Toshiba TV800 User manual

STE 80745–2
TV800
TV1000/TS3100
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.
December 2008
TOSHIBA MACHINE CO., LTD.

TRANSPORTATION AND INSTALLATION MANUAL
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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TRANSPORTATION AND INSTALLATION MANUAL
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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TRANSPORTATION AND INSTALLATION MANUAL
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 of the actual caution are indicated with pictures or
words in or near the symbol.
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TRANSPORTATION AND INSTALLATION MANUAL
!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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TRANSPORTATION AND INSTALLATION MANUAL
!CAUTION
Prohibited
• NEVER lift the robot by the arm 1 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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TRANSPORTATION AND INSTALLATION MANUAL
Table of Contents
Page
1. Specifications............................................................................................................9
1.1 Name of Each Part ..........................................................................................9
1.2 External Dimensions......................................................................................10
1.3 Specifications Table.......................................................................................12
2. Transportation.........................................................................................................13
2.1 Unpacking......................................................................................................13
2.2 Transportation ...............................................................................................15
2.2.1 Mass and Dimensions.......................................................................15
2.2.2 Transporting the Robot......................................................................16
2.2.3 Transporting the Controller................................................................18
2.3 Storage..........................................................................................................19
2.3.1 Storage Precautions for the Robot....................................................19
2.3.2 Storage Precautions for the Controller..............................................19
3. Installation ..............................................................................................................20
3.1 Installation Environment ................................................................................20
3.2 Robot Installation...........................................................................................21
3.2.1 External Dimensions .........................................................................21
3.2.2 Working Envelope.............................................................................24
3.2.3 Coordinate System............................................................................27
3.2.4 Installing the Robot............................................................................28
3.3 Mechanical End Change................................................................................29
3.3.1 Change of Axis-1 Mechanical Ends...................................................30
3.3.2 Change of Axis-2 and Axis-3 Mechanical Ends.................................34
3.4 Installing the Controller..................................................................................45
3.4.1 External Dimensions .........................................................................45
3.4.2 Precautions for Direct Installation......................................................46
3.4.3 Rack Mounting Dimensions...............................................................47
3.4.4 Precautions for Rack Mounting .........................................................47
3.5 Precautions for Handling the Teach Pendant ................................................49
3.6 Safety Measures............................................................................................50
4. System Connections...............................................................................................51
4.1 Cable Wiring..................................................................................................51
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4.1.1 Connector Arrangement on the Controller.........................................51
4.1.2 ConnectingthePowerCable“ACIN”(cofFig.4.1;plugconnectorattached)........52
4.1.3 ConnectingtheMotorCable“CN21”(dofFig.4.1)(Cableattached) ..................53
4.1.4 ConnectingtheEncoderCable“CN20”(eofFig.4.1)(Cableattached)...............54
4.1.5 ConnectingtheRobotControlSignalCable“CN20”(f.hofFig.4.1)(Cable:option)..54
4.1.6 Connecting and Disconnecting Cables..............................................54
4.1.7 Examples of Connector Terminal Arrangement.................................56
4.2 Controller Connector Signals.........................................................................59
4.2.1 Connector Signal Connection Diagrams ...........................................59
4.2.2 Jumpers for Safety Related Signals..................................................59
4.3 Separating Control Panel from Controller......................................................61
4.3.1 Removing Control Panel ...................................................................61
4.3.2 Cable between Controller and Control Panel ....................................61
4.3.3 Control Panel Mounting Dimensions.................................................62
4.3.4 Mounting Dummy Panel on Controller...............................................63
4.3.5 Dimensions when Separating Control Panel.....................................64
5. Tool Interface..........................................................................................................65
5.1 Mounting Tool................................................................................................65
5.2 Tool Wiring and Piping...................................................................................66
5.2.1 Tool Signals (Controller Side)............................................................66
5.2.2 Tool Wiring........................................................................................70
5.2.3 Tool Air Piping...................................................................................75
5.3 Permissible Load Conditions and Program Setting........................................76
