Toshiba TH650A-IP User manual

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INSTRUCTION MANUAL
DUST-PROOF & DRIP-PROOF TYPE
INDUSTRIAL ROBOT SPECIFICATIONS
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.
November, 2008
TOSHIBA MACHINE CO., LTD.
NUMAZU, JAPAN
TH650A–IP/TS2100

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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
This manual describes the specifications of the TH–A series dust-proof and drip-proof type
industrial robot.
This manual is essential to keep the robot performance for a long time, to prevent failures
and to assure safety. Be sure to look through this manual and set up a maintenance
program before actually starting the robot.
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 imminently
lead to fatalities or major injuries".
!WARNING
This means that "incorrect handling may 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.

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[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 and caution.
Details of the actual danger and caution are indicated with
pictures or words in or near the symbol.
[Maintenance and inspection]
Be sure to observe the following items to use this product safely.
!DANGER
Prohibited
• DO NOT incinerate, disassemble or charge the batteries.
Otherwise, they may rupture.
Mandatory
• Be sure to turn off the main power switch of the controller
before starting inspection or maintenance.
• Batteries should be disposed of according to the user's in-
house regulations.

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!CAUTION
Disassembly
prohibited
• The user must NEVER replace or modify parts other than
those described in the instruction manual. Otherwise, the
performance may deteriorate or faults or accidents will be
caused.
Mandatory
• Always use the Toshiba Machine's designated spare parts
when replacing the parts.
• Maintenance and inspection should be performed regularly.
Otherwise, the system may malfunction or accidents will be
caused.

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This manual is comprised of the following seven (7) sections:
Section 1 Specifications
This section describes the basic specifications and names of respective parts
for the dust-proof and drip-proof type industrial robot.
Section 2 Transportation
This section describes how to remove the dust-proof and drip-proof type robot
from its box and how to transport it to the installation site. This section also
deals with the precautions to be taken when the robot is to be stored
temporarily after unpacked.
Section 3 Installation
This section discusses the dust-proof and drip-proof type robot installation
environment, space requirements, and how to install the robot.
Section 4 Tool Interface
This section discusses how to connect the cables and pipelines for the tool of
the dust-proof and drip-proof type robot.
Section 5 Maintenance
This section describes the structure of the dust-proof and drip-proof type robot
and all items required for the maintenance and inspection of the same robot.
Section 6 Cleaning of Robot Body
This section describes the precautions to be taken when the robot body is to
be cleaned and washed.
Section 7 Maintenance and Replacement Parts
This section explains the maintenance and replacement parts.

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Table of Contents
Page
1. Specifications ...........................................................................................................9
1.1 Name of Each Part ..........................................................................................9
1.2 Outer Dimensions..........................................................................................10
1.3 Specifications Table.......................................................................................12
2. Transportation ........................................................................................................14
2.1 Unpacking......................................................................................................14
2.2 Transportation ...............................................................................................14
2.2.1 Mass and Outer Dimensions.............................................................15
2.2.2 Transporting the Robot......................................................................16
3. Installation ..............................................................................................................18
3.1 Installation Environment ................................................................................18
3.2 Ingress Protection (IP) Class of Dust-Proof and Drip-Proof Specifications....19
3.3 Air Purge........................................................................................................20
3.4 Coordinate System........................................................................................21
3.5 Installing the Robot........................................................................................22
3.6 Cable Connection..........................................................................................24
3.6.1 Cables between Robot and Controller...............................................24
3.6.2 Connecting and Disconnecting Connectors ......................................24
3.6.3 Connector Terminal Layout...............................................................25
4. Tool Interface..........................................................................................................26
4.1 Wiring between Tools of the Robot................................................................26
4.1.1 How to Connect Connectors .............................................................27
4.2 Air Pipes Used for Tools of the Robot............................................................32

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Page
5. Maintenance...........................................................................................................34
5.1 Layout of Mechanical Components................................................................34
5.2 Maintenance Tools and Preparatory Parts ....................................................35
5.3 Replacement Procedures of Bellows.............................................................35
5.3.1 Replacement Procedures of Lower Bellow........................................35
5.3.2 Replacement Procedures of Upper Bellow........................................37
5.4 Mounting and Dismounting Covers................................................................39
5.4.1 Base Cover .......................................................................................40
5.4.2 Arm 1 Cover......................................................................................42
5.4.3 Arm 2 Cover......................................................................................43
5.4.4 Lid Used for Arm 2 Panel............................................................... 43B
6. Cleaning Robot Body..............................................................................................44
7. Maintenance and Replacement Parts.....................................................................45
7.1 List of Maintenance and Replacement Parts.................................................45

