Toshiba THL Series User manual

STE85356-9
INSTRUCTION MANUAL
INDUSTRIAL ROBOT
TRANSPORTATION AND INSTALLATION MANUAL
Notice
Make sure that this instruction manual is delivered to the final
user of Toshiba Machine’s industrial robot.
Before operating the industrial robot, read through and
completely understand this manual.
After reading through this manual, keep it nearby for future
reference.
July, 2012
TOSHIBA MACHINE CO., LTD.
NUMAZU, JAPAN
THL Series
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 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 parts:
Section 1-3 Specifications
This section describes the basic specifications and names of respective
units of the robot and controller.
Section 4-6 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 7-12 Installation
This section discusses the equipment installation environment, space
requirements, and how to install the equipment.
Section 13-15 System Connections
This section describes how to connect the robot, controller and peripheral
equipment.
Section 16-21 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 (for THL500 to THL1000).
•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 misoperation by noise.

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!CAUTION
Prohibited
•NEVER lift the robot by the arm 2 cover. 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 (for THL500 to THL1000), 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
1. Specifications (THL300 and THL400)......................................................................12
1.1 Correspondence between the Robots and the Robot Controllers...................12
1.2Robot Configuration Diagram (TSL3000)........................................................12
1.3 Robot Configuration Diagram (TSL3000E) ...................................................13
1.4Robot Configuration Diagram (TS3000 and TS3000E)...................................14
1.5Name of Each Part..........................................................................................15
1.6External Dimensions.......................................................................................16
1.7Specifications Table........................................................................................18
2. Specifications (THL500, THL600 and THL700).......................................................20
2.1 Correspondence between robot and controller, and equipment configuration
diagram...........................................................................................................20
2.2 Name of Each Parts........................................................................................20
2.3 External Dimensions.......................................................................................22
2.4 Specifications Table........................................................................................25
3. Specifications (THL800, THL900 and THL1000).....................................................27
3.1 Correspondence between robot and controller, and equipment configuration
diagram...........................................................................................................27
3.2 Name of Each Parts........................................................................................27
3.3 External Dimensions.......................................................................................29
3.4 Specifications Table........................................................................................32
4. Transportation (THL300 and THL400).....................................................................34
4.1 Unpacking (TSL3000).....................................................................................34
4.2 Unpacking (TSL3000E)...................................................................................36
4.3 Unpacking (TS3000 and TS3000E)................................................................38
4.4Transportation.................................................................................................40
4.4.1 Mass and Dimensions........................................................................40
4.4.2 Transporting the Robot.......................................................................41
4.4.3 Transporting the Controller.................................................................42
4.5Storage ...........................................................................................................43
4.5.1 Storage Precautions for the Robot .....................................................43
4.5.2 Storage Precautions for the Controller ...............................................43
5. Transportation (THL500, THL600 and THL700)......................................................44
5.1 Unpacking (TSL3000).....................................................................................44
5.2 Unpacking (TSL3000E) .................................................................................46
5.3Unpacking (TS3000 and TS3000E)................................................................48
5.4Transportation.................................................................................................49
5.4.1 Mass and Dimensions........................................................................49

