Toshiba TH180 User manual

STE85389-0
INSTRUCTION MANUAL
INDUSTRIAL ROBOT
TRANSPORTATION AND INSTALLATION MANUAL
Notice
1. Make sure that this instruction manual is delivered to the final
user of Toshiba Machine’s industrial robot.
2. Before operating the industrial robot, read through and
completely understand this manual.
3. After reading through this manual, keep it nearby for future
reference.
August 2012
TOSHIBA MACHINE CO., LTD.
NUMAZU, JAPAN
TH180
TH250A
TH350A／TS3000

TRANSPORTATION AND INSTALLATION MANUAL
Copyright 2012 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 industrial robot TH series and
controller. Specifically, it describes how to unpack the shipment containing the equipment,
how to install the equipment, how to connect wiring and air piping, and how to attach tools.
Be sure to look through this manual before unpacking the shipment.
Before beginning the work according to this manual, read through the Startup 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 five (5) sections:
Section 1 Transportation
This section describes how to remove the robot and controller from their
boxes and how to transport them to the installation site. This section also
discusses how to temporarily store the equipment after unpacking the
shipment.
Section 2 Installation
This section discusses the equipment installation environment, 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 Tool Interlace
This section describes how to connect the tool to the robot arm and how to
connect pipes and wires to the tool. This section also discusses maximum
permissible loads of the tool.
Section 5 Specifications
This section describes the specifications of the robot and the robot controller.
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Precautions on Safety
Important information on the robot and controller is noted in the instruction manual to
prevent injury to the user and persons nearby, prevent damage to assets and to ensure
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 major 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 treatment.
*2) Physical damage refers to major fires 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). The
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). The
details of the actions that must be done are indicated with
pictures or words in or near the symbol.
This means danger.
The details of the actual danger are indicated with pictures or
words in or near the symbol.
This means caution.
The details of the actual caution are indicated with pictures or
words in or near the symbol.
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!
CAUTION
• Always read through the Safety Manual provided separately before starting
actual work to ensure safety work covering from the robot installation to
operation.
[Installation and transportation]
Always observe the following items to safely use the robot.
!
DANGER
Prohibited
• DO NOT install or operate if any parts are damaged or
missing.
Doing so could lead to electric shocks, fires or faults.
• DO NOT install the robot where it may be subject to fluids
such as water. Doing so could lead to electric shocks, fires
or faults.
• Do not place the robot near combustible matters. Doing so
could lead to fires if the matter ignites due to a fault, etc.
Mandatory
• Always secure the robot with the attached clamps before
transporting it. Failure to do so could lead to injuries if the
arm moves when the robot is suspended.
• Wire the robot after installation.
Wiring the robot before installation could lead to electric
shocks or injuries.
• Always use the power voltage and power capacity designated
by Toshiba Machine. Failure to do so could lead to device
faults or fires.
• Always use the designated power cable. Using a cable other
than that designated could lead to fires or faults.
Always
ground
• Completely connect the grounding cable. Failure to do so
could lead to electric shocks or fires if a fault or fault current
occurs. Noise could lead to malfunction.
Also, it could cause mis-operation by noise.
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! CAUTION
Prohibited
• NEVER lift the robot by the arm 2 cover or arm 2. Doing so
will apply an excessive force on the robot's mechanism
section and could lead to faults.
• For the controller, secure the ample space for air vent.
Heating of controller could lead to malfunction.
Mandatory
• When lifting the robot, lift it up slowly. The robot will tilt
slightly, so lifting it up suddenly could be hazardous.
• When storing the robot, securely fix it on the base. The robot
will be unstable if just set down, and it could tilt over.
