Toshiba TS3000 Series User manual

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INSTRUCTION MANUAL
INTERFACE 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.
NUMAZU, JAPAN
TS3100 SCARA / LINEAR / 6-AXIS system

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INTERFACE MANUAL
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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INTERFACE MANUAL
Preface
This manual describes the type, function and handling method of external cables
connecting the TS3100 robot controller with an external equipment.
This manual is intended for the system designers and manufacturing engineers.
The TS3100 robot controller can work in concert with the external equipment through
digital input and output signals that can be programmed by the SCOL language. Also,
system input signals that can allows external operation of the controller, system output
signals informing an operator of the controller status (PLC processing function) and
serial input and output signals that can be connected with the host computer, etc., are
provided so that the user can easily construct an FA system.
* Instruction manuals which are referred to from this manual
• Installation & Transport Manual
• Maintenance Manual
• Safety Manual
• Operator’s Manual
• User Parameter Manual
• Simple PLC Function Manual
• Communication Manual
• Conveyor Synchronous Function Instruction Manual
!CAUTION
This manual does not contain any detailed descriptions
on power and robot connection.
For the connection of the power and robot, see the
Installation & Transport Manual.

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INTERFACE MANUAL
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 damages to assets and to assure
correct use.
Make sure that you well understand the following details (indications and symbols)
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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INTERFACE MANUAL
!CAUTION
To perform the work ranging from robot installation to
operation with safety, read through and through the Safety
Manual provided separately before actually starting the
work.

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Maintenance and Inspection
To use the robot safety, strictly observe the following matters.
!DANGER
Prohibited
• NEVER burn, disassemble or charge the battery. Otherwise,
it may explode.
!
Mandatory
• Before performing the maintenance and inspection, be sure to
turn off the main power switch of the controller.
• When disposing of batteries, be sure to follow the user's
regulations.
!CAUTION
Disassembly
Prohibited
• The user should NEVER replace or change parts other than
those stipulated in the instruction manual. Otherwise, the
performance will deteriorate, resulting in troubles.
!
Mandatory
• To replace parts, use the spare parts designated by Toshiba
Machine.
• Carry out the maintenance and inspection on a regular basis.
Otherwise, the equipment may go wrong or accidents will be
caused.
!CAUTION
To perform the maintenance and inspection of the robot
with safety, read through and through the Maintenance
Manual provided separately before actually starting the
work.

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INTERFACE MANUAL
Table of Contents
Page
1. Type of External Cable .......................................................................................... 10
1.1 Layout and Name of Connectors ................................................................ 10
1.2 TS3100 Power Cable "ACIN" "POWER"..................................................... 11
1.3 Robot Control Cables.................................................................................. 11
1.3.1 TS3100 Motor Drive Cable "MOTOR" ............................................ 11
1.3.2 TS3100 Encoder Cable "ENC" ....................................................... 11
1.3.3 Robot Control Signal Cable "HAND"............................................... 11
1.3.4 Robot Control Signal Cable "BRK" ................................................. 12
1.4 External I/O Signal Cables.......................................................................... 12
1.4.1 Power Supply for I/O and Safe Input Cable “EMS”......................... 12
1.4.2 External Input Signal Cable "INPUT".............................................. 12
1.4.3 External Output Signal Cable "OUTPUT"....................................... 12
1.4.4 External I/O Signal Cable "SYSTEM"............................................. 12
1.5 Serial I/O Signal Cable................................................................................ 13
1.5.1 Serial I/O Signal "COM1"................................................................ 13
1.5.2 Serial I/O Signal "HOST"................................................................ 13
1.5.3 TCPRGOS "TCPRG"...................................................................... 13
1.6 Trigger Cable "TRIG" .................................................................................. 14
1.7 Memory Cable "MEM"................................................................................. 14
1.8 LAN Cable "LAN"........................................................................................ 14
1.9 Conveyor Cable "CONV" ............................................................................ 14
1.10 Fuse Cable "FUSE"..................................................................................... 14
1.11 Fieldbus Cable "FieldBUS" (Option)............................................................ 15
1.12 Teach Pendant Cable "TP" ......................................................................... 15
1.13 Remote I/O Cable "EXT–I/O"...................................................................... 15
2. Connecting Power Cable....................................................................................... 16
3. Connecting Robot Control Cable........................................................................... 17
3.1 Connecting Motor Drive Cable.................................................................... 17
3.1.1 Connecting Motor Drive Cable (SCARA Type Robot) .................... 17
3.1.2 Connecting Motor Drive Cable (6-axis Robot)................................. 18
3.2 Connecting Encoder Cable ......................................................................... 19
3.2.1 Connecting Encoder Cable (SCARA Type Robot).......................... 19
3.2.2 Connecting Encoder Cable (6-axis Robot) ..................................... 20

