Toshiba TVL Series User manual

STE85440-4
TVL Series
INSTRUCTION MANUAL
MAINTENANCE 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

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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.

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WARRANTY
This machine is delivered to each customer only after it is inspected very carefully to make
sure that it satisfies the Toshiba Machine’s standard. Should it cause an inconvenience,
we will guarantee as described below.
1. Warranty period
Toshiba Machine agrees to repair or replace as necessary all defective material or
workmanship up to the period shown below, whichever comes first.
1) Eighteen (18) months from the date of dispatch from our plant.
2) Twelve (12) months from the date of machine installation at customer’s job site.
3) 2,400 running hours from the date of initial machine operation.
2. Contents of warranty
1) Only the product delivered to the customer is subject to Toshiba Machine’s
Guarantee. Such Guarantee covers the specifications and functions as defined
in the product specifications manual, catalog, instruction manual, etc. In no
event does the Guarantee cover any damage caused by malfunction of the
delivered product.
2) Toshiba Machine repairs the product free of charge only when it malfunctioned
after handling or use according to the instruction manual attached to the product
within the specified warranty period.
3. Exemption from responsibility
Toshiba Machine’s Guarantee shall not cover the following cases.
1) Incorrect use not described in the instruction manual, and trouble or damage
caused by negligent use.
2) Inconvenience caused by aged deterioration or long-term usage (natural fading of
coating or painting, deterioration of consumable parts (*1), etc.).
3) Inconvenience caused by sensuous phenomena (noise generation, etc. which will
not affect the function).
4) Remodeling or disassembly which Toshiba Machine will not permit.
5) Trouble and damage caused by insufficient maintenance/inspection or improper
repair.

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6) Trouble and damage caused by disaster, fire or other external factor.
7) Internal data such as program and point which were created by the customer.
8) When the robot purchased in Japan was shipped overseas.
4. Precautions
1) Unless the robot was used pursuant to its specifications, Toshiba Machine will not
guarantee the basic performance of the robot.
2) If the customer did not observe the warnings and cautions described in this
manual, Toshiba Machine will not assume the responsibility for any consequential
accident resulting in injury or death, damage or trouble.
3) Please note that the warnings, cautions and other descriptions stipulated in this
manual are only those which can be assumed by Toshiba Machine as of now.
(*1) The consumable parts signify the replacement parts for maintenance as listed in Section
7 of this manual.

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INTRODUCTION
This manual describes the TVL500/TVL700 industrial robot and TSL3100 controller,
TSL3100E and TS3100.
The maintenance and inspection are essential to maintain the robot performance for long
years to prevent a trouble and improve the safe work.
Before starting an actual operation, it is strongly recommended to read through this manual
and draw up a maintenance schedule.
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 assure 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
This means that "incorrect handling will lead to fatalities or
serious injuries."
This means that "incorrect handling will lead to fatalities or
serious injuries."
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 medical treatment.
*2) Physical damage refers to damages due to destruction of assets or resources.
DANGER
!
WARNING
!
CAUTION
!

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[Explanation of symbols]
Symbol
Meaning of symbol
This means that the action is prohibited (must not be done).
Details of the actions actually prohibited are indicated with pictures
or words in or near the symbol.
This means that the action is mandatory (must be done).
Details of the actions that must be done are indicated with pictures
or words in or near the symbol.
This means danger and caution.
The details of the actual caution are indicated with pictures or
words in or near the symbol.
[Maintenance and inspection]
Be sure to observe the following items to use the robot safely.
!DANGER
Prohibited
•DO NOT incinerate, disassemble or charge the batteries.
Otherwise, they may rupture.
Mandatory
•Be sure to turn off the main power switch of the controller
before starting inspection or maintenance.
•Batteries should be disposed of according to the user's
in-house regulations.
!CAUTION
Disassembly
prohibited
•The user must NEVER replace or modify parts other than those
described in the instruction manual. Otherwise, the
performance may deteriorate or faults or accidents will be
caused.
Mandatory
•Always use the Toshiba Machine's designated spare parts
when replacing the parts.
•Maintenance and inspection should be performed regularly.
Otherwise, the system may malfunction or accidents will be
caused.

