Toshiba TH450A User manual

STE 80808–2
TH450A
TH550A/TS3000
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.
February, 2010
TOSHIBA MACHINE CO., LTD.
NUMAZU, JAPAN

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Copyright 2009 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 the basic specifications of the industrial robot and controller, and
how to unpack and install them. 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 Safety Manual so
that you can understand the safety measures.
This manual is divided into the following five (5) sections:
Section 1 Specifications
This section describes the basic specifications and names of respective units
of the robot and controller.
Section 2 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 3 Installation
This section discusses the equipment installation environment, space
requirements, and how to install the equipment.
Section 4 System Connections
This section describes how to connect the robot, controller and peripheral
equipment.
Section 5 Tool Interface
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.

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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".
!WARNING
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 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 and caution.
The details 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, secure it to the base. The robot will
be unstable if just set down, and it could tilt over.

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Table of Contents
Page
1. Specifications .........................................................................................................11
1.1 Robot Configuration Diagram ........................................................................11
1.2 Name of Each Part ........................................................................................12
1.3 External Dimensions......................................................................................13
1.4 Specifications Table.......................................................................................15
2. Transportation ........................................................................................................16
2.1 Unpacking......................................................................................................16
2.2 Transportation ...............................................................................................18
2.2.1 Mass and Dimensions.......................................................................18
2.2.2 Transporting the Robot......................................................................19
2.2.3 Transporting the Controller................................................................22
2.3 Storage..........................................................................................................23
2.3.1 Storage Precautions for the Robot....................................................23
2.3.2 Storage Precautions for the Controller..............................................23
3. Installation ..............................................................................................................24
3.1 Installation Environment ................................................................................24
3.2 Robot Installation...........................................................................................25
3.2.1 External Dimensions .........................................................................25
3.2.2 Working Envelope.............................................................................25
3.2.3 Coordinate System............................................................................28
3.2.4 Installing the Robot............................................................................30
3.3 Installing the Controller..................................................................................31
3.3.1 External Dimensions .........................................................................31
3.3.2 Precautions for Direct Installation......................................................32
3.3.3 Rack Mounting Dimensions...............................................................33
3.3.4 Precautions for Rack Mounting .........................................................33
3.4 Precautions for Handling the Teach Pendant ................................................35
3.5 Safety Measures............................................................................................36
4. System Connections...............................................................................................37
4.1 Cable Wiring..................................................................................................37
4.1.1 Connector Arrangement on the Controller.........................................37

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4.1.2 Connecting the Power Cable “ACIN”
(cof Fig. 4.1; plug connector attached)............................................38
4.1.3 Connecting the Motor Cable “MOTOR”
(dof Fig. 4.1) (Cable attached)........................................................39
4.1.4 Connecting the Encoder Cable “ENC”
(eof Fig. 4.1) (Cable attached)........................................................40
4.1.5 Connecting the Robot Control Signal Cable “HAND”
(fof Fig. 4.1) (Cable attached)........................................................40
4.1.6 Connecting the Brake Signal Cable “BRK”
(jof Fig. 4.1) (Cable attached)........................................................41
4.1.7 Connecting and Disconnecting Cables..............................................41
4.1.8 Examples of Connector Terminal Arrangement.................................43
4.2 Controller Connector Signals.........................................................................46
4.2.1 Connector Signal Connection Diagrams ...........................................46
4.2.2 Jumpers for Safety Related Signals..................................................46
4.3 Separating Control Panel from Controller......................................................48
4.3.1 Removing Control Panel ...................................................................48
4.3.2 Cable between Controller and Control Panel ....................................48
4.3.3 Control Panel Mounting Dimensions.................................................49
4.3.4 Mounting Dummy Panel on Controller...............................................50
4.3.5 Dimensions when Separating Control Panel.....................................51
5. Tool Interface..........................................................................................................52
5.1 Mounting Tool................................................................................................52
5.2 Tool Wiring and Piping...................................................................................53
5.2.1 Tool Signals (Controller Side)............................................................53
5.2.2 Tool Wiring........................................................................................57
5.2.3 Tool Air Piping...................................................................................64
5.3 Permissible Load Conditions and Program Setting........................................66
5.3.1 Permissible Load Conditions.............................................................66
5.3.2 Load Conditions and Program Setting...............................................67
5.3.3 Setting Maximum Speed and Robot Acceleration/
Deceleration for Load Conditions......................................................70