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3.3 Connecting Robot Control Signal Cable...................................................... 21
3.3.1 Connecting Robot Control Signal Cable (SCARA Type Robot)...... 21
3.3.2 Connecting Robot Control Signal Cable (6-axis Robot).................. 23
4. Connecting External I/O Signal Cable.................................................................... 27
4.1 Connecting External Input Signal Cable (INPUT)........................................ 27
4.2 Connecting External Output Signal Cable (OUTPUT)................................. 30
4.3 Connecting External I/O Signal Cable (SYSTEM)....................................... 33
4.4 Safe Input Signal Cable (EMS) ................................................................... 36
4.5 Digital Input Signal...................................................................................... 37
4.6 System Input Signal.................................................................................... 38
4.7 Jumper of Safety Measure Signal............................................................... 62
4.8 Digital Output Signal ................................................................................... 63
4.9 System Output Signal ................................................................................. 65
4.10 Fabricating External I/O Signal Cable......................................................... 81
4.11 Attaching and Detaching External I/O Signal Cable.................................... 82
4.12 Example of Controller Operation, Using External Signals........................... 83
5. Connecting Serial Signal Cable ............................................................................. 87
5.1 Connecting Serial I/O Signal Cables COM1, HOST, and TCPRG .............. 87
5.2 Attaching and Detaching Serial I/O Signal Cables COM1, HOST, and
TCPRG.................................................................................................................. 88
6. Connecting TP (Teach Pendant) Cable................................................................. 89
7. Connecting EXT–I/O Cable.................................................................................... 91
7.1 Connecting EXT–I/O Cable......................................................................... 91
7.2 EXT–I/O Communication ............................................................................ 94
7.3 Attaching and Detaching EXT–I/O Cable.................................................... 97
8. Connecting Extension I/O Signal Cable (Option)................................................... 99
8.1 TR48DIOCN................................................................................................ 99
8.1.1 Connecting Extension Input Signal Cable....................................... 99
8.1.2 Connecting Extension Output Signal Cable.................................. 102
8.2 TR48DIOC................................................................................................ 103
8.2.1 Connecting Extension Input Signal Cable..................................... 103
8.2.2 Connecting Extension Output Signal Cable.................................. 105
8.3 Fabricating Extension I/O Signal Cable..................................................... 106
8.4 Attaching and Detaching Extension I/O Signal Cable ............................... 107

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9. Connecting Trigger Input Signal Cable (TRIG).................................................... 108
9.1 Fabricating Trigger Input Signal Cable...................................................... 109
9.2 Attaching and Detaching Trigger Input Signal Cable................................. 109
10. Connecting Conveyor Synchronization Signal Cable (CONV)............................. 110
10.1 Fabricating Incremental Encoder Input Signal Cable................................ 111
10.2 Attaching and Detaching Incremental Encoder Input Signal Cables......... 112
11. LAN Signal Cable "LAN"...................................................................................... 112
12. Memory Cable "MEM".......................................................................................... 113
13. Robot Control Signal Cable "BRK"....................................................................... 113
13.1 Connecting Motor Brake Signal Cable (SCRARA Type Robot)................. 113
13.2 Connecting Motor Brake Signal Cable (6-axis Robot)............................... 114
14. Connecting External I/O Power Supply Cable (EMS) .......................................... 114
15. Appendixes.......................................................................................................... 116
15.1 System Signal Table................................................................................. 116
15.2 Fabricating Cable Using D-SUB Connector .............................................. 119
15.3 Fabricating Cable Using Half-Pitch Connector.......................................... 120

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1. Type of External Cable
1.1 Layout and Name of Connectors
The TS3100 robot controller is connected with the robot and external equipment,
using connectors and terminal block provided on the front and rear sides of the
controller.
Field BUS
TCPRGSYSTEMEMS
INPUTOUTPUT
EXT I/O
24V FGBA0V
3
2
1
15
16
18
17
19
20
21
4
5
6
7
9
8
10
11
12
13
14
Fig. 1 Layout and name of connectors