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Table of Contents
Page
1. Maintenance...........................................................................................................10
Maintenance Schedule ..................................................................................101.1
Items for Maintenance and Inspection...........................................................111.2 1.2.1 Inspection at Power OFF (at Non-Operation)....................................11
1.2.2 Inspection at Power ON (at Operation) .............................................12
1.2.3 Overhaul............................................................................................12
Maintenance Tools ........................................................................................131.3
Maintenance Contract and Repair.................................................................131.4 1.4.1 Maintenance Contract.......................................................................13
1.4.2 Repair................................................................................................13
1.4.3 Modification.......................................................................................14
2. Maintenance of the Main Robot..............................................................................15
Cautions on Maintenance and Inspection......................................................152.1 2.1.1 Clamping Hexagon Socket Head Cap Screws..................................15
TVL500/TVL700 Structure and Components.................................................172.2
Details of Inspection ......................................................................................182.3 2.3.1 Check of Each Bolt (or Screw) for Clamping.....................................18
2.3.2 Checking the cable clamp for looseness...........................................19
Dismounting and Mounting Each Cover ........................................................202.4 2.4.1 Base Covers......................................................................................21
2.4.2 Base Swivel Cover............................................................................21
2.4.3 Arm-2 (1) Cover ................................................................................22
2.4.4 Arm-2 (2) Covers...............................................................................23
2.4.5 Arm-3 Cover......................................................................................23
Replacing Position Detector (or Encoder) Batteries.......................................242.5 2.5.1 Battery Unit Location.........................................................................25
2.5.2 Replacing Batteries...........................................................................25
2.5.3 Battery Error Code ............................................................................26
3. Maintenance of Controller (In case of TSL3100) ....................................................28
Cautions on Maintenance and Inspection......................................................283.1
Layout of Controller Parts..............................................................................293.2
Maintenance Procedures...............................................................................303.3 3.3.1 Check of Controller Air Vent Holes....................................................30
3.3.2 Check of Safety Devices for Function ...............................................31

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3.3.3 Battery Replacement.........................................................................33
3.3.4 Replacement of Switching Power Supply Unit ..................................35
3.3.5 Replacement of Fuse (X8YX Printed Board Installed).......................40
3.3.6 Replacement of Output ICs (X8YX Printed Board Installed) .............41
4. Maintenance of Controller (In case of TSL3100E)..................................................45
Cautions on Maintenance and Inspection......................................................454.1
Layout of Controller Parts..............................................................................464.2
Maintenance Procedures...............................................................................474.3 4.3.1 Check of Controller Air Vent Holes....................................................47
4.3.2 Check of Safety Devices for Function ...............................................48
4.3.3 Battery Replacement.........................................................................50
4.3.4 Replacement of Switching Power Supply Unit ..................................52
4.3.5 Replacement of Fuse (X8YJ Printed Board Installed).......................57
5. Maintenance of Controller (In case of TS3100) ......................................................59
Cautions on Maintenance and Inspection......................................................595.1
Controller Component Layout........................................................................605.2
Maintenance Procedure.................................................................................615.3 5.3.1 Checking the Status of the Controller's Air Vent Holes .....................61
5.3.2 Checking the Safety Device Function................................................62
5.3.3 Battery Replacement.........................................................................65
5.3.4 Replacement of Switching Power Supply Unit ..................................68
5.3.5 Replacement of Fuse........................................................................69
5.3.6 Replacement of Output ICs (X8GC and X8GN (X8GI) Printed Boards)71
6. Robot Home Point and Position Detector Error ......................................................74
Setting Robot Home Point .............................................................................746.1
Position Detector Error ..................................................................................756.2
Restoring Operation from Position Detector Error .........................................786.3 6.3.1 Encoder status screen.......................................................................78
6.3.2 Encoder Error Reset Operation.........................................................79
Restoring Home Position Data by HOME Function .......................................806.4 6.4.1 Outline of HOME Function ................................................................80
6.4.2 Setting HOME1 and HOME2.............................................................81
6.4.3 How to Restore Data by HOME1 or HOME2.....................................82
6.4.4 Locations of Robot Home Point Match-Marks...................................83
6.4.5 How to Restore Data by HOME3 or HOME4.....................................84
Restoring Home Position Data by ZEROP Function......................................846.5

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6.5.1 Preparation before Restoring Operation............................................85
6.5.2 Setting New Home Position Data......................................................86
6.5.3 Confirming Home Position.................................................................87
6.5.4 Saving Data.......................................................................................88
Restoring Home Position Data by Multi-Turn Data Clear...............................896.6
Axis Operation in Manual Mode.....................................................................896.7
7. Replacement Parts for Maintenance.......................................................................91
Notes on Replacement Parts for Maintenance ..............................................917.1
List of Replacement Parts –Main Robot (TVL500/TVL700)..........................927.2
List of Replacement Parts –Controller (for the TSL3100) .............................92
7.3
List of Replacement Parts –Controller (for the TSL3100E)...........................937.4
List of Replacement Parts for Maintenance –Controller (for the TS3100).....937.5
Servo Amplifier Corresponding Table............................................................947.6