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Wiring panel
Axis 4
(rotation)
Base
Battery box
Axis 3
(vertical)
Ball screw spline
(tool shaft)
Bellows
Tool flange
Arm 1
Axis 1
(rotation)
Arm 2
Bellows
Batter
y
box
Cover
Axis 2
(rotation)
1. Specifications
1.1 Name of Each Part
The names of respective parts of the dust-proof and drip-proof type robot are shown in
Fig. 1.1 below.
Fig. 1.1 Name of each part
3xM5 hand-operated air joint Brake OFF switch
Cannon connector
Details of wiring panel
Square connector
For motor drive, encoder and
control signal cables
CN20 (CN3, CN4, CN5)
Air purge joint
Quick joint (φ8) with
speed controller
Cable clamp
(spare)
Air tube quick joint
(φ6) (3 places)
When viewed from arrow Z
Z

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1.2 Outer Dimensions
Fig. 1.2 and Fig. 1.3 show the outer dimensions and operating range of the robot.
Fig. 1.2 Outer dimensions of the robot
Wiring panel
Space required for cable connection
Z-axis stroke 200 mm Z-axis stroke 370 mm
Option: Z-axis stroke
Standard
Z-axis stroke

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Fig. 1.3 Operating range of the robot
(Axis 2 operating range)
(Axis 2 operating range)
(Axis 1 operating range)
(Axis 1 operating range)

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1.3 Specifications Table
Item Specifications
Structure Horizontal articulated type SCARA robot
Model TH650A–IP
Ingress protection (IP) class of
dust- and drip-proof structure IP65 (*1)
Applicable controller TS2100 (*2)
Mass of robot body 53 kg
No. of controlled axes Four (4)
Arm length 650 mm (300+350)
Axis 1 1,000 (W)
Axis 2 600 (W)
Axis 3 400 (W)
Motor capacity
Axis 4 400 (W)
Axis 1 ±160 (deg)
Axis 2 ±143 (deg)
Axis 3 200 (mm) [Option: 400 (mm)]
Operating range
Axis 4 ±360 (deg)
Axis 1 340 (deg/s)
Axis 2 600 (deg/s)
Axis 3 2,050 (mm/s)
Axis 4 1,700 (deg/s)
Maximum speed
(*3) Composite
speed of
axes 1 and 2 7.52 (m/s)
Rated payload mass 2 (kg)
Maximum payload mass 10 (kg)
Permissible load inertia (*3) 0.1 (kg·m2)
X, Y ±0.01 (mm)
Z ±0.01 (mm)
Repeatability (*4) C ±0.004 (deg)
Cycle time (*5) (When payload
mass is 2 kg) 0.32 (sec)
Drive system By means of AC servo motors
Position detection method Absolute

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*1: For details of the ingress protection class, see Paragraph 3.2 (page 9).
*2: The robot controller is not constructed to provide dust-proof and drip-proof
protection.
*3: 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.
*4: The ambient temperature is predetermined at 20°C.
*5: 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 wooden crates or corrugated
cardboards.
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 no
part has been damaged during transport.
The package posture and contents are the same as in the standard robot. Refer to the
TH650A Installation and Transportation Manual provided separately.
For the dust-proof and drip-proof type robot, strictly observe the following cautions.
!CAUTION
• The main robot is factory-packed in a vinyl bag for shipment. Carefully
remove the bag after the shipment has reached your office. If the vinyl bag
is pulled by force, the cap or cover may be damaged.
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 of the clamp and base attaching bolts
completely and put the equipment back into the wooden crates or corrugated
cardboards.

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When Z-axis stroke is 200 mm
When Z-axis stroke is 370 mm
Fixture
Mass of main robot = 53 kg
2.2.1 Mass and Outer Dimensions
The mass and outer dimensions of the robot are shown in Fig. 2.1.
Fig. 2.1 Outer dimensions during transport

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2.2.2 Transporting the Robot
The dust-proof and drip-proof specification robot has dust-proof and drip-proof parts
such as bellows, etc. added to the standard robots. The instructions during transport of
the robot are listed below. The instructions other than those listed below are the same
as those for the standard robots. Refer to the TH650A Installation and Transportation
Manual provided separately.
Fig. 2.2 Robot handling prohibited areas
After the installation, remove the clamp and eyebolt used for transport.
DO NOT hold
the bellows.
DO NOT hold
the bellows.
DO NOT hold the tool flange
and ball screw spline shaft.
DO NOT hold the
connectors.
DO NOT hold
the arm 2 cover. Handling areas
(shaded areas)

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!CAUTION
• When lifting up the robot by workers, hold the shaded locations by hands, as
shown in Fig. 2.2. If the ball screw spline shaft is held by hands, an
unusually large force is exerted, resulting in a malfunction.
• If the bellows is held or gripped by hands, it may be broken due to friction
with the parts inside.
• When carrying the robot by workers, take careful precautions to prevent
their hand or leg from being caught in the robot.
• The work should always be performed by two (2) or more workers.

