Toshiba THL Series User manual

STE85358-6
THL Series
INSTRUCTION MANUAL
SAFETY 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.
November, 2011
TOSHIBA MACHINE CO., LTD.
NUMAZU, JAPAN
Robot controller TSL3000
Robot controller TSL3000E
Robot controller TS3000
Robot controller TS3000E

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This Instruction Manual applies to the following robots:
THL Series: THL300, THL400, THL500, THL600, THL700, THL800, THL900, THL1000
Copyright 2011 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 safety measures for the system robots (THL series) built by Toshiba
Machine. You are requested to read through this manual and handle the robot, strictly observing
the instructions given throughout the manual, so that you can completely understand the
performance of the robot and use its functions safely over the long years to come.
This manual consists of the following sections.
Cautions on Safety
This section deals with the important information on using the robot safely and properly.
Locations of Warning Labels
This section describes the locations of warning labels affixed to the robot and controller.
Safety Measures
This section describes the safety functions of the robot and controller, and safety cautions on
installing and operating the robot.
Compliant Standards and Safety Performance
This section describes the compliant standards and safety performance of the robot and
controller.

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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 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 "incorrect handling will lead to fatalities or
serious injuries."
!WARNING
This means "incorrect handling will lead to fatalities or
serious injuries."
!CAUTION
This means "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).
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, warning or caution.
The details of the actual danger, warning or caution are indicated
with pictures or words in or near the symbol.

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[Operation]
!DANGER
Prohibited
•During operation, NEVER enter the dangerous area of the
robot. Otherwise, you will be injured seriously.
(The dangerous area signifies an area near the robot, where,
if a person has entered, he or she will be jeopardized.)
•DO NOT leave in the working range any machinery or
materials that will hinder the operation. If the equipment went
wrong, a person nearby will be injured or involved in an
accident.
•Anyone other than the operator MUST NOT approach the
equipment. Should he negligently touch a dangerous part of
the equipment, he will get injured or involved in a serious
accident.
•NEVER perform an inappropriate operation which is not
described in the instruction manual. Otherwise, the
equipment will start by mistake, resulting in personal injury or
serious accident.
Mandatory
•If you feel even a little that you are exposed to danger or the
equipment works abnormally, press the EMERGENCY stop
pushbutton switch to stop the equipment. If the equipment is
used as it is, you will be injured or involved in a serious
accident. When this happens, ask our after-sale service
agent for repair.
•During operation, be sure to close the equipment cover.
Should the cover be opened during operation, you will be
struck by an electric shock or get injured.
•Only a well-trained and qualified person is allowed to perform
the operation. Should the equipment be operated improperly,
it will start by mistake, causing a personal injury or serious
accident.
•If the equipment has malfunctioned, turn the power off, identify
and remove the cause of the abnormality, maintain the
peripheral equipment and completely restore the
malfunctioned equipment. Then start the equipment at a low
speed. If the equipment starts, leaving the abnormality, you
will be involved in a serious accident.

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!WARNING
Prohibited
•NEVER enter the movable range of the robot. Otherwise, an
accident causing injury or death will occur.
•NEVER put your hands close to the moving part of the robot.
Otherwise, your hands will get caught in the moving part and
get injured.
!CAUTION
Prohibited
•DO NOT change the data of the system parameter files.
Otherwise, the robot will operate abnormally, resulting in
damage or an accident.
Mandatory
•In principle, teaching operation should be performed outside
the dangerous area of the robot. (The dangerous area
signifies an area near the robot, where, if a person has
entered, he or she will be jeopardized.)
If it should be performed inevitably within the dangerous area,
strictly observe the following matters.
(1) The teaching operation should be always performed by two
(2) persons. One person performs the job and the other
person watches outside the dangerous area. Also, both
persons should try to prevent mis-operation with each
other.
(2) If the operator performs teaching operation within the
dangerous area, he or she should hold the controller
master key and teach pendant to prevent an unrelated
person from operating the robot.
(3) The operator should do the job in an attitude ready to
press the EMERGENCY stop pushbutton switch at any
time. Also, he should perform the job at a position from
which he can evacuate immediately at the time of an
emergency after confirming the robot working range and
shields nearby.
(4) The supervisor should keep watch on the job at a position
where he can see the entire robot system and operate the
EMERGENCY stop pushbutton switch at the time of an
emergency. Also, he should keep anyone from entering
the dangerous area.