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5.4.2 Transporting the Robot.......................................................................51
5.4.3 Transporting the Controller.................................................................53
5.5Storage ...........................................................................................................54
5.5.1 Storage Precautions for the Robot.....................................................54
5.5.2 Storage Precautions for the Controller ...............................................54
6. Transportation (THL800, THL900 and THL1000)....................................................55
6.1 Unpacking (TSL3000).....................................................................................55
6.2 Unpacking (TSL3000E) .................................................................................56
6.3Unpacking (TS3000 and TS3000E)................................................................58
6.4Transportation.................................................................................................60
6.4.1 Mass and Dimensions........................................................................60
6.4.2 Transporting the Robot.......................................................................62
6.4.3 Transporting the Controller.................................................................64
6.5Storage ...........................................................................................................65
6.5.1 Storage Precautions for the Robot .....................................................65
6.5.2 Storage Precautions for the Controller ...............................................65
7. Robot Installation (THL300 and THL400)................................................................66
7.1 Installation Environment..................................................................................66
7.2 Installation.......................................................................................................67
7.2.1 External Dimensions and Working Envelope......................................67
7.2.2 Changing the Operation Ranges of Axes 1 and 2..............................70
7.2.3 Changing the Operating Range of Axis 3...........................................72
7.2.4 Changing Software Limits...................................................................78
7.2.5 Coordinate System.............................................................................79
7.2.6 Installing the Robot.............................................................................80
7.3 Precautions for Handling the Teach Pendant..................................................81
7.4 Safety Measures.............................................................................................82
8. Robot Installation (THL500, THL600 and THL700) .................................................83
8.1 Installation Environment..................................................................................83
8.2 Installation.......................................................................................................83
8.2.1 External Dimensions and Working Envelope......................................83
8.2.2 Changing the Operating Ranges of Axes 1 and 2..............................87
8.2.3 Changing the Operating Range of Axis 3...........................................89
8.2.4 Changing Software Limits...................................................................95
8.2.5 Coordinate System.............................................................................96
8.2.6 Installing the Robot.............................................................................97
8.3 Precautions for Handling the Teach Pendant..................................................98
8.4 Safety Measures.............................................................................................98
9. Robot Installation (THL800, THL900 and THL1000) ...............................................99

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9.1 Installation Environment..................................................................................99
9.2 Installation.......................................................................................................99
9.2.1 External Dimensions and Working Envelope......................................99
9.2.2 Changing the Operating Ranges of Axes 1 and 2............................103
9.2.3 Changing the Operating Range of Axis 3.........................................105
9.2.4 Changing Software Limits.................................................................111
9.2.5 Coordinate System...........................................................................112
9.2.6 Installing the Robot...........................................................................113
9.3 Precautions for Handling the Teach Pendant................................................114
9.4 Safety Measures...........................................................................................114
10.Installing the Controller (TSL3000)........................................................................115
10.1 External Dimensions.....................................................................................115
10.2 Precautions for Direct Installation .................................................................116
10.3 Rack Mounting Dimensions ..........................................................................117
10.4 Precautions for Assembling the Control Panel..............................................118
11.Installing the Controller (TSL3000E)......................................................................121
11.1 External Dimensions.....................................................................................121
11.2 Precautions for Direct Installation .................................................................122
11.3 Rack Mounting Dimensions ..........................................................................123
11.4 Precautions for Rack Mounting.....................................................................124
12. Installing the Controller (TS3000 and TS3000E)...................................................126
12.1 External Dimensions.....................................................................................126
12.2 Precautions for Direct Installation .................................................................127
12.3 Rack Mounting Dimensions ..........................................................................128
12.4 Precautions for Rack Mounting.....................................................................128
13. System Connections (TSL3000)............................................................................132
13.1 Cable Wiring .................................................................................................132
13.1.1 Connector Arrangement on the Controller........................................132
13.1.2 Connecting the Power Cable "ACIN" (of Fig. 13.1) (Plug connector
attached) ..........................................................................................133
13.1.3 Connecting the Motor Cable "ROBOT" (of Fig. 13.1) (THL300 to
THL1000) .........................................................................................134
13.1.4 Connecting the Encoder Cable "ROBOT" (of Fig. 13.1)...............135
13.1.5 Connecting the Robot Control Signal Cable "ROBOT" (of Fig. 13.1) ....135
13.1.6 Connecting the Brake Signal Cable "ROBOT" (of Fig. 13.1)........135
13.1.7 Connecting the External Input/Output Power Cable "GNDP24V" (of
Fig. 13.1)..........................................................................................136
13.1.8 Connecting and Disconnecting Cables.............................................137
13.1.9 Examples of Connector Terminal Arrangement (Controller side).....139

