Toshiba TVL Series User manual

STE85441-4
TVL Series
INSTRUCTION MANUAL
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.
April 2014
TOSHIBA MACHINE CO., LTD.
Robot controller TSL3100
Robot controller TSL3100E
Robot controller TS3100

TRANSPORTATION AND INSTALLATION MANUAL
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This manual is applicable to the following robots.
TVL Series : TVL500,TVL700
Copyright 2014 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 notice to effect
improvements.

TRANSPORTATION AND INSTALLATION MANUAL
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Preface
This manual describes the basic specifications of the industrial robot and controller, and
how to unpack and install them. Specifically, it describes how to unpack the shipment
containing the equipment, how to install the equipment, how to connect wiring and air
piping, and how to attach tools. Be sure to look through this manual before unpacking the
shipment.
Before beginning the work according to this manual, read through the Safety Manual so
that you can understand the safety measures.
This manual is divided into the following five (5) sections:
Section 1 Specifications
This section describes the basic specifications and names of respective
units of the robot and controller.
Section 2 Transportation
This section describes how to remove the robot and controller from their
boxes and how to transport them to the installation site. This section
also discusses how to temporarily store the equipment after unpacking
the shipment.
Section 3 to 6 Installation
This section discusses the equipment installation environment, space
requirements, and how to install the equipment.
Section 7 to 9 System Connections
This section describes how to connect the robot, controller and peripheral
equipment.
Section 10 to 13 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 of the actual caution are indicated with pictures or
words in or near the symbol.

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!CAUTION
•Always read through the Safety Manual provided separately before starting
actual work to ensure safety work covering from the robot installation to
operation.
[Installation and transportation]
Always observe the following items to safely use the robot.
!DANGER
Prohibited
•DO NOT install or operate if any parts are damaged or missing.
Doing so could lead to electric shocks, fires or faults.
•DO NOT install the robot where it may be subject to fluids such
as water. Doing so could lead to electric shocks, fires or
faults.
•Do not place the robot near combustible matters. Doing so
could lead to fires if the matter ignites due to a fault, etc.
Mandatory
•Always secure the robot with the attached clamps before
transporting it. Failure to do so could lead to injuries if the arm
moves when the robot is suspended.
•Wire the robot after installation.
Wiring the robot before installation could lead to electric shocks
or injuries.
•Always use the power voltage and power capacity designated
by Toshiba Machine. Failure to do so could lead to device
faults or fires.
•Always use the designated power cable. Using a cable other
than that designated could lead to fires or faults.
Always
ground
•Completely connect the grounding cable. Failure to do so
could lead to electric shocks or fires if a fault or fault current
occurs. Noise could lead to malfunction.
Also, it could cause mis-operation by noise.

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!CAUTION
Prohibited
•NEVER lift the robot by the cable duct or arm 2. Doing so will
apply an excessive force on the robot's mechanism section and
could lead to faults.
•For the controller, secure the ample space for air vent.
Heating of controller could lead to malfunction.
Mandatory
•When lifting the robot, lift it up slowly. The robot will tilt
slightly, so lifting it up suddenly could be hazardous.
•When storing the robot, secure it to the base. The robot will
be unstable if just set down, and it could tilt over.

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Table of Contents
Page
1. Specifications ..............................................................................................11
1.1. Equipment Configuration Diagrams....................................................................11
Equipment Configuration Drawing (For the TSL3100)..............................111.1.1.
Equipment Configuration Drawing (For the TSL3100E) ...........................121.1.2.
Equipment Configuration Drawing (For the TS3100)................................131.1.3.
1.2. Name of Each Part .............................................................................................14
1.3. External Dimensions...........................................................................................15
1.4. Specifications Table............................................................................................17
2. Transportation .............................................................................................19
2.1. Unpacking (for the TSL3100,TSL3100E)............................................................19
2.2. Unpacking (for the TS3100)................................................................................21
2.3. Transportation.....................................................................................................23
Mass and Dimensions..............................................................................232.3.1.
Transporting the Robot.............................................................................242.3.2.
Transporting the Controller.......................................................................272.3.3.
2.4. Storage...............................................................................................................27
Storage Precautions for the Robot ...........................................................272.4.1.
Storage Precautions for the Controller .....................................................272.4.2.
3. Installation of the Robot Body ......................................................................28
3.1. Installation Environment......................................................................................28
3.2. Robot Installation................................................................................................29
External Dimensions.................................................................................293.2.1.
Working Envelope ....................................................................................323.2.2.
Coordinate System...................................................................................353.2.3.
Installing the Robot...................................................................................363.2.4.
3.3. Working Envelope Change.................................................................................38
Change of Axis-1 Working Envelope ........................................................393.3.1.
Change of Axis-2 Working Envelope ........................................................433.3.2.
Change of Axis-3 Working Envelope ........................................................493.3.3.
3.4. Precautions for Handling the Teach Pendant......................................................54
3.5. Safety Measures.................................................................................................54
4. Installing the Controller(In case of TSL3100) ................................................55
4.1. External Dimensions...........................................................................................55
4.2. Precautions for Direct Installation .......................................................................56