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!CAUTION
Mandatory
•If an abnormality has generated or the POWER LED lamp on
the control panel remains off after the power of the equipment
was turned on (TS3000 and TS3000E), turn off the main
power immediately and confirm the wiring. Otherwise, you
will be struck by an electric shock or a fire will break out.
•Unless the robot operates toward a designated direction at
manual guide, shut down the system by activating emergency
stop. Otherwise, the robot will be damaged or you will be
involved in an accident. When this happens, call us at the
after-sale service agent.
•Pushbutton operations of the control panel (TS3000 and
TS3000E) and teach pendant should be confirmed visually.
Otherwise, you will be involved in an accident due to incorrect
operation.
•Before operating the equipment, perform the following
inspection.
(1) Make sure that visual appearance of the robot, controller,
peripheral equipment and cables is in good condition.
(2) Make sure that no obstacle stands in or near the operating
range of the robot and peripheral equipment.
(3) Make sure that the emergency stop and other safety
devices operate properly.
(4) Make sure that no abnormal noise or vibration is involved
in the robot operation.
If the above prior inspection is skipped, the equipment will be
damaged or you will be involved in an accident.

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!CAUTION
!
Caution
•The speed of test operation is initially set at 20% of the
maximum robot speed and limited to 250mm/sec.
Based on requirements by 5.6.2 Reduced speed control
operation of ISO10218-1 Safety requirements for industrial
robots, during test operation the speed of the TCP(Tool
Center Point) does not exceed 250mm/s. This limitation takes
higher priority than robot maximum speed limit setting of 20%
during test operation.
•The speed of automatic operation is initially set at 100% of the
maximum robot speed.
•When the robot servo is turned off, the arm may move by the
counterforce of the twist of the main body harness.

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[Installation and transportation]
Strictly observe the following items to use the robot safely.
!DANGER
Prohibited
•DO NOT install or operate the robot if any part is damaged or
missing. Otherwise, electric shocks, fires or faults will be
caused.
•DO NOT install the robot at a place where it is exposed to
splash of water or other fluids. Otherwise, electric shocks,
fires or faults will be caused.
•DO NOT place the robot near a combustible material. If it
ignites due to a fault, etc., a fire will break out.
Mandatory
•Always secure the robot with attached clamps before carrying
it. Otherwise, you will be injured if the arm moves when the
robot is lifted.
•Wire the robot after installation. Otherwise, electric shocks or
injuries will be caused.
•Always use the line voltage and power capacity designated by
Toshiba Machine. Otherwise, the equipment will be
damaged or a fire will break out.
•Always use the designated power cables.
(For details, see the "Transportation and Installation Manual.")
If a cable other than the designated is used, fires or faults will
be caused.
•Install the controller outside the dangerous area where the
operator can always watch the robot movements. Otherwise,
it is very dangerous should the robot start during the controller
operation.
Always ground
•Completely connect the grounding cable. Otherwise, electric
shocks or fires will be caused if a fault or fault current occurs.
Also, it could cause mis-operation by noise.