TRANSPORTATION AND INSTALLATION MANUAL
Tables and Drawings
Page
Fig. 1.1 Robot Configuration Diagram.............................................................................11
Fig. 1.2 Name of each part..............................................................................................12
Fig. 1.3 External dimensions of the robot (TH450A) .......................................................13
Fig. 1.4 External dimensions of the robot (TH550A) .......................................................14
Fig. 2.1 Packaging state..................................................................................................17
Fig. 2.2 Outer dimensions at transport (TH450A)............................................................18
Fig. 2.3 Outer dimensions at transport (TH550A)............................................................19
Fig. 2.4 Lifting up the robot..............................................................................................20
Fig. 2.5 Robot handling areas.........................................................................................21
Table 3.1 Environmental conditions for robot and controller ...........................................24
Fig. 3.1 External view and working envelope (TH450A)..................................................26
Fig. 3.2 External view and working envelope (TH550A)..................................................27
Fig. 3.3 Base coordinate system and joint angle origin...................................................29
Fig. 3.4 Installation method.............................................................................................30
Fig. 3.5 External view of controller ..................................................................................31
Fig. 3.6 Controller ventilation space................................................................................32
Fig. 3.7 Screw hole dimensions for securing controller...................................................33
Fig. 3.8 Removing upper cover.......................................................................................34
Fig. 3.9 Clearance of controller front side........................................................................35
Fig. 4.1 Robot controller connector arrangement............................................................37
Table 4.1 Power supply specifications ............................................................................38
Fig. 4.2 Robot side connector arrangement....................................................................40
Fig. 4.3 Connecting and disconnecting a circular connector...........................................41
Fig. 4.4 Connecting and disconnecting a square connector............................................42
Fig. 4.5 Removing control panel......................................................................................48
Fig. 4.6 Control panel mounting dimensions...................................................................49
Fig. 4.7 Mounting dummy panel......................................................................................50
Fig. 4.8 Cable connections of dummy panel and control panel.......................................51
Fig. 5.1 Tool mounting dimensions..................................................................................52
Fig. 5.2 Wiring to sequencer, etc.....................................................................................58
Fig. 5.3 Tool wiring c......................................................................................................60
Fig. 5.4 Tool wiring（Type-N）...........................................................................................61
Fig. 5.4-A Tool wiring （Type-P）.................................................................................. 61A
Fig. 5.5 Wiring method c................................................................................................62
Fig. 5.6 Wiring method d................................................................................................63
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Table 5.1 Permissible load conditions ............................................................................66
Fig. 5.8 Robot tool .......................................................................................................67
Fig. 5.9 Setting of maximum speed and acceleration/deceleration in relation to
load mass .......................................................................................................71
Fig. 5.10 Setting of maximum speed and acceleration/deceleration in relation to
gravity center offset (Axes 1 and 2) (TH450A)................................................72
Fig. 5.11 Setting of maximum speed and acceleration/deceleration in relation to
gravity center offset (Axis 4) (TH450A)...........................................................73
Fig. 5.12 Setting of maximum speed and acceleration/deceleration in relation to
gravity center offset (Axes 1 and 2) (TH550A)................................................74
Fig. 5.13 Setting of maximum speed and acceleration/deceleration in relation to
gravity center offset (Axis 4) (TH550A)...........................................................75

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1. Specifications
1.1 Robot Configuration Diagram
Fig. 1.1 Robot Configuration Diagram
Operation panel
Split type (option)
PC (obtained by customer)
Program support software
TSPC (option)
TCPRGOS (option)
Robot controller
Teach pendant (option)
Cable between robot and
controller
TSPC communication
cable (obtained by
customer)
TH450A/TH550A
robot unit
TP cable

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1.2 Name of Each Part
Fig. 1.2 shows the name of each part of the robot. The name of each part of the robot
is common between the TH450A and TH550A.
Fig. 1.2 Name of each part
Ball screw spline
(tool shaft)
Arm 2 Arm 1
Cover
Base
Axis 2 (rotation)
Axis 1
(rotation)
Axis 4
(rotation)
Axis 3
(vertical
movement
)
Two spares (grommet)
4×ø4
Hand-operated
quick joint
Brake
encoder I/O
Motor power
connector
Eyebolt
Wiring panel
Brake OFF switch
Hand I/O connector
4 × ø4
Hand-operated quick joint
Wiring panel
Wiring panel
(base side)
Wiring panel (base side)

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1.3 External Dimensions
Fig. 1.3 refers to the external dimensions of the robot.
Fig. 1.3 External dimensions of the robot (TH450A)
Brake OFF switch
Hand I/O connector
Hand-operated air Joint
4 ×ø4 tube 4
×
ø14
mounting holes
630 (Z-axis stroke at 300 mm)
Optional Z-axis stroke (Z-axis stroke at 150 mm)
Standard Z-stroke
About 350
Space for cable