5.3.1 Permissible Load Conditions.............................................................76
5.3.2 Load Conditions and Program Setting...............................................77
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Tables and Drawings
Page
Fig. 1.2 External dimensions of the TV800 .........................................................................10
Fig. 1.3 External dimensions of the TV1000 .......................................................................11
Fig. 2.1 Packaging state......................................................................................................14
Fig. 2.2 Outer dimensions at transport................................................................................15
Fig. 2.3 Lifting up the robot..................................................................................................16
Fig. 2.4 Robot handling areas............................................................................................. 17
Table 3.1 Environmental conditions for robot and controller...............................................20
Fig. 3.1 External view TV800 ..............................................................................................22
Fig. 3.2 External view TV1000 ............................................................................................23
Fig. 3.3 Working envelope TV800.......................................................................................25
Fig. 3.4 Working envelope TV1000.....................................................................................26
Fig. 3.5 Base coordinate system and joint angle origin.......................................................27
Fig. 3.6 Setting method....................................................................................................... 28
Fig. 3.7 Axis-1 mechanical end setting................................................................................ 30
Fig. 3.8 Factory-set mechanical stopper............................................................................. 31
Fig. 3.9 Mechanical stopper location (at the base)..............................................................31
Fig. 3.10 Example of changing axis-1 mechanical ends .....................................................32
Fig. 3.11 Example of changing mechanical stoppers (reference) .......................................33
Table 3.2 Factory-set working angles .................................................................................34
Fig. 3.12 Axis-2 mechanical stopper reference drawing......................................................35
Fig. 3.13 Axis-3 mechanical stopper reference drawing......................................................36
Fig. 3.14 Example of changing axis-2 mechanical ends (1)................................................ 37
Fig. 3.15 Example of changing axis-2 mechanical ends (2)................................................ 39
Fig. 3.16 Example of changing axis-3 mechanical ends (1)................................................ 41
Fig. 3.17 Example of changing axis-3 mechanical ends (2)................................................ 43
Fig. 3.18 External view of controller ....................................................................................45
Fig. 3.19 Controller ventilation space.................................................................................. 46
Fig. 3.20 Screw hole dimensions for securing controller.....................................................47
Fig. 3.21 Removing upper cover .........................................................................................48
Fig. 3.22 Clearance of controller front side .........................................................................49
Fig. 4.1 Robot controller connector arrangement................................................................ 51
Table 4.1 Power supply specifications................................................................................ 52
Fig. 4.2 Robot side connector arrangement........................................................................53
Fig. 4.3 Connecting and disconnecting a circular connector...............................................55
Fig. 4.4 Connecting and disconnecting a square connector ...............................................55
Fig. 4.5 Removing control panel.......................................................................................... 61
Fig. 4.6 Control panel mounting dimensions.......................................................................62
Fig. 4.7 Mounting dummy panel..........................................................................................63
Fig. 4.8 Cable connections of dummy panel and control panel........................................... 64
Fig. 5.1 Tool mounting dimensions .....................................................................................65
Fig. 5.2 Wiring to PLC, etc. .................................................................................................71
Fig. 5.3 Tool wiring.............................................................................................................. 73
Table 5.1 CN22 Cable (option) list...................................................................................... 73
Fig. 5.4 Internal connection diagram................................................................................... 74
Fig. 5.6 Tool air piping.........................................................................................................75
Table 5.2 Permissible load conditions.................................................................................76
Fig. 5.7 Robot tool............................................................................................................... 77
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1. Specifications
1.1 Name of Each Part
Fig. 1.1 shows the name of each part of the robot.
Axis 2
(rotation)
Axis 3
(rotation)
Arm 1
Arm 1 duct
Arm 2 (1) Axis 4 (rotation)
Arm 2 (2)
Arm 3
Axis 5
(rotation)
Base swivel
Axis 6
(rotation) Base
Axis 1
(rotation)
Standard panel Tool tube joint (6mm diameter): 3 locations
Tool tube joint (6mm
diameter): 3 locations
Spare:
1 location
External I/O
(grommet)
I/O connector（CN22）
Optional panel
(optional solenoid valve) Connector
(CN20) for
encoder
cable/control
signal cable
Motor drive
cable
connector
(CN21)
Air manifold for tool Fig. 1.1 Name of each part
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I/O connector
（CN22）

TRANSPORTATION AND INSTALLATION MANUAL
1.2 External Dimensions
Fig. 1.2 and Fig. 1.3 refers to the external dimensions of the robot.