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!CAUTION
Prohibited
•NEVER lift the robot by the arm 2 cover. Otherwise, an
excessive force will be exerted on the robot mechanism,
resulting in damage of the robot.
•For the controller, secure an ample space for ventilation.
(For details, see the "Transportation and Installation Manual.")
Otherwise, the controller will heat and go wrong.
Mandatory
•When lifting the robot, lift it up slowly as the robot will tilt
slightly. If it is lifted up suddenly, it will cause a very
hazardous situation.
•When storing the robot, secure it to the base completely.
If the robot is just placed on the floor, it becomes unstable and
will fall down.
!
Caution
•When operating the robot after long-hour stop at a low
temperature (10°C or less), be sure to perform a continuous
operation at a low speed (approximately 20% of the maximum
speed) for a few minutes. Otherwise, a motor overload error
may occur due to solidified grease.

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[Maintenance and inspection]
Strictly observe the following items to use the robot safely.
!DANGER
Prohibited
•DO NOT incinerate, disassemble or charge the battery.
Otherwise, it will rupture.
Mandatory
•Be sure to turn off the main power of the controller before
starting inspection or maintenance.
•When disposing of the battery, follow the user's provided
regulations.
!CAUTION
Prohibited
•The user NEVER replace or modify parts other than those
described in the instruction manual. Otherwise, the robot
performance will deteriorate, or faults or accidents will be
caused.
Mandatory
•Always use the Toshiba Machine designated spare parts when
replacing the parts.
•Perform maintenance and inspection regularly. Otherwise,
the equipment will go wrong or you will be involved in an
accident.
!
Caution
•The axis 4 motor of the THL series robots is not provided with
a brake. With the servo off, therefore, Axis 4 may rotate due
to the dead weight of the tool and hand, offset condition or
touch by hand. Once Axis 4 rotates, Axis 3 will move up or
down. Take careful precautions not to have your hand and
leg caught in it.
•A brake release switch is provided at the back of the base
(THL300, THL400) and at the upper part of the axis 2 arm
cover (THL500 –THL1000). If the brake release switch is
pressed while a heavy load such as a hand or workpiece is
mounted on arm 3, arm 3 will drop. Take careful precautions
not to have your hand or leg caught in it.

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Locations of Warning Labels
(1) Locations of robot warning labels (THL300, THL400)
Right of the robot
Left of the robot
Top of the robot

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(2) Locations of robot warning labels (THL500, THL600, THL700)
Left of the robot
Front of the robot
Top of the robot

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(3) Locations of robot warning labels (THL800, THL900, THL1000)
Left of the robot
Right of the robot
Top of the robot
Front of the robot