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1.2 TS3100 Power Cable "ACIN" "POWER"
Fig.1-[1], [3] (with connector)
TS2000：The power cable is an interface feeding the main power (single phase,
200–240 VAC, 50/60 Hz) to the TS3100 robot controller.
Connector "ACIN" is used. Switch “POWER” is used.
For details, see the Installation & Transport Manual provided separately.
1.3 Robot Control Cables
1.3.1 TS3100 Motor Drive Cable "MOTOR"
Fig. 1-[2] (with cable)
The motor drive cable connects the TS3100 robot controller and robot.
It feeds the 3-phase AC power to each axis feed motor of the robot.
Connector "MOTOR" is used.
For details, see the Installation & Transport Manual provided separately.
1.3.2 TS3100 Encoder Cable "ENC"
Fig. 1-[9] (with cable)
The encoder cable is an interface which inputs the rotation angle detection
encoder signal (axis 1 to axis 6) of each robot axis to the TS3100 robot controller.
Connector "ENC" is used.
For details, see the Installation & Transport Manual provided separately.
1.3.3 Robot Control Signal Cable "HAND"
Fig. 1-[10] (with cable)
This cable is used to input and output the robot control signals through hand
operation. Among the robot control signal cables, the input/output signal cables
for controlling the hand effector such as robot hand can be controlled by the robot
language program. Also, they can be turned on and off manually through the
teach pendant.
Connector "HAND" is used.
For details, see the Installation & Transport Manual provided separately.
For the robot language, see the Robot Language Manual. For the operation of
hand input and output signals from the teach pendant, see the Operation Manual.

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1.3.4 Robot Control Signal Cable "BRK"
Fig. 1-[12] (with cable)
This cable is used to turn on and off the parking brake for securing the robot motor
shaft. Connector "BRK" is used.
1.4 External I/O Signal Cables
1.4.1 Power Supply for I/O and Safe Input Cable “EMS”
Fig. 1-[21] (with dummy connector)
This is the connector for input of the power supply (P24 V) for digital input/output (32
inputs/32 outputs) and system input/output (13 inputs/12 outputs) of the TS3100
robot controller. These signals also turn on and off the emergency stop input (2
inputs) and safety stop input (2 inputs).
1.4.2 External Input Signal Cable "INPUT"
Fig. 1-[17]
This cable is used to input the digital signal from the external equipment to the
TS3100 robot controller. The external input signals enable control by the user of 32
programmable digital input signals using robot language. Connector "INPUT" is
used.
1.4.3 External Output Signal Cable "OUTPUT"
Fig. 1-[20]
The external output signal cable is an interface which outputs the digital signal
from the external equipment to the TS3100 robot controller. Connector "OUTPUT"
is used.
1.4.4 External I/O Signal Cable "SYSTEM"
Fig. 1-[19] (with dummy connector)
The external input/output signal cable is an interface which inputs the digital signal
from the external equipment to the TS3100 robot controller, and outputs the digital
signal from the TS3100 robot controller to the external equipment. There are 13
external operation input signals that enable operation of the controller from the
external equipment and 12 external operation output signals that output the
controller status. These signals, together with the external input signal in Para.

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1.4.2 and external output signal in Para. 1.4.3, allow the robot controller to work in
concert with the external equipment.
1.5 Serial I/O Signal Cable
1.5.1 Serial I/O Signal "COM1"
Fig. 1-[4]
Of the serial input and output signals of three (3) channels equipped on the
TS3100 robot controller, the D-SUB 9-pin connector located on the first line of the
front connector unit in Fig. 1 is COM1. COM1 is exclusively used for the RS-232C
and allows data communication with an image processing equipment or other FA
equipment that can connect an RS-232C interface. Connector "COM1" is used.
1.5.2 Serial I/O Signal "HOST"
Fig. 1-[5]
Of the serial input and output signals of three (3) channels equipped on the
TS3100 robot controller, the D-SUB 9-pin connector located on the second line
from the top of the front connector unit in Fig. 1 is HOST. HOST is exclusively used
for the RS-232C and allows transfer and saving of various parameters and
updating of the system when connected with the host computer. Connector
"HOST" is used.
1.5.3 TCPRGOS "TCPRG"
Fig. 1-[18]
The TS3100 robot controller uses exclusive sequence control tool "TCPRGOS"
(option) to transfer, save and monitor sequence programs in the built-in
programmable controller (PLC).
To connect with this sequence control tool, the D-SUB 9-pin connector located at
the upper rear part of Fig. 1 is TCPRG.
Connector "TCPRG" is used.
For the use of TCPRGOS, see the Simple PLC Function Manual (option) provided
separately.