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Fig. 1.4 External dimensions of the robot (TH550A)
Brake OFF switch
Hand I/O connector
Hand-operated air Joint
4 ×ø4 tube 4
×
ø14
mounting holes
630 (Z-axis stroke at 300 mm)
Optional Z-axis stroke 500 (Z-axis stroke at 150 mm)
Standard
Z-stroke
About 350
Space for cable

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1.4 Specifications Table
Item Specifications
Structure Horizontal multi-joint type SCARA robot
Model TH450A TH550A
Applicable controller TS3000
Mass of robot body 26 kg 28 kg
No. of controlled axes Four (4)
Arm length 450 mm
(250 mm + 200 mm) 550 mm (250 mm + 300 mm)
Axis 1 ±120 (deg)
Axis 2 ±145 (deg)
Axis 3 150 (mm) [Option: 300 (mm)]
Operating range
Axis 4 ±360 (deg)
Axis 1 600 (deg/s) 375 (deg/s)
Axis 2 600 (deg/s)
Axis 3 2000 (mm/s)
Axis 4 2000 (deg/s)
Maximum speed
(*1) Composite
speed of axes 1
and 2 7.3 (m/s) 6.4 (m/s)
Rated payload mass 2 (kg)
Maximum payload mass 5 (kg)
Permissible load inertia (*1) 0.06 (kg·m2)
X, Y ±0.01 (mm)
Z ±0.01 (mm)
Repeatability C ±0.005 (deg)
Cycle time (*2)
(When payload mass is 2 kg) 0.30 (sec)
Drive system By means of AC servo motors
Position detection method Absolute
*1: When the mass of load exceeds 2 kg, or when the gravity center position of load
is away from the axis 4 center position, both the speed and acceleration should
be reduced, using the PAYLOAD command.
*2: Shuttle time for rough positioning in horizontal direction of 300 mm and vertical
direction of 25 mm.

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2. Transportation
2.1 Unpacking
The robot and controller are shipped separately in corrugated cardboards. Fig. 2.1
shows each packaging state.
Open the packages in a location easily accessible, where the equipment is to be
installed. Take careful precautions not to damage the robot and controller.
After opening the packages, make sure that all the accessories are present and that
nothing has been damaged during transport.
Cables
Teach pendant
Instruction manuals
Accessories included in the instruction manuals
System floppy disk (or CD-ROM): 2 pcs. (2 pcs.)
CD-ROM for TCPRGOS (option): 1 pc.
CD-ROM for TSPC (option): 1 pc.

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Fig. 2.1 Packaging state
!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 wooden pallet, corrugated cardboards, polyethylene shipping bags
and cushion material according to the customer’s in-house regulations.
Accessories included in the controller package
EMS dummy connector: 1 pc.
SYSTEM dummy connector: 1 pc.
TP dummy connector: 1 pc.
Corrugated cardboard
(Cushion for the top plate)
Corrugated cardboard
(external box)
Corrugated cardboard
(Cushion for the bottom plate)

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2.2 Transportation
Move the robot and controller very carefully. Make sure that no excessive impact 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 clamp and base set bolts 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.
2.2.1 Mass and Dimensions
The mass and outer dimensions of the robot are shown in Fig. 2.2 and Fig. 2.3.
For the mass and outer dimensions of the controller, see Fig. 3.5 of Para. 3.3.1.
Fig. 2.2 Outer dimensions at transport (TH450A)
Mass of robot body
26 kg
Clamp

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Fig. 2.3 Outer dimensions at transport (TH550A)
2.2.2 Transporting the Robot
In principle, the robot should be transported in the state shown in Fig. 2.2 and Fig. 2.3
above. Fold back and secure the arm with the attached clamp. (The robot is
shipped in this posture. After you have unpacked the shipment, you should move it as
it is.) At this time, take careful precautions not to impose a large force on the tool
shaft.
!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.
Mass of robot body
28 kg
Clamp

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It is possible to lift up and transport the robot. Pass the wire through the attached
eyebolt, then lift up the robot carefully, as shown in Fig. 2.4.
The figure shows the TH450A.
Fig. 2.4 Lifting up the robot
!CAUTION
• The wire to be used should be such that can well withstand the mass of the
robot.
• When lifting up the robot, it may tilt a little. Lift it up slowly.
• Lifting up and down should be performed carefully so that any impact cannot
be exerted on the robot.
• When carrying the robot by workers, take careful precautions to prevent
their hand or leg from being caught in the robot.
Wire