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4.3. Installation surface dimensions...........................................................................57
4.4. Cautions for assembling the control panel..........................................................58
5. Installing the Controller (In case of TSL3100E) .............................................61
5.1. External Dimensions...........................................................................................61
5.2. Precautions for Direct Installation .......................................................................62
5.3. Installation surface dimensions...........................................................................63
5.4. Cautions for assembling the control panel..........................................................64
6. Installing the Controller (In case of TS3100) .................................................66
6.1. External Dimensions...........................................................................................66
6.2. Precautions for Direct Installation .......................................................................67
6.3. Installation surface dimensions...........................................................................68
6.4. Precautions for Rack Mounting...........................................................................68
7. System Connections(In case of TSL3100) ....................................................71
7.1. Cable Wiring.......................................................................................................71
Connector Arrangement on the Controller................................................717.1.1.
Connecting the Power Cable “ACIN” ([1] of Fig. 7.1; plug connector7.1.2.
attached)...............................................................................................................72
Connecting the Motor Cable/Encoder Cable ............................................747.1.3.
Connecting the Brake Cable/Robot Control Signal Cable ........................757.1.4.
Connecting Power Supply Cable for External Input/Output "GND, P24V"7.1.5.
([6] in Fig. 7.1).......................................................................................................75
Connecting and Disconnecting Cables.....................................................767.1.6.
Examples of Connector Terminal Arrangement (for the TSL3100) ...........787.1.7.
7.2. Controller Connector Signals..............................................................................82
Connector Signal Connection Diagrams...................................................827.2.1.
Jumpers for Safety Related Signals .........................................................827.2.2.
8. System Connections (In case of TSL3100E) .................................................84
8.1. Cable Wiring.......................................................................................................84
Connector Arrangement on the Controller................................................848.1.1.
Connecting the Power Cable “ACIN” ([1] of Fig. 8.1; plug connector
8.1.2.
attached)...............................................................................................................85
Connecting the Motor Cable/Encoder Cable ............................................878.1.3.
Connecting the Brake Cable/Robot Control Signal Cable ........................888.1.4.
Connecting Power Supply Cable for External Input/Output "GND, P24V"8.1.5.
([6] in Fig. 8.1).......................................................................................................88
Connecting and Disconnecting Cables.....................................................898.1.6.
Examples of Connector Terminal Arrangement (for the TSL3100) ...........928.1.7.
8.2. Controller Connector Signals..............................................................................95