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(4) Locations of controller warning labels (TSL3000)
MODEL
Mfd.IN
POWER CAPACITY KVA
MASS kg
TOSHIBA MACHINE CO.,LTD. MADE IN JAPAN
■感電による死傷のおそれがあります。
Unit powered by hazardous voltage will cause shock,
burn or death.
保守・点検作業の前に必ず電源を切り、コントローラの電源
コネクタ（ACIN）を外してください。
Turn off power and disconnect power connector(ACIN)
■異常の場合はコントローラの電源を切り、弊社まで
ご連絡ください。
改造しないでください。
■本ロボットおよびコントローラを弊社の許可なく
Do not modify this robot and controller without
our permission.
誤配線すると感電や機器破損の原因になります。
配線にしてください。
■コネクタ（ACIN）の電源線とアース線の接続は必ず下図の
as follows.
Connect wires for ground and power lines of ACIN
Hazardous voltage may result in electric shock
＜CONTROLLER＞
ACIN
Robot Controller
警 告
WARNING
注 意
CAUTION
In case of trouble, turn off power and call us.
in case of miss-wiring.
before maintenance.
50/60Hz
AC190～240V
1
2
3
uiu{E? oie? aia{abagu{a ? uAaRaoagaiu[aee? e? e? e? a gi ce? e┼
e?Agupe!e\e│eouB
Robot,contorollerhaving below listed numbers were
combined.They must be used in the same combination.
Otherwise,problems such as vibration and inacuracy
aia{abagu{a ? E?a ooEi a
mayoccur.
ROBOT BODY SERIAL No.
aRaoagaiu[ae E? a ooEi a
CONTROLLER SERIAL No.
uie┘AYe? AUice? aRaoagaiu[aee? odi ? eEIeTuAo\ Ade? e┼
e?yAuie!e\ e│eouB
uiu{aia{abage?eμeDaRaoagaiu[aeeo\Ade? i ue┬e? e!
Incase of some troubles, turn off power and call us .
u@e3aoeAe?eoe┼e!e\e│eouB
Donot modify this robot and controller without
ourpermission.
uiaRalaNa^(ACIN)e? odi ? E3eaaAu[aXE3e? E┌a ? e? oKec e? E}e?
u@ozE3e?eAe─e!e\e│eouB
u@iUozE3eAeUeae┤odeOi@eYoja? e? i ┤e÷eae? eTe? eAuB
Connectwires for ground and power lines of ACIN
asfollows.
Hazardousvoltage may result in electric shock
incase of misswiring.
uaCONTROLLERua
ACIN
1aE
AC200u`250V
50/60Hz
Aiu@eE
CAUTION
uie┤ode? eμeTACAOe?e?e?eUe￢eaeTe?eAuB
Unitpowered by hazardous voltage will cause shock,
burnor death.
u@o?At uEo_i ? iyi ae? a Oe? oKec odi ? eEI eTuAaRaoagaiu[aee? odi ?
u@aRalaNa^(ACIN)eeOeAe─e!e\e│eouB
beforebeginning maintenance checks.
Turnoff power and disconnect power connector (ACIN)
i xu@iE
WARNING
MODEL
Mfd.IN
MASS kg
POWER CAPACITY KVA
Robot Controller TOSHIBA MACHINE CO.,LTD. MADEIN JAPAN
ご使用ください。
■本製品のロボット本体、コントローラは以下の組合せで
must be used in combination.
Robot and contoroller with below listed numbers
Otherwise, problems such as vibration and inaccuracy
may occur.
ロボット本体 製造番号
ROBOT BODY SERIAL No.
コントローラ 製造番号
CONTROLLER SERIAL No.
Top of the controller
Right side of the controller

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(5) Locations of controller warning labels (for the TSL3000E)
Controller top view
Controller side view
ご使用ください。
■本製品のロボット本体、コントローラは以下の組合せで
must be used in combination.
Robot and contoroller with below listed numbers
Otherwise, problems such as vibration and inaccuracy
may occur.
ロボット本体 製造番号
ROBOT BODY SERIAL No.
コントローラ 製造番号
CONTROLLER SERIAL No.

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(6) Locations of controller warning labels (TS3000 and TS3000E)
■異常の場合はコントローラの電源を切り、弊社まで
ご連絡ください。
In case of trouble, turn off power and call us.
■本ロボットおよびコントローラを弊社に許可なく
改造しないでください。
Do not modify this robot and controller without
■コネクタ(ACIN)の電源線とアース線の接続は必ず下図の
our permission.
配線にしてください。
誤配線すると感電や機器破損の原因となります。
Connect wires for ground and power lines of ACIN
as follows.
Hazardous voltage may result in electric shock
in case of miss-wiring.
ACIN
＜CONTROLLER＞
1φ
AC200～240V
50/60Hz
注 意
CAUTION
警 告
■感電により死傷のおそれがあります。
Unit powered by hazardous voltage will cause shock,
burn or death.
保守･点検作業の前に必ず電源を切り、コントローラの電源
コネクタ(ACIN)を外してください 。
Turn off power and disconnect power connector(ACIN)
before maintenance.
WARNING
MODEL
Mfd.IN
MASS kg
POWER CAPACITY KVA
Robot Controller TOSHIBA MACHINE CO.,LTD. MADE IN JAPAN
ご使用ください。
■本製品のロボット本体、コントローラは以下の組合せで
must be used in combination.
Robot and contoroller with below listed numbers
Otherwise, problems such as vibration and inaccuracy
may occur.
ロボット本体 製造番号
ROBOT BODY SERIAL No.
コントローラ 製造番号
CONTROLLER SERIAL No.
Top of the controller
Front of the controller