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1. Maintenance
Maintenance Schedule1.1
Maintenance comes in the two (2) types: daily inspection, and regular inspection and
maintenance. For the regular inspection and maintenance, inspection items are
added every 1,200 running hours.
3-month
check
3-month
check
3-month
check
3-month
check
1-year
check
3-month
check
3-month
check
3-month
check
6-month
check
6-month
check
6-month
check
6-month
check
1-year
check
Overhaul
(every 5 years)
Daily inspection
Running hours
(h)
0
1200
2400
4800
3600
6000
7200
8400
9600
24000
(h)
3-month
check
2-year
check
Inspection schedule
•When the system is operated for 16 hours per day:
1,200 hours 16 hours 25 days = 3 months
•When the system is operated for 24 hours per day:
1,200 hours 24 hours 25 days = 2 months
When the system is operated for 16 hours per day, regular inspection should be
conducted every three (3) months. However, if the running hours per day are
increased, regular inspection must be done at shorter intervals.

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Items for Maintenance and Inspection
1.2
This section describes the items for maintenance and inspection.
For the executing procedures, see the relevant paragraph listed in the table below.
1.2.1 Inspection at Power OFF (at Non-Operation)
D: Daily inspection Q: Quarterly inspection
S: Semi-annual inspection A: Annual inspection
Description
Check position
D
Q
S
A
Refer to
Make sure that all bolts
are completely tightened
and secured. Otherwise,
tighten the bolts
completely.
Tool set bolts
[1]
[1]
[1]
[1]
Para.
2.3.1
Robot installation bolts
[1]
[1]
[1]
[1]
Bolts for each joint
reduction gear

Motor set bolts

Check if the cable clamp
is loosened or not.
Base cable clamp
[1]
[1]
[1]
[1]
Para.
2.3.2
Make sure that no cut or
scratch is found. Clean
the contaminant, if any.
Entire robot
[1]
[1]
[1]
[1]
Make sure that each
timing belt is not worn off
or cracked. Check each
timing belt for tension.
Inside of arm 2 (1)


Inside of arm 2 (2)


Make sure that the cables
and air tubing are not
worn out.
Cables and air tubing of
each unit



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1.2.2 Inspection at Power ON (at Operation)
D: Daily inspection Q: Quarterly inspection
S: Semi-annual inspection A: Annual inspection
B: Biennial inspection
Description
Check position
D
Q
S
A
B
Refer to
Using the TP in the servo
ON condition, make sure
that each axis moves
normally in the jog mode.
Entire robot



Push each arm by hand in
the servo ON condition to
make sure that the arm is
secured.
Each joint


Make sure that no abnormal
vibration or noise is caused.
Entire robot
[1]
[1]
[1]
[1]
[1]
Make sure that the teaching
points are in place.
Entire robot
[1]
[1]
[1]
[1]
[1]
Replace the batteries for
position detection with new
ones.
Base swivel unit
[1]
Para.
2.5.2
1.2.3 Overhaul
Description
Maintenance parts
Every 5
years
Refer to
Check for the consumable parts
and replace as necessary.
Reduction gears,
motors, belts, harness
●
Replace the battery with a new
one.
Backup battery in the
controller
[1]
Replace the switching power
supply unit with a new one.
In the controller
[1]
Note: The items marked “●” may include some technical work.
It is difficult for the customer to implement such work, so please ask Toshiba
Machine Service Department.

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!CAUTION
•If inspection is to be performed in the power ON state (during operation), carry
it out carefully while making sure of safety.
Maintenance Tools1.3
We recommend to use the following tools for maintaining the robot and controller.
•Phillips screwdrivers: #1 ~ #2
•Hexagonal wrench set: M3 ~ M10
•Torque wrench set: M3 ~ M10
Recommended provisions other than the tools:
•Waste cloth
•TSPC6ax (for axis 6) program creation/teaching support software (option)
Maintenance Contract and Repair1.4
1.4.1 Maintenance Contract
Some of semi-annual and longer-term inspection items of mechanical components for
which is marked in the above tables need special technical work. Do not attempt
to carry out the work, and ask Toshiba Machine Service Department to deal with the
inspection items. We recommend that the user contact Toshiba Machine Service
Department and conclude an after-sale service contract with us.
1.4.2 Repair
If a fault has occurred or if repair is necessary, turn off the controller power and
contact the Toshiba Machine Service Department. At this time, advise us of the
details of the fault and the following information stated on the robot and controller.
•Robot model
•Manufacture number
•Date of manufacture of controller
•Date of manufacture of robot
•Running hours