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13.2 Controller Connector Signals........................................................................141
13.2.1 Connector Signal Connection Diagrams...........................................141
13.2.2 Jumpers for Safety Related Signals .................................................141
14. System Connections (TSL3000E) .........................................................................143
14.1 Cable Wiring .................................................................................................143
14.1.1 Connector Arrangement on the Controller........................................143
14.1.2 Connecting the Power Cable............................................................144
14.1.3 Connecting the Motor Cable/Encorder Cable...................................145
14.1.4 Connecting the Brake Signal Cable and the Robot Control Signal Cable..146
14.1.5 Connecting the External Input/Output Power Cable................................146
14.1.6 Connecting and Disconnecting Cables.............................................147
14.1.7 Examples of Connector Terminal Arrangement (for the TSL3000E) 150
14.2 Controller Connector Signals........................................................................153
14.2.1 Connector Signal Connection Diagrams...........................................153
14.2.2 Jumpers for Safety Related Signals .................................................153
15. System Connections (TS3000 and TS3000E).......................................................155
15.1 Cable Wiring .................................................................................................155
15.1.1 Connector Arrangement on the Controller........................................155
15.1.2 Connecting the Power Cable "ACIN" (of Fig. 15.1) (plug connector
attached) ..........................................................................................156
15.1.3 Connecting the Motor Cable "MOTOR" (of Fig. 15.1) (THL300 to
THL1000) .........................................................................................157
15.1.4 Connecting the Encoder Cable "ENC" (of Fig. 15.1)....................158
15.1.5 Connecting the Robot Control Signal Cable "HAND" (of Fig. 15.1).......158
15.1.6 Connecting the Brake Signal Cable "BRK" (of Fig. 15.1) .............159
15.1.7 Connecting the External Input/Output Power Cable "EMS" (of Fig. 15.1)...159
15.1.8 Connecting and Disconnecting Cables.............................................160
15.1.9 Examples of Connector Terminal Arrangement (Controller Side).....162
15.2 Controller Connector Signals........................................................................165
15.2.1 Connector Signal Connection Diagrams...........................................165
15.2.2 Jumpers for Safety Related Signals .................................................165
15.3 Separating Control Panel from Controller .....................................................167
15.3.1 Removing Control Panel...................................................................167
15.3.2 Cable between Controller and Control Panel (option) ......................167
15.3.3 Control Panel Mounting Dimensions................................................168
15.3.4 Mounting Dummy Panel on Controller (option).................................169
15.3.5 Dimensions when Separating Control Panel....................................170
16. Tool Interface (THL300 and THL400).................................................................171
16.1 Mounting Tool...............................................................................................171

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16.2 Tool Air Piping...............................................................................................172
16.3 Permissible Load Conditions and Program Setting.......................................173
16.3.1 Permissible Load Conditions............................................................173
16.3.2 Load Conditions and Program Setting..............................................174
16.3.3 Setting Maximum Speed and Robot Acceleration/Deceleration for Load
Conditions ........................................................................................178
17. Tool Interface (THL500, THL600 and THL700) ..................................................184
17.1 Mounting Tool...............................................................................................184
17.2 Tool Air Piping...............................................................................................185
17.3 Permissible Load Conditions and Program Setting.......................................186
17.3.1 Permissible Load Conditions............................................................186
17.3.2 Load Conditions and Program Setting..............................................187
17.3.3 Setting Maximum Speed and Robot Acceleration/Deceleration for Load
Conditions ........................................................................................187
18. Tool Interface (THL800, THL900 and THL1000).................................................197
18.1 Mounting Tool...............................................................................................197
18.2 Tool Air Piping...............................................................................................198
18.3 Permissible Load Conditions and Program Setting.......................................199
18.3.1 Permissible Load Conditions............................................................199
18.3.2 Load Conditions and Program Setting..............................................200
18.3.3 Setting Maximum Speed and Robot Acceleration/Deceleration for Load
Conditions ........................................................................................200
19. Tool Interface (TSL3000).......................................................................................210
19.1 Tool Wiring....................................................................................................210
19.2 Tool Signals (Controller Side) .......................................................................221
20.Tool Interface (TSL3000E)....................................................................................225
20.1 Tool Wiring....................................................................................................225
20.2 Tool Signals (Controller Side).......................................................................236
21.Tool Interface (TS3000 and TS3000E)..................................................................240
21.1 Tool Wiring....................................................................................................240
21.1 Tool Signals (Controller Side).......................................................................252

