Toshiba TCR Series User manual

STE 80897-0
TCR5L/TS2000
INSTRUCTION MANUAL
TRANSPORTATION & INSTALLATION
Notice
1. Make sure that this instruction manual is delivered to the
final user of Toshiba Machine's industrial robot.
2. Before installing and operating the industrial robot, read
through and completely understand this manual.
3. After reading through this manual, keep it nearby for future
reference.
July, 2010
TOSHIBA MACHINE CO., LTD.
NUMAZU, JAPAN

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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
This manual describes how to unpack and install the robot and robot controller.
Specifically, it describes how to unpack the shipments containing the robot and controller,
how to install them, how to connect wiring and air piping and how to mount a tool on the
robot arm. Be sure to read through this manual before unpacking each shipment.
Before beginning the work according to this manual, read through the Setup Manual and
Safety Manual so that you can learn the names and functions of various components and
the safety measures.
This manual is divided into the following four (4) sections.
Section 1: Transportation
This section describes how to unpack the shipments containing the robot
and controller and how to carry them to the installation site. Also, it
describes the precautions to be observed when the equipment are to be
stored temporarily after the unpacking.
Section 2: Installation
This section discusses the environment in which the robot and controller are
installed, space requirements and how to install the equipment.
Section 3: System Connections
This section describes how to connect the robot, controller and peripheral
equipment.
Section 4: Hand Interface
This section describes how to mount a tool on the robot arm and how to
connect wiring and air piping to the tool.

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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 or caution.
The details of the actual caution are indicated with pictures or
words in or near the symbol.

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!CAUTION
• Be sure to read through the Safety Manual provided separately before starting
actual work to assure safety of the work covering from the robot installation to
operation.
[Installation and transportation]
Be sure to observe the following items to use the robot safely.
!DANGER
Prohibited
• DO NOT install or operate if any parts are damaged or
missing. Otherwise, electric shocks, fires or faults could be
caused.
• DO NOT install the robot where it may be exposed to splash of
liquids such as water. Otherwise, electric shocks, fires or
faults could be caused.
• DO NOT place the robot near the combustibles.
Otherwise, fires could be caused if the material ignites due to
a fault, etc.
Mandatory
• Be sure to secure the robot with the attached clamps before
carrying the robot. Otherwise, you could be involved in
injuries if the arm moves when the robot is lifted.
• Connect the robot only after installation. If wiring is
performed before the robot installation, you could be involved
in electric shocks or injuries.
• Be sure to use the master power voltage and power capacity
designated by Toshiba Machine. Otherwise, the equipment
could be damaged or catch fires.
• Be sure to use the designated power cable.
Otherwise, fires or faults could be caused.
Always ground
• Completely connect the grounding cable.
Otherwise, electric shocks or fires could be caused if a fault or
leak current occurs, in addition to malfunction by noise.

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!CAUTION
Prohibited
• NEVER lift the robot arm during the transport. Otherwise, an
excessive force will be exerted on the mechanical part of the
robot, resulting in faults.
• For the controller, keep an ample space for air vent.
Otherwise, the controller will be heated, causing faults.
Mandatory
• When lifting up the robot, do so carefully. If lifted suddenly,
the robot will tilt, which is very dangerous.
• When storing the robot, completely clamp the base.
If placed directly on the floor, the robot will be unstable and fall
over.

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Table of Contents
Page
Section 1 Transportation................................................................................ 1–1
1.1 Unpacking............................................................................................ 1–1
1.2 Transport ............................................................................................. 1–2
1.2.1 Mass and External Dimensions.............................................. 1–2
1.2.2 Transporting the Robot........................................................... 1–2
1.2.3 Transporting the Controller..................................................... 1–4
1.3 Storage................................................................................................ 1–5
1.3.1 Cautions on Robot Storage.................................................... 1–5
1.3.2 Cautions on Robot Controller Storage.................................... 1–5
Section 2 Installation...................................................................................... 2–1
2.1 Installation Environment ...................................................................... 2–1
2.2 Installing the Robot.............................................................................. 2–2
2.2.1 External Dimensions .............................................................. 2–2
2.2.2 Working Envelope.................................................................. 2–2
2.2.3 Origin Posture and Coordinate System of the Robot.............. 2–4
2.2.4 Robot Installation Procedures ................................................ 2–5
2.3 Installing the Controller........................................................................ 2–6
2.3.1 External Dimensions .............................................................. 2–6
2.3.2 Rack Mounting Dimensions.................................................... 2–7
2.3.3 Cautions on Rack Mounting ................................................... 2–7
2.3.4 Cautions on Direct Installation................................................ 2–10
2.4 Cautions on Handling of Teach Pendant ............................................. 2–11
2.5 Safety Measures.................................................................................. 2–12
2.6 Position Detector Backup Batteries ..................................................... 2–13