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For the manufacture number and date of manufacture, see the following labels
attached to main base of the robot.
1.4.3 Modification
The robot and controller MUST NOT be modified or disassembled without a prior
consent from Toshiba Machine.
!CAUTION
•The user must NEVER replace or modify parts other than those described in
the instruction manual. Otherwise, the performance may deteriorate or faults
or accidents will be caused.

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2. Maintenance of the Main Robot
Cautions on Maintenance and Inspection2.1
When performing inspection or maintenance of the robot, strictly observe the
following precautions to protect yourself and coworkers.
!DANGER
•Be sure to turn off the main power of the controller before approaching the robot
for maintenance and inspection.
•If inspection/maintenance is to be performed in the power ON state, carry it out
carefully while making sure of safety.
2.1.1 Clamping Hexagon Socket Head Cap Screws
This robot uses hexagon socket head cap screws at places requiring mechanical
strength. At the time of factory-assembly, screw locking adhesives are applied and
each screw is tightened with the following clamping torque.
When these screws are tightened again according to the inspection and maintenance
as stipulated in this manual, use a torque wrench, etc. to assure the appropriate
clamping torque.
Screw
M3
M4
M5
M6
M8
M10
Clamping torque
2.0 N·m
4.7 N·m
9.0 N·m
15 N·m
37 N·m
75 N·m

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For the screws arranged on a circle, tighten them in the diagonal order, as shown
below.
DO NOT tighten one (1) screw at a time. Tighten each screw in multiple steps, using
a hexagonal wrench key, and secure with appropriate clamping torque by means of a
torque wrench.
1
8
7
6
5
4
3
2

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TVL500/TVL700 Structure and Components
2.2 * In this instruction manual, the diagrams of the TVL500 robot are used for the
explanation.
Fig. 2.1 Robot Structure and Components
Arm 2 (1)
Base
Arm 1
Arm 3
Base swivel
Arm 2 (2)
Cable duct

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Tool flange
Details of Inspection
2.3
2.3.1 Check of Each Bolt (or Screw) for Clamping
(1) Tool Set Bolts
Make sure, using the hexagonal wrench key, that the hexagon socket head cap
screws of the tool set flange, which are securing the arm 3 are tightened
completely. If loosened, tighten them completely.
Make sure, using the hexagonal wrench key, that the hexagon socket head cap
screws securing the tool flange and tool are tightened completely. Otherwise,
tighten them completely.
Fig. 2.2 Tool set bolts
Tool set bolt
M5 x 4 pcs.; Recommended
clamping torque 9.0 N·m
Tool flange clamp bolt
M3 x 8 pcs.; Recommended
clamping torque 2.0 N·m
Tool

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(2) Robot Installation Bolts
Make sure, using the hexagonal wrench key, that the installation bolts of the
main robot base are tightened completely. If loosened, tighten them
completely.
Fig. 2.3 Robot base set bolts
2.3.2 Checking the cable clamp for looseness
Check if the cable clamp connected to the base of the robot body is loosened or not.
Fig. 2.4 Cable clamp at the base
Main robot installation bolt
M10 x 4 pcs.; Recommended
clamping torque 75 N·m
Check if the cable clamp is
loosened or not.
Check whether the cable clamp of
the controller side is locked properly.

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Dismounting and Mounting Each Cover
2.4
This paragraph describes the dismounting and mounting of the covers, which are
common to the maintenance and replacement of each unit.
!DANGER
•When opening the cover, take careful precautions not to allow entry of moisture
or contaminant into the robot. If the power is turned on while moisture or
contaminant is left, you may get an electric shock or the robot may malfunction,
which is very dangerous. If moisture or contaminant has got into the robot,
remove it thoroughly.
!CAUTION
•When mounting the covers, take careful precautions not to catch any cable in it.
If the cable is bent and pushed by force, it will be broken. The cables are
secured to the plates (sheet metal) with cable straps; therefore, it is
recommended to take pictures beforehand so that where to route the cables and
where to use the cable straps are identifiable in restoration work.
•Run the cables along the original route without any change. Forced bending or
strapping shortens the service life of cables.