 Editing of Load Element ......................................................... 5-83
5.6.3 Addition of New Load Data [INS]............................................ 5-86
5.6.4 Deletion of Load Data (ALT + BS).......................................... 5-88
5.6.5 Call of Position Data Directory Display [POINT]..................... 5-89
5.6.6 Call of Coordinate Data Directory Display [TRANS]............... 5-90
Section 6 Test Operation................................................................................ 6-1
6.1 Selecting Test Operation Mode ........................................................... 6-2
6.2 Selecting File [SEL].............................................................................. 6-4
6.3 Selecting Run Mode [MODE]............................................................... 6-6
6.4 Speed Override [OVRD] ...................................................................... 6-8
6.5 Executing Program Step [STEP].......................................................... 6-10
6.6 Startup [RUN] ...................................................................................... 6-13
6.7 Stop ..................................................................................................... 6-15
6.7.1 CYCLE Stop........................................................................... 6-15
7.7.2 STOP...................................................................................... 6-17
6.7.3 BREAK................................................................................... 6-18
6.7.4 FEED HOLD........................................................................... 6-19
6.7.5 EMERGENCY Stop................................................................ 6-21
6.8 Reset [RESET] .................................................................................... 6-22
6.8.1 Program Reset ....................................................................... 6-22
6.8.2 Step Reset.............................................................................. 6-24
6.8.3 Cycle Reset............................................................................ 6-26
6.8.4 Output Signal Reset ............................................................... 6-28
6.8.5 Execution File Reset............................................................... 6-30
6.9 Direct Execution [DO] .......................................................................... 6-32
6.10 Variable Monitor................................................................................... 6-34
6.11 Display of Line to be Executed ............................................................ 6-38
6.12 Finishing Test Operation...................................................................... 6-40

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Section 7 Internal Automatic Operation.......................................................... 7-1
7.1 Selecting Internal Automatic Operation Mode...................................... 7-2
7.2 Selecting File [SEL].............................................................................. 7-4
7.3 Selecting Run Mode [MODE]............................................................... 7-6
7.4 Speed Override [OVRD] ...................................................................... 7-8
7.5 Startup................................................................................................. 7-10
7.6 Stop ..................................................................................................... 7-11
7.6.1 Cycle Stop.............................................................................. 7-11
7.6.2 STOP...................................................................................... 7-12
7.6.3 BREAK................................................................................... 7-13
7.6.4 FEED HOLD........................................................................... 7-14
7.6.5 EMERGENCY Stop................................................................ 7-16
7.7 Reset [RESET] .................................................................................... 7-17
7.7.1 Program Reset ....................................................................... 7-17
7.7.2 Step Reset.............................................................................. 7-19
7.7.3 Cycle Reset............................................................................ 7-21
7.7.4 Output Signal Reset ............................................................... 7-23
7.7.5 Execution File Reset............................................................... 7-24
7.8 Variable Monitor................................................................................... 7-26
7.9 Display of Line to be Executed ............................................................ 7-30
Section 8 External Automatic Operation......................................................... 8-1
8.1 Selecting External Automatic Operation Mode .................................... 8-2
8.2 Selecting File ....................................................................................... 8-5
8.3 Selecting Run Mode............................................................................. 8-7
8.4 Speed Override.................................................................................... 8-8
8.5 Startup................................................................................................. 8-9
8.6 Stop ..................................................................................................... 8-10
8.6.1 Cycle Stop.............................................................................. 8-10
8.6.2 STOP...................................................................................... 8-11
8.6.3 BREAK................................................................................... 8-12
8.6.4 FEED HOLD........................................................................... 8-13
8.6.5 EMERGENCY Stop................................................................ 8-15
8.7 Reset ................................................................................................... 8-16
8.8 Variable Monitor................................................................................... 8-18
8.9 Display of Line to be Executed ............................................................ 8-22

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Section 9 File Operation................................................................................. 9-1
9.1 Directory Display [DIR]...................................................................... 9-1
9.2 File Copy [COPY].............................................................................. 9-4
9.3 File Rename [REN] ........................................................................... 9-8
9.4 File Delete [DEL]............................................................................... 9-12
Section 10 Utility............................................................................................... 10-1
10.1 Selecting Utility Mode........................................................................ 10-1
10.2 Auxiliary Signal Display [AUX]........................................................... 10-4
10.3 External Input/Output Signal Display [I/O]......................................... 10-6
10.4 Current Position Display [POS]......................................................... 10-13
10.5 Selecting Work/Tool Coordinate System [TRANS]............................ 10-17
10.6 Working Time Display [WK-TM]........................................................ 10-19
10.7 Reproducing the Origin [REORG]..................................................... 10-22
10.8 Joint Limit Setting [J-LIM].................................................................. 10-24
10.9 Date and Time Setting [DATE].......................................................... 10-28
10.10 Version Display [VER]....................................................................... 10-31
10.11 Servo Encoder Data Display [END]................................................... 10-34
10.12 PLC Monitor [PLC-M]........................................................................ 10-35
10.13 Zero Position Setting [ZEROP].......................................................... 10-37
10.14 Motor Load Display [MOTOR]........................................................... 10-38
10.15 Ethernet Status Display [ETHER]...................................................... 10-41
10.16 Payload Settings During Manual Guidance [PAYLD]........................ 10-44
10.17 Initialization to Factory Settings [FCTRY].......................................... 10-48
10.18 RAM Disk Backup [BCKUP].............................................................. 10-49