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3. Installation
3.1 Installation Environment
Table 3.1 shows the environmental specifications for the robot and controller.
Table 3.1 Environmental specifications
Item Specifications
In operation : 0 to 40°CTemperature In storage : –10 to 50°C
Humidity 20 to 90 % (Non-condensing)
Altitude 1000 m or less
Vibration In operation : 0.98 m/s2or less
Dust No inductive dust should exist.
Gas No corrosive or combustible gas should exist.
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.
Dust-proof and
drip-proof Any place where the equipment sinks in liquid shall not exist. Small chips involved in turning or cutting operation shall not be
contained.
Mist of cutting fluid or coolant oil shall not be contained.
!DANGER
• Do not place the robot or controller near combustible. If it is not be done
completely, an ignition may occur due to a fault causing a fire.

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3.2 Ingress Protection (IP) Class of Dust-Proof and Drip-Proof Specifications
The Model TH650A robot (dust-proof and drip-proof specifications) has IP65 or
equivalent ingress protect against water and dust.
Be sure to perform air purge. Ingress of water and dust cannot be prevented according
to some operating environments.
I P 6 5
Indicates a degree of protection against ingress of water.
Water jetted at any angle does not have harmful effects on the robot.
Jetting water pressure: 30 kPa (30 kN/m2=: 0.3 kgf/cm2)
Flowrate: 12.5 L/min
Distance from nozzle: 2.5 ~ 3 m
Duration: Three (3) minutes
Indicates a degree of protection against solid foreign substances.
Dust does not enter into the interior of the robot.
Is a symbol to indicate protection characteristics.
!WARNING
• DO NOT use the entire robot or part of the robot sinking in water. Otherwise, the
water will enter the robot interior.
• DO NOT use the robot in an environment exceeding the specified IP class against
water and dust. Otherwise, the water or dust may enter the robot interior, resulting
in shortening of the robot life, deterioration of operating accuracy or mis-operation
of the robot.
• The robot controller is not compliant with the dust-proof and drip-proof
specifications.
• For drip-proofness of objects other than water, contact us.
• The bellows may discolor according to the operating environments, but there is no
problem with dust-proof performance.
• Be sure to perform air purge. Otherwise, the dust-proof and drip-proof
performance will drop.
• The dust-proof and drip-proof specification robots are not explosion-proof type
robots.

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3.3 Air Purge
The dust-proof and drip-proof type robot is provided with an air supply port for air purge
in its base connector unit. See Fig. 1.1. (Quick-joint with speed controller)
Ingress of dust into the interior of the robot can be prevented by supplying air to the air
supply port.
The air supply unit (reducer or pressure reducing valve, air filter, etc.) and air tube (8
mm-dia.) should be provided by the user.
• Air specifications
Maximum operating pressure: 0.58 MPa (6 kgf/cm2)
Tube size: Outer dia. 8 mm ×Inner dia. 5 mm
Fluid used: Fresh dry air not containing compressor oil, etc.
Degree of the air filtration 10 μm or less
• How to regulate flowrate
Fully close the speed controller attached to the robot base connector unit.
Set the pressure to 0.3 MPa ~ 0.58 MPa (maximum pressure), using a regulator (or
pressure reducing valve: to be provided by the user), then connect the air tube.
Turn the speed controller needle valve counterclockwise from the fully closed
position to increase the air flow rate. Regulate the flowrate while observing the
bellows condition and tighten the lock nut on the speed controller.
When feeding excessive amount of air, the bellows are expanded. Therefore the
feeding operation of air should be stopped immediately before the bellows starts to
expand.
!CAUTION
• Be sure to use fresh dry air. If you neglect the instruction, condensation will occur
in the interior of the robot, and water will accumulate within the interior of the robot,
thus causing earth leakage or malfunction.
• DO NOT increase a pressure exceeding the specified maximum pressure. If you
do not follow the instruction, seals attached at each joint will be damaged, and the
dust-proof and drip-proof performance will be impaired.
Tube insertion
hole (φ8 mm) Needle
Lock nut
Speed controller
Close (Flowrate
decreases.)
Open (Flowrate
increases.)