Connector panel for hand
Fig. 1.2 External dimensions of the TV800
180
Dimensions used for cable
connections
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TRANSPORTATION AND INSTALLATION MANUAL
Connector panel for hand
Fig. 1.3 External dimensions of the TV1000
180
Dimensions used for cable
connections
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1.3 Specifications Table
Item Specifications
Structure Vertical multi-joint 6-axis robot
Model TV800 TV800-BL TV1000 TV1000-BL
Applicable controller TS3100
Mass of actuator 45.5kg 47kg
No. of controlled axes 6
Arm length 800mm (380mm + 420mm)
Reach: 892mm 1000mm (480mm + 520mm) Reach: 1090mm
Axis 1 ±170 (deg)
Axis 2 +150 to -100 (deg)
Axis 3 +167 to -127 (deg)
Axis 4 ±190 (deg)
Axis 5 ±120 (deg)
Operating
range
Axis 6 ±360 (deg)
Axis 1 237 (deg/s)
Axis 2 240 (deg/s)
Axis 3 288 (deg/s)
Axis 4 350.5 (deg/s)
Axis 5 484 (deg/s)
Axis 6 576 (deg/s)
Maximum
speed *2
Maximum
composite
speed 8058 (mm/s) 9610 (mm/s)
Rated payload mass 2 (kg)
Maximum payload mass 5 (kg)
Maximum allowable inertia
moment around axes 4 and
5 0.3 (kg•m2) *1
Maximum allowable inertia
moment around axis 6 0.05 (kg•m2) *1
Repeatability X, Y, Z ±0.02 (mm) *2 ±0.03 (mm) *2
Cycle time *3 0.4 (sec) unit 0.6(sec) unit
Drive system AC servomotor
All axes with a
motor brake
AC servomotor
Axes 1, 4, and 6
with no motor
brake*4
AC servomotor
All axes with a
motor brake
AC servomotor
Axes 1, 4, and 6
with no motor
brake*4
Position detection method Absolute
*1: The speed and acceleration are limited in accordance with the operation pattern, the load mass, and the
offset value.
*2: In environment in which the ambient temperature is constant
*3: Continuous operation cannot be performed if the effective load factor of the standard cycle operation
pattern is exceeded.
Shuttle time for rough positioning in horizontal direction of 300 mm and vertical direction of 25 mm
*4: Theaxes2,3,and5areequippedwithamotorbrake.
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TRANSPORTATION AND INSTALLATION MANUAL
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.
Corrugated
cardboard
Controller
Teach pendant
Wooden pallet
Robot body (actuator)
packed in a
polyethylene shipping
bag.
Instruction manuals
Cables
Accessories included in the instruction
manuals
System floppy disk: 3 pcs.
CD-ROM for TCPRGOS (option): 1 pc.
CD-ROM for TSPC6axis (option): 1 pc.
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Corrugated cardboard
(external box)
Styrene foam
cushions
Controller
Corrugated cardboard
(bottom plate)
Accessories included in the controller package
EMS dummy connector: 1 pc.
SYSTEM dummy connector: 1 pc.
TP dummy connector: 1 pc.
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.
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TRANSPORTATION AND INSTALLATION MANUAL
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.
For the mass and outer dimensions of the controller, see Fig. 3.18 of Para. 3.4.1.
Joint
A
ngle (deg.) Joint
A
ngle (deg.)
Fixed jig
Lifting jig
Mass of robot body
(including jigs shipped)
47 kg (48.5 kg)
Fig. 2.2 Outer dimensions at transport

TRANSPORTATION AND INSTALLATION MANUAL
2.2.2 Transporting the Robot
In principle, the robot should be transported in the state shown in Fig. 2.2 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.)
!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.
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. 2.3.
Wire
Fig. 2.3 Lifting up the robot
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!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.
DO NOT hold the arms 2 and 3.
Handlin
g
areas
Handlin
g
areas
Fig. 2.4 Robot handling areas
After the installation, remove the clamp and eyebolt used for transport.
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!CAUTION
•Do not remove the fixing brackets when transporting the
TV800-BL/TV1000-BL. Doing so can cause the rotation of the axes with
no motor brake.
• When lifting up the robot by workers, hold the locations (arrowed parts) by
hands as shown in Fig. 2.4. If the arm 2 and arm 3 are held by hands, an
unusually large force is exerted, resulting in a malfunction.
• When carrying the robot by workers, take careful precautions to prevent
their hand or leg from being caught in the robot.
• Do not hold the arm-1 duct cover when handling the robot. Otherwise, it
will be deformed.
• The work should be performed by three or more workers.
2.2.3 Transporting the Controller
Disconnect all cables and teach pendant before transporting the controller.
!DANGER
• When placing the controller on the floor, etc., make sure not to have your
hands or feet caught.
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2.3 Storage
Avoid storing the robot and controller for long periods of time after unpacking them. If
this is unavoidable, however, strictly observe the following precautions for storage.
2.3.1 Storage Precautions for the Robot
!CAUTION
• Secure the base completely to prevent the robot from falling over. When
placed directly on the floor, the robot is unstable and will fall over.
• Keep the robot out of direct sunlight. The timing belts and resin covers
may deteriorate.
• Seal the robot in a vinyl bag to prevent rust development and contaminant.
Put a desiccant in the bag to absorb moisture.
• Before starting an operation, perform running completely.
• During storage, the life of the backup batteries will shorten. It is
recommended to replace the batteries at the time of operation.
2.3.2 Storage Precautions for the Controller
!CAUTION
• Keep the controller out of direct sunlight. Otherwise, the controller interior
will be excessively heated up, causing a trouble.
• Seal the controller in a vinyl bag to prevent rust development and
contaminant. Put a desiccant in the bag to absorb moisture.
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