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1. Specifications (THL300 and THL400)
1.1 Correspondence between the Robots and the Robot Controllers
Table 1.1 shows the correspondence between the robots and the robot controllers.
There are several models of robots and controllers. The THL series robots are
compatible with the THL3000, THL3000E, TH3000 and TH3000E robot controllers.
Table 1.1 Correspondence between the Robots and the Robot Controllers
Robot
THL300, THL400
THL500, THL600, THL700
THL800, THL900, THL1000
Robot
controller
TSL3000



TSL3000E



TS3000



TS3000E



: Supported
1.2 Robot Configuration Diagram (TSL3000)
Fig. 1.1 Robot Configuration (TSL3000)
Power source 200V
Power source 24V
Robot unit THL series
Cable between robot
and controller
TSPC
Communication cable
(obtained by customer)
Personal computer
(To be provided by the
customer)
TSPC (option)
TCPRGOS (option)
TP cable
Teach pendant (option)
Robot controller (TSL3000)

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For connection of the 200-volt power source, see "13.1.2 Connecting the Power Cable
"ACIN"". For connection of 24-volt power source, see "13.1.7 Connecting the External
Input/Output Power Cable "GNDP24V"".
1.3 Robot Configuration Diagram (TSL3000E)
Fig. 1.2 Robot Configuration (TSL3000E)
For connection of the 200-volt power source, see "14.1.2 Connecting the Power Cable".
For connection of 24-volt power source, see "14.1.5 Connecting the External
Input/Output Power Cable".
Robot controller (TSL3000E)
Power source 200V
Power source 24V
Personal computer
(To be provided by the
customer)
TSPC (option)
TCPRGOS (option)
TSPC
Communication cable
(obtained by customer)
TP cable
Teach pendant (option)
Robot unit THL series
Cable between robot
and controller

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1.4 Robot Configuration Diagram (TS3000 and TS3000E)
Fig. 1.3 Robot Configuration (TS3000 and TS3000E)
For connection of the 200-volt power source, see "15.1.2 Connecting the Power Cable
"ACIN"". For connection of 24-volt power source, see "15.1.7 Connecting the External
Input/Output Power Cable "EMS"".
Personal computer
(To be provided by the
customer)
TSPC (option)
TCPRGOS (option)
Robot controller (TS3000, TS3000E)
TP cable
THL500/THL600/THL700
Cable between robot and
controller
TSPC communication
cable (To be provided
by the customer)
Operation panel
(separated type; option)
Power source 200V
Power source 24V

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1.5 Name of Each Part
Fig. 1.4 shows the name of each part of the robot (THL300 and THL400).
Fig. 1.4 Name of each part (THL300 and THL400)
For the cable between
the robot and the controller
Arm 1
For the names of the parts on
the rear of Arm 2, see the Arm
2 rear panel.
Battery box
Base
For the names of the parts on
the rear of the base, see the
wiring panel (back of base).
Cover
Ball screw spline
(tool shaft)
Arm 2
Axis 1
(rotation)
Axis 2
(rotation)
Axis 3
(vertical
movement)
Axis 4
(rotation)
One-touch joint
for 3 x 4 mm air tube
D-SUB connector
(Robot control signal)
Arm 2 rear panel
Wiring panel (back of base)
Grommet (spare)
Brake release switch

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1.6 External Dimensions
Fig. 1.5 External dimensions of robot (THL300)
*The example shows the
case of TSL3000.
Multiple cables are used
with other controllers.
Reference planes
Reference planes
4 x 9 mounting hole
Space for cable connection
(The product comes with the air tube.
It needs to be installed by the customer.)
Air coupler for the hand
For 3 x 4 tube
Z-axis stroke

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Fig. 1.6 External dimensions of robot (THL400)
Reference planes
Reference planes
4 x 9 mounting hole
Space for cable connection
(The product comes with the air tube.
It needs to be installed by the customer.)
Air coupler for the hand
For 3 x 4 tube
Z-axis stroke
*The example shows the
case of TSL3000.
Multiple cables are used
with other controllers.