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1.6 Trigger Cable "TRIG"
Fig. 1-[6]
The standard controller includes eight (8) trigger function inputs. This is used for
data latch, conveyor synchronization, and other functions. Connector "TRIG" is
used, which is the D-sub 15-pin connector located on the top section of the front
panel.
1.7 Memory Cable "MEM"
Fig. 1-[7]
A USB memory device can be used to transfer and save various parameters and
to back up programs and other data. Connector "MEM" located on the front panel
is used.
1.8 LAN Cable "LAN"
Fig. 1-[8]
The controller supports 10BASE-T connections. If a hub is used, connect using a
straight cable. Use a cross cable when connecting a computer directly to controller.
Also, TCP/IP protocol can be used to enable communication on the same local
area network with computers and visual equipment on the Ethernet. This allows
program creation and editing, debugging start support, and maintenance using the
computer programmer TSPC.
1.9 Conveyor Cable "CONV"
Fig. 1-[11]
This is used when using the conveyor synchronization function. Use an encoder
having an output circuit with RS-422 differential output (line driver) and A and B
phase signals with a 90-degree phase. Signals from an incremental encoder and
input signals from a conveyor synchronization start trigger switch are required.
1.10 Fuse Cable "FUSE"
Fig. 1-[13]
This is a fuse for detecting over-current (3A) in the digital signal input/output to the
robot controller. It is used for pattern protection. "FUSE" is located in the bottom
section of the front panel in Fig. 1.

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1.11 Fieldbus Cable "FieldBUS" (Option)
Fig. 1-[16]
The Fieldbus slave module supports three Fieldbus types: Profibus, DeviceNet,
and CC-LINK. "FieldBUS" is located in the top section of the rear panel in Fig. 1.
1.12 Teach Pendant Cable "TP"
Fig. 1-[14] (with dummy connector)
This is an interface connecting the TS3100 robot controller and teach pendant. The
TP1000 is an option. By connecting the TP cable, creation of motion programs,
manual robot guidance, etc., are possible through the teach pendant. Connector
"TP" is used. The TP cable is secured to the teach pendant and cannot be
disconnected from the teach pendant. The standard cable length is 5 m.
1.13 Remote I/O Cable "EXT–I/O"
Fig. 1-[15] (with connector)
This is an RS-485 communication terminal connecting the optional remote I/O
module function (TR48DIOCN/TR48DIOC module, etc.) of the TS3100 robot
controller. To connect, the terminal block on the rear side of the controller is used.

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2. Connecting Power Cable
To connect the power cable, use the attached connector (JL04V–6A22–22SE-EB-R;
made by Japan Aviation Electronics Industry).
Robot controller User side
AC IN
RL1
SL2
A
B
C
DFGPE
Single phase
Grounding (Class D grounding)
JL04V-2E22-22PE-B
50/60 Hz (±1 Hz)
Connector: JL04V-6A22-22SE-EB-R
Clamp: JL04-2022CK (14)-R
200-240 VAC
Fig. 1 Connection of power cable
For details of the power cable connection, see the Installation & Transport Manual
provided separately.

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3. Connecting Robot Control Cable
3.1 Connecting Motor Drive Cable
3.1.1 Connecting Motor Drive Cable (SCARA Type Robot)
To connect the motors, use the attached cables.
TS3100
robot controller
Motor drive
cable
U-A
Connector
MOTOR Robot
U
V
W
U
V
W
E
Axis 1
U
V
W
E
E
U
V
W
E
Connector
MOTOR
SM
A
E
F
N
P
U
B
C
G
R
V
W
M
V-A
W-A
U-B
V-B
W-B
U-C
V-C
W-C
U-D
V-D
W-D
SM
SM
SM
A
E
F
N
P
U
B
C
G
R
V
W
J
K
FG
Axis 2
Axis 3
Axis 4
Fig. 3.1 Connection of motor drive cables (SCARA type robot)
For details of the motor drive cable connection, see the Installation & Transport
Manual provided separately.