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Page
Section 3 System Connection........................................................................ 3–1
3.1 Cable Connection................................................................................ 3–1
3.1.1 Connector Layout of the Controller......................................... 3–1
3.1.2 Connecting Power Cable........................................................ 3–2
3.1.3 Connecting Motor Cable......................................................... 3–3
3.1.4 Connecting Encoder Cable..................................................... 3–3
3.1.5 Connecting Robot Control Signal Cable................................. 3–3
3.1.6 Inserting and Removing Connectors...................................... 3–3
3.1.7 List of Connector Terminal Arrangement Examples............... 3–5
3.2 Controller Connector Signals............................................................... 3–7
3.2.1 Connector Signal Connection Diagrams................................. 3–7
3.2.2 Jumpers for Safety Related Signals....................................... 3–7
3.3 Separating Control Panel from Controller............................................ 3–9
3.3.1 Removing Control Panel......................................................... 3–9
3.3.2 Cable between Controller and Control Panel ......................... 3–10
3.3.3 Control Panel Mounting Dimensions...................................... 3–10
3.3.4 Mounting Dummy Panel on Controller.................................... 3–11
3.3.5 Dimensions when Separating Control Panel.......................... 3–12
Section 4 Hand Interface................................................................................ 4–1
4.1 Hand Attachment................................................................................. 4–1
4.2 Wiring and Piping for Hand.................................................................. 4–1

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Section 1 Transportation
1.1 Unpacking
The robot and controller are shipped separately in wooden crates and corrugated
cardboards. The packaging state of the controller is shown in Fig. 1.1.
The teach pendant and other accessories including instruction manuals are packed
separately.
Open the shipments at a location easily accessible for subsequent transport and
installation. At this time, take careful precautions not to damage the robot and
controller. After unpacking, make sure that all accessories are present and that all
equipment have not been damaged during transport.
!DANGER
• If any parts of the equipment are found defective or damaged, or if some
accessories are missing when the robot and controller have reached your
office, DO NOT install or operate the equipment. Otherwise, the equipment
could malfunction. Contact us immediately at our sales agent in your territory.
• After unpacking, dispose of the wooden crates, corrugated cardboards,
polyethylene shipping bags and cushion materials according to your
regulations.
Fig. 1.1 Packaging state of controller
Corrugated cardboard
(outside box)
Styrene foam
cushions
Controller
Corrugated cardboard
(bottom board)

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1.2 Transport
Carefully move the robot and controller to avoid excessive impact (9.8 m/s2or over) or
vibration from being exerted on them. If the equipment are subject to vibration over a
long period of time, be sure to completely tighten all nuts and screws.
When relocating the equipment at another place, apply the cushions as originally set,
then put the equipment back into the wooden crates and corrugated cardboards.
1.2.1 Mass and External Dimensions
The mass of controller TS2000 is 12 kg. For the mass of the basic robot, see the
relevant specifications.
1.2.2 Transporting the Robot
When transporting the robot, observe the following procedures, fully confirming the
cautions.
!DANGER
• When transporting the robot, be sure to use the attached lifting fixtures.
• When transporting the robot, be sure to secure the arm with the attached
clamp beforehand. Otherwise, a hazardous situation may be caused
because the arm will move when the robot is suspended.
When transporting the robot by a crane, observe the following procedures.
1) Make sure that the arm clamps are attached.
2) Make sure that the eyebolts are attached to the transport fixtures.
3) Pass wire ropes through the eyebolts. To assure safety, be sure to use four (4)
wire ropes. If there is a fear that the wire rope will contact the robot body due
to the length of the wire rope, use a cushion.

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4) Lift up the robot carefully, using the crane.
Next, disconnect the robot body from the transport fixtures to carry the robot.
5) Remove the hexagon socket head cap screws and washers, then mount the
M10 eyebolts in the screw holes instead.
6) Remove the arm clamps and move so that the arms can overlap each other.
7) Pass wire ropes through the eyebolts. To assure safety, be sure to use the
four (4) wire ropes. If there is a fear that the wire rope will contact the robot
body due to the length of the wire rope, use a cushion.
8) After the installation, remove the eyebolts and mount the attached hexagon
socket head cap screws and washers in the screw holes.
Fig. 1.2 Lifting posture of the robot (double-hand specifications)
Eyebolt 10
4 places
Arm clamp
Transport fixture
Hexagon socket
head cap screw
and washer
Position the
cushions
Wire rope

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!CAUTION
• Use the wires which can well withstand the robot mass.
• The robot will tilt more or less when lifted. Carefully lift it up.
• When raising and lowering the robot, take careful precautions not to exert any
excessive impact (9.8 m/s2or over) on the robot.
• When placing the robot on the floor, etc., take utmost care not to have your
hand or foot caught under the robot.
1.2.3 Transporting the Controller
Before transporting the controller, disconnect all cables and teach pendant.
!DANGER
• When placing the controller on the floor, etc., take utmost care not to have
your hand or foot caught under the controller.