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Table of Contents
Page
Section 1 Transportation...................................................................................................9
1.1 Unpacking.........................................................................................................9
1.2 Transportation ................................................................................................12
1.2.1 Mass and Dimensions.....................................................................................12
1.2.2 Transporting the Robot...................................................................................12
1.2.3 Transporting the Controller.............................................................................16
1.3 Storage...........................................................................................................16
1.3.1 Storage Precautions for the Robot..................................................................16
1.3.2 Storage Precautions for the Controller............................................................16
Section 2 Installation.......................................................................................................17
2.1 Installation Environment .................................................................................17
2.2 Robot Installation............................................................................................18
2.2.1 External Dimensions.......................................................................................18
2.2.2 Working Envelope...........................................................................................18
2.2.3 Coordinate System .........................................................................................22
2.2.4 Installing the Robot.........................................................................................26
2.3 Changing the Mechanical Ends......................................................................29
2.3.1 Changing the Mechanical Ends of Axes 1 and 2 (TH180)..............................30
2.3.2 Changing the Mechanical Ends of Axis 3........................................................37
2.3.3 Changing Software Limits...............................................................................44
2.4 Installing the Controller..........................................................................................45
2.4.1 External Dimensions.......................................................................................45
2.4.2 Precautions for Direct Installation ...................................................................46
2.4.3 Rack Mounting Dimensions ............................................................................47
2.4.4 Precautions for Rack Mounting.......................................................................48
2.5Precautions for Handling the Teach Pendant.................................................50
2.6 Safety Measures.............................................................................................51
2.7 Position Detector Backup Batteries................................................................52
2.8 Using the Robot in Clean Room .....................................................................53
Section 3 System Connections.......................................................................................54
3.1 Cable Wiring...................................................................................................54
3.1.1 Connector Arrangement on the Controller......................................................54
3.1.2 Connecting the Power Cable “ACIN” [1] of Fig. 3.1 (Plug Connector Attached)
........................................................................................................................55
3.1.3 Connecting the Motor Cable “MOTOR” Fig. 3.1-[1] (Cable Attached).............56
3.1.4 Connecting the Encoder Cable “ENC” Fig. 3.1 [3] (Cable attached)...............58
3.1.5 Connecting the Hand Control Signal Cable “HAND” Fig. 3.1-[4] (Cable
Optional).........................................................................................................58
3.1.6 Connecting the Brake Signal Cable "BRK" Fig. 3.1-[8] (Cable Attached).......58
3.1.7 Grounding the Robot.......................................................................................59
3.1.8 Inserting and Removing Cables......................................................................59
3.1.9 Examples of Connector Terminal Arrangement..............................................61
3.2 Controller Connector Signals..........................................................................63
3.2.1 Connector Signal Connection Diagrams.........................................................63
3.3 Separating Control Panel from Controller.......................................................64
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3.3.1 Removing Control Panel.................................................................................64
3.3.2 Cable between Controller and Control Panel..................................................65
3.3.3 Control Panel Mounting Dimensions...............................................................66
3.3.4 Mounting Dummy Panel on Controller............................................................67
3.3.5 Dimensions when Separating Control Panel...................................................68
Section 4 Tool Interface..................................................................................................69
4.1 Mounting Tool.................................................................................................69
4.2 Tool (Hand) Wiring and Piping........................................................................71
4.2.1 Controller's Tool Signals.................................................................................74
4.3 Permissible Load Conditions and Program Setting........................................78
4.3.1 Permissible Load Conditions ..........................................................................78
4.3.2 Load Conditions and Program Setting............................................................80
4.3.3 Setting Robot Acceleration and Maximum Speed for Load Conditions ..........83
Section 5 Specifications..................................................................................................92
5.1 Specifications Table .......................................................................................92
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Section 1 Transportation
1.1 Unpacking
The robot and controller are shipped separately in corrugated cardboards. The teach
pendant and other accessories such as the instruction manual are packaged
separately.
Open the packages in a location easily accessible to where the equipment is to be
installed. Take careful precautions not to damage the robot or controller. After
opening the packages, make sure that all the accessories are present and that nothing
has been damaged in transit.
! DANGER
• If any parts of the equipment are found damaged or any accessories are missing
after the shipment containing the robot and controller have reached your office, DO
NOT install and operate them. Otherwise, the equipment will malfunction.