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3.1.2 Connecting Motor Drive Cable (6-axis Robot)
To connect the motors, use the attached cables.
TS3100
robot controller
Motor drive
cable
U-A
Connector
MOTOR
Robot
U
V
W
U
V
W
E
Axis 1
U
V
W
E
E
U
V
W
E
Connector
CN21
U
V
W
E
SM
A
E
F
N
P
U
B
C
G
R
V
W
D
H
I
S
T
X
M
V-A
W-A
U-B
V-B
W-B
U-C
V-C
W-C
U-D
V-D
W-D
U-E
V-E
W-E
U
V
W
E
U-F
V-F
W-F
SM
SM
SM
SM
SM
A1
A2
A3
A4
A5
A6
A8
A9
A10
A11
A12
A13
A15
A16
A17
A18
A19
A20
Case
A7
FG
A14
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
Fig. 3.2 Connection of motor drive cables (6-axis robot)
For details of the motor drive cable connection, see the Installation & Transport
Manual provided separately.

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INTERFACE MANUAL
3.2 Connecting Encoder Cable
3.2.1 Connecting Encoder Cable (SCARA Type Robot)
To connect the encoders to the TS3100 digital servo printed board (X8GL), use the
attached cables.
Axis 1
encode
LG
Robot
1
3
8
9
J1B
1
3
8
9
1
3
8
9
1
3
8
9
15
15
15
15
TS3100
robot controller
Connector
ENC Encoder cable
1RQ / SD
1RQ / SD *
P5V
LG
2RQ / SD
2RQ / SD *
P5 V
FG
LG
3RQ / SD
3RQ / SD *
P5 V
FG
LG
4RQ / SD
4RQ / SD *
P5V
FG
J2B
J3B
J4B
1
2
19
13
20
14
7
8
25
31
26
32
5
6
23
17
24
18
3
4
21
15
22
16
Case
LG
ARQ/ SD
ARQ/ SD*
P5V
LG
BRQ / SD
BRQ / SD*
P5V
LG
CRQ/SD
CRQ/SD*
P5V
LG
DRQ/ SD
DRQ/ SD *
P5V
LG
P5V
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
Case
CN3
Connector
Axis 2
encode
Axis 3
encode
Axis 4
encode
Fig. 3.3 Connection of encoder cables (SCARA type robot)
For details of the encoder cable connection, see the Installation & Transport
Manual provided separately.

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3.2.2 Connecting Encoder Cable (6-axis Robot)
To connect the encoder to the TS3100 digital servo printed board (X8GL), use the
attached cables.
Axis 1
encoder
LG
Robot
J1BS
4
5
7
8
3
TS3100
robot controller
Connector
ENC Encoder cable
1RQ/ SD
1RQ / SD *
P5V
LG
2RQ/ SD
2RQ/ SD *
P5V
FG
LG
3RQ/ SD
3RQ/ SD *
P5V
FG
LG
4RQ/ SD
4R Q/ S D *
P5V
LG
5RQ/ SD
5RQ / SD *
P5V
LG
6RQ/ SD
6RQ / SD *
P5V
FG
J2BS
BP
1
2
19
13
20
14
7
8
25
31
26
32
5
6
23
17
24
18
3
4
21
15
22
16
11
12
29
35
30
36
9
10
27
33
28
34
Case
LG
ARQ/SD
ARQ/ SD*
P5V
LG
BRQ/ SD
BRQ/SD*
P5V
LG
CRQ/SD
CRQ/SD*
P5V
LG
DRQ/SD
DRQ/SD*
P5V
LG
ERQ/SD
ERQ/SD*
P5V
LG
FRQ/ SD
FRQ/ SD *
P5V
LG
P5V
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
Case
4
5
7
8
3
A1
A2
A3
A4
A5
A6
A7
A8
A10
B1
B2
B3
B4
B5
B6
B7
A9
FG
B8
B21
B22
B23
B24
B25
Connector
CN20
Axis 2
encoder
Axis 3
encoder
Axis 4
encoder
Axis 5
encoder
Axis 6
encoder
Fig. 3.4 Connection of encoder cable (6-axis robot)
For details of the encoder cable connection, see the Installation & Transport
Manual provided separately.