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1.3 Storage
Both the robot and controller should not be stored for a long period of time after
unpacked. When this is unavoidable, however, be sure to observe the following
cautions on storage.
1.3.1 Cautions on Robot Storage
!CAUTION
• Secure the robot base completely to prevent the robot from falling over.
• Keep the robot out of direct sunlight. Otherwise, the parts may deteriorate.
• Seal the robot in a vinyl bag to prevent rust development and contaminant.
Put a desiccant in the bag to absorb moisture.
• When the robot motor drive cable was disconnected from the controller,
connect the short-circuit connector to the same cable.
1.3.2 Cautions on Robot Controller Storage
!CAUTION
• Keep the robot controller out of direct sunlight. Otherwise, the controller
interior will be heated up, resulting in faults.

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Section 2 Installation
2.1 Installation Environment
Table 2.1 shows the environmental conditions for the location in which the robot and
controller TS2000 are to be installed.
Table 2.1 Environmental conditions for the robot and controller
Item Specifications
Temperature At operation : 0 ~ 40°C
At storage : –10°C ~ 50°C
Humidity 20 ~ 90 % (non-condensing)
DO NOT install the robot and controller at places where
they are exposed to splash of liquids such as water.
Altitude 1,000 m or less
Vibration At operation : 0.98 m/s2or less
At transport : 9.8 m/s2or less
Dust No inductive dust should be involved.
Consult with Toshiba Machine first if you have to use the
robot and controller in a hostile environment.
Gas No corrosive gas or combustible gas should be involved.
Sunlight The robot and controller should not be exposed to direct
sunlight.
Power source noise No device causing an excessive noise should exist nearby.
Magnetic field No device causing a strong magnetic field should exist
nearby.
!DANGER
• DO NOT place the robot and controller near combustibles. Otherwise, fires
could be caused if the material ignites due to a fault, etc.

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2.2 Installing the Robot
Before actually installing the robot, you should review a layout, fully considering the
working envelope, coordinate system and space for maintenance.
2.2.1 External Dimensions
See the external view drawing of the robot attached to the specifications.
2.2.2 Working Envelope
See the external view drawing of the robot attached to the specifications.

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Fig. 2.1 External view

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2.2.3 Origin Posture and Coordinate System of the Robot
The origin posture and coordinate system of the robot are exemplified in Fig. 2.2.
Fig. 2.2 Coordinate system of the robot
Axis 2 (+)
Axis 4 (+)
Rotation 0(deg) direction
Axis 4 (–)
Axis 3 (+)
Controller body panel
Axis 1 (–)
Axis 1 (+)
Axis 3 (-)

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2.2.4 Robot Installation Procedures
The robot is secured, using the set holes on the robot base.
The robot base set areas should be rigid enough and their surfaces should be
machined with flatness accuracy as small as 0.2 or less.
!CAUTION
• The robot will suddenly accelerate and decelerate during operation. When
installing the robot on the frame, make sure that the frame has enough rigidity.
If the robot is installed on a frame that is not rigid enough, vibration will be
caused during the robot operation, resulting in faults.
When installing the robot on the floor, secure it with anchor bolts, etc.
• Install the robot on the leveled place. Otherwise, the robot performance will
deteriorate or the robot will go wrong.
Fig. 2.3 Robot base
8 × 11 drill
Controller body panel

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2.3 Installing the Controller
2.3.1 External Dimensions
Fig. 2.4 shows the external dimensions of the TS2000 robot controller.
Top view
Front view Side view
Rear view
Fig. 2.4 External view of TS2000 controller

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2.3.2 Rack Mounting Dimensions
When installing the robot controller in the rack, set the side brackets, using the screw
holes on both ends of the front panel, then secure the controller to the rack.
(Side brackets [1] in Fig. 2.5 are optional.)
POWER
EXT.SIGNAL
EXT.PC
MODE
SERVO
ON
SERVO
OFF
RUN STOP CYCLE
SELECT
ALARM
RESET
UF1
UF2
LINE
USER
ALARM
EMERGENCY
INT
EXT MAN U
COM1
HOST
TCPRG
POD
TP
TP
di sc on ne c t
ＴＯＳＨＩＢＡ ＭＡＣＨＩＮＥ
Robot Controller
TS2000
11.5 40 150 40
10 319.4 10
４－Ｒ３
Fig. 2.5 Dimensions of controller rack clamp screw holes
2.3.3 Cautions on Rack Mounting
Take careful precautions on the following matters when mounting the robot controller
in the rack.
a) When mounting the controller in the rack, use the screw holes provided on both
ends of the front panel and secure the controller. (The optional side brackets
are required.)
!CAUTION
• If the rack is completely sealed, provide holes for air vent, or compulsively
ventilate the rack with a fan or cool the rack indirectly, so that the heat will not be
trapped in the rack.
If the heat is trapped in the rack or controller, the controller will malfunction.