Contact Toshiba Machine immediately.
• Dispose of the corrugated cardboards, polyethylene shipping bags and cushion
material according to your standards.
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Fig. 1.1 Packaging state (TH250A)
Fig. 1.2 Packaging state (TH350A)
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Fig. 1.3 Packaging state (TH180)
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1.2 Transportation
Move the robot and controller very carefully. Make sure that no excessive impact
(9.8 m/s2or more) or vibration is exerted on the equipment. If the equipment is to be
subject to vibration over a long period, be sure to tighten all the nuts and screws
completely.
If the equipment is to be moved to a location some distance from where it was
unpacked, reposition the cushions as they were and put the equipment back into the
corrugated cardboards.
1.2.1 Mass and Dimensions
The mass and dimensions of the robot and controller are shown in Table 1.1.
Table 1.1
Type
Mass
Robot TH180 9 kg
Robot TH250A 14 kg
Robot TH350A 14 kg
Robot TH350A‐T 14 kg
Controller TS3000 13 kg
1.2.2 Transporting the Robot
To transport the robot, fold back and secure the arm with the attached clamp. (The
robot is shipped in this posture. After you have unpacked the shipment, you can
move it as it is.)
! DANGER
• Be sure to secure the arm with the attached clamp before transporting the
robot. Failure to do so could cause a hazardous situation as the arm will
move when the robot is lifted.
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!
CAUTION
• When transporting or unpacking the robot and robot controller, take careful
precautions not to get injured by the drop of them or not to damage the
equipment.
• When lifting the robot by workers, hold the locations (shaded areas) by
hands as shown in Figs. 1.4 to 1.6. If the arm 2 or cover is held by hands,
an unusually large force is exerted, resulting in a malfunction.
• If the robot has been carried manually by workers, take utmost care to
prevent their hand or leg from being caught in the robot when placing it on
the floor.
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Fig. 1.4 Robot handling area (shaded area) (TH250A, TH350A)
Fig. 1.5 Robot handling area (shaded area) (TH180)
After the installation, remove the clamp used for transport.
Robot harness
Arm 2 cover
Base
Arm 1
Tool shaft
Arm 2
Base
Robot harness
Arm 2 cover
Arm 2
Tool shaft
Arm 1
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Fig. 1.6 Robot handling area (shaded area) (TH350A‐T)
Arm 1
Arm 2 cover
Robot harness
Base
Arm 2
Tool shaft
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1.2.3 Transporting the Controller
Disconnect all cables and teach pendant before transporting the controller.
! DANGER
• When placing the controller on the floor, etc., make sure not to catch your
hands or feet.
1.3 Storage
Avoid storing the robot and controller for long periods of time after unpacking them. If
this is unavoidable, however, strictly observe the following precautions for storage.
1.3.1 Storage Precautions for the Robot
It is recommended to secure the robot in the shipment posture, using the attached
clamp for transport.
! CAUTION
• Secure the base completely to prevent the robot from falling over. When
placed directly on the floor, the robot is unstable and will fall over.
• Keep the robot out of direct sunlight. The timing belts and resin covers
may deteriorate.
• Seal the robot in a vinyl bag to prevent rust development and contaminant.
Put a desiccant in the bag to absorb moisture. As the tool shaft is
susceptible to rust development, coat it with rust-preventive agent or
grease.
1.3.2 Storage Precautions for the Controller
!
CAUTION
• Keep the controller out of direct sunlight. Otherwise, the controller interior
will be excessively heated up, causing a trouble.
• Store the controller in a plastic bag to prevent rust and dust, and place a
desiccant inside the bag.
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Section 2 Installation
2.1 Installation Environment
Table 2.1 shows the environmental conditions for the location in which the TH series
Robot and TS3000 controller are to be installed.
Table 2.1 Environmental conditions for robot and controller
Item Specifications
Temperature In operation : 0 to 40°C
In storage : –10 to 50°C
Humidity 20 to 90 % (Non-condensing)
DO NOT install the robot where it may be subject to fluids
such as water.