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Connector Signal Connection Diagrams...................................................95
8.2.1.
Jumpers for Safety Related Signals .........................................................958.2.2.
9. System Connections(In case of TS3100) ......................................................97
9.1. Cable Wiring.......................................................................................................97
Connector Arrangement on the Controller................................................979.1.1.
Connecting the Power Cable “ACIN” ([1] of Fig. 9.1; plug connector 9.1.2.
attached)...............................................................................................................98
Connecting the Motor Cable/Encoder Cable ............................................999.1.3.
Connecting the Brake Cable/Robot Control Signal Cable ........................999.1.4.
Connecting Power Supply Cable for External Input/Output "GND, P24V"9.1.5.
([8] in Fig. 9.1......................................................................................................100
Connecting and Disconnecting Cables...................................................1029.1.6.
Examples of Connector Terminal Arrangement (for the TS3100) ...........1049.1.7.
9.2. Controller Connector Signals (for the TS3100).................................................107
Connector Signal Connection Diagrams.................................................1079.2.1.
Jumpers for Safety Related Signals .......................................................1079.2.2.
9.3. When Detaching the Control Panel from the Controller (for the TS3100) .........109
Dismounting the Control Panel...............................................................1099.3.1.
Cables between the Controller and the Control Panel............................1099.3.2.
Installation Dimensions of the Control Panel..........................................1109.3.3.
Mounting the Dummy Panel to the Controller......................................... 1119.3.4.
Dimensions When the Control Panel Is Detached..................................1129.3.5.
10. Tool Interface (Robot Body Side)................................................................ 113
10.1.Mounting Tool ...................................................................................................113
10.2.Tool Air Piping...................................................................................................114
10.3.Permissible Load Conditions and Program Setting...........................................116
Permissible Load Conditions..................................................................11610.3.1.
Load Conditions and Program Setting....................................................11810.3.2.
11. Tool Interface (for the TSL 3100) ................................................................121
11.1.Tool wiring.........................................................................................................121
Tool Signals (Controller Side).................................................................12111.1.1.
Tool Wiring (Robot Arm Side) .................................................................12511.1.2.
12. Tool Interface (for the TSL3100E)...............................................................132
12.1.Tool wiring.........................................................................................................132
Tool Signals (Controller Side).................................................................13212.1.1.
Tool Wiring (Robot Arm Side) .................................................................13612.1.2.
13. Tool Interface (for the TS3100)...................................................................143

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13.1.Tool wiring.........................................................................................................143
Tool Signals (Controller Side).................................................................14313.1.1.
Tool Wiring (Robot Arm Side) .................................................................14713.1.2.

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1. Specifications
1.1. Equipment Configuration Diagrams
The TVL series robots are compatible with the TSL3100 and TS3100 robot controllers.
The equipment configuration drawings of these robot controllers are shown in Fig. 1.1
and Fig. 1.2, respectively.
Equipment Configuration Drawing (For the TSL3100)1.1.1.
Fig. 1.1 Equipment Configuration (TSL3100)
As for the connection method of power supply 200V, see "7.1.2 Connecting the Power
Cable "ACIN"". Again, for the connection method of power supply 24V, see "7.1.5
Connecting Power Supply Cable for External Input/Output".
Robot controller
TSL3100
TP cable
TVL500
Cable between the robot and the
controller
For TSPC6ax
communication
cable (provided
by the customer)
PC (provided by the
customer)
Program support software
TSPC6ax (option)
TCPRGOS (option)
200V power
supply
24V power
supply
RS-232C (cross cable )
or
LAN cable (cross cable)
* The LAN cable is
connected to the rear of the
controller.
Teaching pendant (option)

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Equipment Configuration Drawing (For the TSL3100E)
1.1.2.
Fig. 1.2 Equipment Configuration (TSL3100E)
As for the connection method of power supply 200V, see "8.1.2 Connecting the Power
Cable "ACIN"". Again, for the connection method of power supply 24V, see "8.1.5
Connecting Power Supply Cable for External Input/Output".
TP cable
TVL500
Cable between the robot and the
controller
For TSPC6ax
communication
cable (provided
by the customer)
PC (provided by the
customer)
Program support software
TSPC6ax (option)
TCPRGOS (option)
200V power
supply
24V power
supply
RS-232C (cross cable )
or
LAN cable (cross cable)
Teaching pendant (option)
Robot controller
TSL3100E

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Equipment Configuration Drawing (For the TS3100)
1.1.3.
Fig. 1.3 Equipment Configuration (TS3100)
As for the connection method of power supply 200V, see "9.1.2 Connecting the Power
Cable "ACIN"". Again, for the connection method of power supply 24V, see "9.1.5
Connecting Power Supply Cable for External Input/Output".
24V power supply
(from the rear)
TVL500
Robot controller
TS3100
Operation panel
of detached
specification
(option)
For TSPC6ax
communication
cable (provided
by the customer)
200V power
supply
TP cable
RS-232C (cross cable )
or
LAN cable (cross cable)
PC (provided by the
customer)
Program support software
TSPC6ax (option)
TCPRGOS (option)
Cable between the robot and the
controller
Teaching pendant (option)