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Section 11 Self-Diagnosis ................................................................................ 11-1
11.1 Classification of Errors ...................................................................... 11-1
11.2 Display at Error Generation............................................................... 11-1
11.3 Error Display ..................................................................................... 11-2
11.4 Error Reset........................................................................................ 11-4
11.5 All Errors Reset................................................................................. 11-5
11.6 Error History Display ......................................................................... 11-6
11.7 Compile Error Display ....................................................................... 11-8

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Section 1 Before Operating Your Robot
1.1 Overview of Operation Functions
Function Descriptions
Control
panel Teach pendant
External
control
signal
HOST
commu-
nication
Main power ON/OFF Used to turn on and off the main
power. {
Servo power
ON/OFF Used to turn on and off the servo driver main circuit power. {Δ
(ON only)
{{
Master mode
selection Used to select either the external automatic mode, internal automatic
mode or teaching mode.
{
Start and stop Used to start and stop automatic
operation. {{{{
Cycle stop Used to stop automatic operation.
(When 1-cycle operation has finished) {{{
Feed hold Used to temporarily stop automatic
operation. {{
Emergency stop Used to immediately stop automatic
operation. {{{{
Teaching operation Used to manually guide the robot by
jogging or inching. {{
Auxiliary signal
operation Used to operate the pneumatic drive shaft for grip, etc. {Δ
Program editing Used to create and edit programs. {{
Data editing Used to create and edit positional
data, coordinate data and load data. {{
File operation Used to manage files by copying into
RAM or USB, renaming, deleting, etc. {Δ
(RAM
only)
Reset Used to reset output signals and
execution environment. {{{
Date setting Used to set the date used by the
system. {
Time setting Used to set the time used by the
system. {
Error display Used to display errors which are yet
to be reset. {{{
Error reset Used to reset errors that have been
corrected. {{
Error history display Used to display a historical list of
errors which have been corrected. {{

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Function Descriptions
Control
panel Teach pendant
External
control
signal
HOST
commu-
nication
Work coordinate
system selection Used to select the work coordinate system. {
Tool coordinate
system selection Used to select the tool coordinate system. {
Present position
monitor Used to display the present position of the robot in each coordinate system. {{
External I/O signal
monitor Used to display the status of digital I/O signals. {{
Working time
monitor Used to display the power ON time and run hours for each operation. {{
File selection Used to select a file to be executed. {{{
Move Used to move the robot to a point
which has been taught. {{
{: Operation is possible.
Δ: Partial operation is possible.

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1.2 Mode Structure
External automatic
mode
(EXERNAL)
Used to perform automatic programmed
operation by means of using external signals
or communication.
Master
mode Internal automatic mode
(INTERNAL)
Used to perform automatic programmed
operation through the control panel or teach
pendant.
Teaching mode
(TEACHING) Used to perform such operations as teaching, guiding, file management and program test
run, using the teach pendant.
The master mode should be selected by means of the MODE select key equipped
on the control panel.
Utility
(UTILITY) Used to perform such operations as coordinate selection, position monitor and
signal monitor.
Error display
(ERROR) Used to display and reset an error through the teach pendant, irrespective of the master
mode currently selected.
The emergency stop and servo OFF operations are possible, irrespective of the
mode currently selected.

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EMERGENCY
TEACHING
INTERNAL
EXT
SERVO
ON SERVO OFF
RUN STOP UF2
UF1
POWER
LINE
USER
ALARM
TP
SELECT
1.2.1 External Automatic Mode
External
control signal
mode
(SIGNAL)
Used to perform automatic programmed
operation by means of external control
signals.
For details, see the Interface Manual.
External
automatic mode
(EXT)
Host mode
(RS232C) Used to perform automatic programmed operation, file uploading and downloading
from the host computer through serial
communication.
For details, see the Communication Manual.
Host mode
(ETHERNET) Used to perform automatic programmed operation, and file uploading and
downloading from the host computer through
ethernet communication. For details, see the
Communication Manual.
File selection, run mode selection and speed override setting in the internal
automatic operation mode or test operation mode are also valid in the external
automatic mode.
The external automatic mode comes in the three (3) sub modes
as shown below. The selection of these modes is carried out
using the user parameter.

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1.2.2 Internal Automatic Mode
File selection
(SEL)
Used to select a file to be executed.
Run mode
selection
(MODE)
Used to select a run mode.
Speed override
(OVRD)
Used to set the speed override.
Internal
automatic
mode
(INTERNAL)
Start
(RUN) Used to start program execution from the control panel.
Stop
(STOP,
BREAK)
Used to stop or interrupt program execution.
Direct run
(DO)
Used to directly execute the SCOL command.
Reset
(RESET) Used to reset the program execution step, variables and digital output signals.