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Safety Measures
This section describes the necessity of safety measures, safety functions provided for the robot and
robot controller, and general safety measures to be taken.
1 Cautions on Safety
Toshiba Machine’s SCARA robots and robot controller are equipped with various safety functions.
When actually operating the robot, however, the following dangers will be supposed.
a) Danger supposed in normal automatic operation
•Operator's mis-operation and mis-judgment, incomplete program.
•Unexpected robot movement, release or drop of workpiece due to fault of an electronic
control device.
b) Danger supposed at teaching and inspection
•Danger of an operator entering the movable range of the robot.
•Operator's negligence from confusion or experience at generation of an unexpected
abnormality, and operator's mis-operation due to shortage of behavior and knowledge.
•Approach of an operator to the robot due to unexpected complex movement of the robot.
•Abnormal movement, etc. caused by mis-wiring, contact failure, deterioration and noise.
c) Danger supposed in a related machine, etc.
•Sudden movement of the robot with a command from a related machine, etc.
•Sudden movement of a related machine after the robot movement.
•Danger of an operator being caught or entangled in the robot when teaching, inspecting or
adjusting the robot while moving a related machine.
To use the robot safely, safety measures should be taken according to the operating conditions.
Otherwise, an unexpected disaster may occur.
If there are safety rules and regulations, strictly observe them. Also, refer to all manuals relating
to the robot and robot controller.

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2 Safety Functions
This robot and robot controller have various safety functions as shown below.
a) Emergency stop function
An EMERGENCY stop pushbutton switch is equipped on the robot controller (TS3000 and
TS3000E) and teach pendant, respectively. When this switch is pressed, the robot stops
immediately and the main power of the robot is turned off.
(Stop category 1)
The emergency stop function is always enabled regardless of the operating status of the
robot.
An emergency stop button uses a switch with the locking mechanism. To unlock the button,
turn and pull up the switch top as shown below.
The external emergency stop contacts are also available. The emergency stop switch can
be added as required. The emergency stop switch that complies with ISO13850 should be
selected.
Emergency stop switch ON Emergency stop switch unlock
Notes on Emergency Stop Switch
Select emergency stop switches, observing the following:
•Install each emergency stop device at a location where an emergency stop would be required
and where they are easy to access when needed.
•Select emergency stop devices structured in a way that once they are activated, their circuits
will only recover automatically after manual recovery, and their contacts cannot be restored
before device recovery.
•Select emergency stop devices in any of the following shapes that are suited to the machine
structure and are characterized to overcome dangerous situations:
1) Mushroom-type pushbutton
2) Rope-pull type, or bar type
3) Belly or knee type
4) Pedal switch without a protective cover
•The pushbutton type of emergency stop device shall have a red actuator on a yellow
background.
•The rope-pull type of emergency stop device shall always maintain proper tension on the rope,
and the rope shall be distinguishable via twisted red and yellow strands.

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b) Safety contact input function
The controller has the redundant safety contact input function that is separate from the
emergency stop system.
Connect interlock switches such as limit switch and foot switch that work with the safety
fence door.
【About Emergency stop function and Safety contact input function】
1) The external emergency stop contacts for the TSL3000 are shown in the following figure.
Connect an emergency stop button to the INPUT connector pins 18-19 and 36-37 on the
front of the TSL3000. Emergency stop buttons for the output common Type-N and Type-P
should also be connected to the pins of the same numbers.
EMS1A
EMS1B
EMS1B
EMS1C
EMS2A
EMS2B
EMS2B
EMS2C
P24V
P24GP5G
P24V
P24GP5G
TSL3000/TSL3100 User side
TP (Teach
Pendant)
External
input signal
unit
To
emergency
stop
processing
P5V
P5V
Emergency stop
contact 1
Emergency stop
contact 2