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1.2. Name of Each Part
Fig. 1.4 shows the name of each part of the robot of the TVL series.
Fig. 1.4 Name of each part (TVL500)
Base swivel
Arm 1
Axis 1
(rotation)
Axis 3
(rotation)
Axis 2
(rotation)
Base
Arm 2 (1)
Axis 6
(rotation)
Axis 5
(rotation)
Axis 4
(rotation)
Arm 2 (2)
Arm 3
Cable duct
HAND I/O connector
Tool tube joint (4 mm diameter):
4 locations
Tool tube joint
(4 mm diameter):
4 locations
HAND signal/brake
cable connector
Motor power/encoder
cable connector
Grommet for wiring hole

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1.3. External Dimensions
Fig. 1.5 to 1.6 refers to the external dimensions of the TVL500/TVL700.
Fig. 1.5 External dimensions of the TVL500
Dimensions used for cable (60)

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Fig. 1.6 External dimensions of the TVL700
Dimensions used for cable (60)

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1.4. Specifications Table
No
Item
Specifications
Remarks
1
Structure
Vertical multi-joint
2
Model
TVL500
TVL700
3
No. of controlled axes
6
4
Arm length
Total length
500(mm)
700(mm)
Arm 1
260(mm)
400(mm)
Arm 2
240(mm)
300(mm)
Reach
602(mm)
801(mm)
5
Motor capacity /
Current limit
Axis 1
400(W) / 18.1(A0-P)
Axis 2
400(W) / 18.1(A0-P)
Axis 3
100(W) / 4.666(Ao-p)
Axis 4
50(W) / 5.091(Ao-p)
Axis 5
50(W) / 5.091(Ao-p)
Axis 6
50(W) / 5.091(Ao-p)
6
Operating range
Axis 1
±170(deg)
Axis 2
-64~+165(deg)
-90~+165(deg)
Axis 3
-0~+150(deg)
-0~+165(deg)
Axis 4
±190(deg)
Axis 5
±120(deg)
Axis 6
±360(deg)
7
Maximum speed
Axis 1
435(deg/sec)
295(deg/sec)
Note 1)
Axis 2
348(deg/sec)
270(deg/sec)
Axis 3
348(deg/sec)
295(deg/sec)
Axis 4
422(deg/sec)
Axis 5
422(deg/sec)
Axis 6
696(deg/sec)
Maximum
composite
speed
7.98(m/sec)
7.71(m/sec)
8
Payload mass
Rating
1(kg)
Note 1)
Max.
3(kg)(Downward 5 kg)
4(kg)(Downward 5 kg)
9
Standard cycle time
(for 1 kg transportation)
0.3 (sec) unit
0.4 (sec) unit
Note 2)
10
Permissible load
inertia
Axes 4 and 5
0.15(kgm2)
0.09(kgm2)
Note 1)
Axis 6
0.20(kgm2)
0.10(kgm2)
11
Repeatability
X-Y-Z
±0.02(mm) Each
component
±0.03(mm) Each
component
Note 3)
12
Drive system
TSL3100/TSL3100E/TS3100
13
Power supply capacity
1.5(kVA)
14
Robot body
Mass
28(kg)
31(kg)
Color
White/blue
Note 4)
Note 1: The speed and acceleration are limited in accordance with the operation pattern, the load
mass, and the offset value.
Note 2: Continuous operation cannot be performed if the effective load factor of the standard cycle
operation pattern is exceeded.
When carrying 1kg, with horizontal direction 300 mm, vertical direction 25 mm round-trip, and
rough positioning

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Note 3: Repeatability in one direction at a constant ambient temperature of 20C
Note 4: The color and surface treatment of the robot body may differ according to each production lot.
Please note that there is no problem in the very nature of the product quality.

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2. Transportation
2.1. Unpacking (for the TSL3100,TSL3100E)
For the TS3100, please see 2.2, "Unpacking (for the TS3100)."
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.
For the accessories, see the accessory list that comes with the controller.
Corrugated
cardboard
Cables
Teach pendant
(option)
Wooden pallet
Robot body (actuator)
packed in a polyethylene
shipping bag.
Controller
Instruction manuals

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Fig. 2.1 Packaging state (TSL3100)
!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.
Corrugated cardboard
(external box)
Styrene foam
cushions
Controller
ラ