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1.7 Specifications Table
Item
Specifications
Structure
Horizontal multi-joint type SCARA robot
Model
THL300
THL400
Applicable controller
TSL3000, TSL3000E, TS3000, TS3000E
Mass of robot body
12 kg
13 kg
No. of controlled axes
4
Arm length
300 mm
(125 mm + 175 mm)
400 mm
(225 mm + 175 mm)
Motor capacity /
Current limit
Axis 1
200 W / 9.84 A0-P
Axis 2
100 W / 4.89 A0-P
Axis 3
100 W / 4.70 A0-P
Axis 4
100 W / 4.89 A0-P
Operating range
Axis 1
±125 deg
Axis 2
±145 deg
Axis 3
0 to 160 mm
Axis 4
±360 deg
Maximum speed
(*1)
Axis 1
660 deg/s
Axis 2
660 deg/s
Axis 3
1120 mm/s
Axis 4
1500 deg/s
Composite speed of
axes 1 and 2
5.1 m/s
6.3 m/s
Rated payload mass (*1)
2 kg
Maximum payload mass (*1)
5 kg
Permissible load inertia (*1)
0.05 kg･m2
Repeatability (*2)
X,Y
±0.01 mm
Z
±0.015 mm
C
±0.007 deg
Cycle time (*3)
(When payload mass is 2 kg)
0.48 s
0.47 s
Drive system
By means of AC servo motors
Position detection method
Absolute
Paint color (*4)
Arm 2: Equivalent to PANTONE 293C, acrylic paint
Body: White alumite processing
Arm cover: White
Power supply capacity
0.7 kVA
*1: There are restrictions on speed and acceleration speed depending on the operation pattern, load, and offset
amount.
*2: This is unidirectional position repeatability when the ambient temperature is constant at 20C. It is not absolute
positioning accuracy. The values of X, Y and C are what Z value is in upper limit. It does not guarantee the
trajectory accuracy.
*3: The standard cycle operation pattern cannot achieve continuous operation exceeding the effective load rate.
With horizontal direction 300 mm, vertical direction 25 mm round trip, and rough positioning.
*4: The tone may be different among production lots, but it does not affect the product quality.

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!CAUTION
Micro vibration may occur depending on the robot posture. If micro vibration occurs, reduce
the acceleration speed to use the robot.
Put the Z-axis (axis 3) in the raised position as much as possible, when moving Axes 1, 2,
and 4.
Moving Axis 1, 2, or 4 when the Z-axis is in low positions can lead to premature damage to
the ball screw spline (Z-axis shaft).
If Axis 1, 2, or 4 must be moved while the Z-axis is in low positions due to unavoidable
circumstances, prevent the ball screw spline vibrations by using the SPEED,
ACCEL/DECEL, and PAYLOAD commands to adjust the operation speed and
acceleration.
If Axis 1, 2, or 4 is moved while the Z-axis is in low positions, be extremely careful not to
collide with any objects. Even if Axis 1, 2, or 4 is moved at low speed, a collision or other
impact with an object can damage the ball screw spline (Z-axis shaft) before alarm occurs.

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2. Specifications (THL500, THL600 and THL700)
2.1 Correspondence between robot and controller, and equipment configuration
diagram
For the correspondence between robot and controller, and equipment configuration
diagram, see the description of 1.1 through 1.4.
2.2 Name of Each Parts
Fig. 2.1 shows the name of each part of the robot (THL500, THL600 and THL700).