Altitude 1000 m or less
Vibration In operation : 0.98 m/s
2
or less
In transport : 9.8 m/ s
2
or less
Dust No inductive dust should exist.
Consult with Toshiba Machine first if you wish to use the
robot and controller in a dusty environment.
Gas No corrosive or combustible gas should exist.
Protection class IEC60529 IP10 (robot side) IP20 (controller side)
Overvoltage category IEC60664-1 Class III (controller side)
Electric shock
protection IEC61140 Class I (controller side)
Contamination level IEC60664-1 Contamination Level 3 (controller side)
Sunlight The robot and controller should not be exposed to direct
sunlight.
Power noise A heavy noise source should not exist nearby.
Magnetic field A heavy magnetic field source should not exist nearby.
Other ambient
conditions Avoid any iron powder, oil or salt content, and organic solvent. Do not wet the robot with water or the like
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! DANGER
• Do not place the robot or controller near combustible. Doing so could lead
to fires if it ignites due to a fault, etc.
2.2 Robot Installation
Before installing the robot, you should plan a layout, fully considering the working
envelope, coordinate system and space for maintenance.
It is recommended to replace the batteries at the time of installation so that they can
be replaced at regular inspection and maintenance. For the battery replacement, see
Para. 2.3.8 of the Maintenance Manual.
2.2.1 External Dimensions
External view drawings of the robot are shown in Figs. 2.1 to 2.4.
2.2.2 Working Envelope
Each axis can operate within the working envelope. To prevent the robot from moving
out of the working envelope by mis-operation, the robot is equipped with mechanical
stoppers outside the working envelope. Additionally, soft limits which can be set by
the user are provided.
! CAUTION
In the case where batteries for detecting the motor position are of alkaline
type, the batteries can overheat, leak battery fluid, or rupture when used
under high temperatures. Also, high temperatures can reduce the
performance and lifespan of the battery. If using the robot under high
temperatures, please consult with the Toshiba Machine sales office.
If high-speed operation is performed when starting in a low temperature
environment, the torque may increase and an error may occur.
To operate the robot in a low temperature environment, be sure to
operate the robot continuously at low speed for several minutes first when
starting in order to soften the grease, and then change to high speed
operation.
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Working envelope
When viewed from
Z arrow-mark
Battery case
Hand I/O connector
Hand air joint
Set hole
Details of hand set part
Scale 1 : 2
Hand set width 27
Details of T-slot for mounting
peripheral equipment
Scale 1 : 2
Clean vacuum air joint
for φ4 tube
Hand I/O connector
Motor power connector
Axis 3 brake OFF switch
Encoder connector
M4 screw hole for grounding
Hand air joint
for 4xφ4 tube
Max. 580
Details of T-slot for mounting
peripheral equipment
Fig. 2.1 External view of TH250A robot
Working envelope
Battery case
Hand I/O connector
Hand air joint
Set hole
Details of hand set part
Scale 1 : 2
Hand set width 27
Details of T-slot for mounting
peripheral equipment
Scale 1 : 2
Clean vacuum air joint
for φ4 tube
Hand I/O connector
Axis 3 brake OFF switch
Motor power connector
Encoder connector
M4 screw hole for grounding
Hand air joint
for 4xφ4 tube
Max. 635
Details of T-slot for mounting
peripheral equipment
When viewed from
Z arrow-mark
Fig. 2.2 External view of TH350A robot
6
6
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4x7 hole
See Details of "A". Details of "A":
T-slot for mounting equipment
Hand I/O connector
Hand air joint
Clean vacuum air joint
for φ6 tube
Hand air joint
for 4xφ4 tube
Space for cable: 80 or over
Battery box
Brake OFF switch
Stroke
Tap for mounting
equipment 2xM4
Both sides
Hand set width 27
Details of hand set part
Fig. 2.3 External view of TH180 robot
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