Toyo Single Axis Series User manual

Installation Manual
Toyo Single Axis Series
www.toyorobot.com
VER.E-201401

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Chapter
Content
Page
1.
General Safety Precaution
2
1-1
Symbol used within the chapter
2
1-2
Essential caution items
3
1-3
Safety function required for the actuator
7
1-4
Safety measure of the system
8
1-5
Trial run
9
1-6
When working inside the safeguard enclosure
10
1-7
Automatic operation
11
1-8
Adjustment and inspection
12
1-9
Repair and modification
13
2.
Warranty
14
3.
Part’s Name
15
4.
Installation
16
4-1
Transportation
16
4-2
Installation environment and base requirement
17
4-3
Driver motor assembly
18
4-4
Installation
28
5.
Inspection and Maintenance
30
5-1
Inspection and maintenance frequency
31
5-2
Applying grease
33
5-3
Replacing and adjusting the dust proof plate
35
5-4
Consumable
37
6.
Trouble Shooting
38
6-1
When there is noise during operation
38
6-2
When actuator does not operate
40
Index

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In order to use TOYO’s product safely and correctly, please make sure to read
through with correct understanding of the content of the entire manual and the
general safety precaution before using or installation of the actuator.
The main purpose of this manual is to prevent personal injury or damage of
the actuator and equipment, please follow the instructions listed and take notes
on all of the warning and caution.
1-1 Symbol used within the chapter
WARNING
Fail to follow the WARNING instruction may cause severe injury and
serious threat endangering the life to the personals around the
actuator.
DANGER
Fail to follow the DANGER instruction will cause severe injury and
serious threat endangering the life to the personals around the
actuator.
CAUTION
Fail to follow the WARNING instruction may cause severe injury to the
personals around the actuator and the damage to the actuator or
equipment.
It is not possible to list all of the safety measures while
operating/installing around the robot. Apart from following the safety
instruction, please go through the entire manual to build a full knowledge of the
safety rules in order to make correct judgments when around the robot.
1.General Safety Precaution

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1-2 Essential caution items
Particularly important cautions for handling or operating the actuator are
described below. In addition, safety information for installation, operation,
inspection and maintenance are listed in the related chapter of this manual,
please comply the safety measures for safe use of the robot.
a) Automatic operation
DANGER
Severe injury and serious threat endangering the life will occur if impact with
moving parts.
Install a safeguard (protective enclosure), which covers the entire
movement range of the actuator, to avoid anyone entering. This is to
prevent anyone suffering from injury due to being stuck by moving parts.
Install a safety interlock that triggers emergency stop when the door or
panel is opened.
Install safeguards so that no entre is allowed except through the door or
panel with safety interlocked equipped.
Stay outside of the safeguard during operation.
Activate emergency stop before entering the safeguard.
b) Use caution to prevent hand or fingers from being caught by the moving parts.
WARNING
Moving part may cause pinch or crush of hands and fingers, keep hands and fingers
away from moving parts.
c) Operation
Be sure to read through the warning labels and this manual carefully, and
make sure you have thoroughly understood the contents before attempting
installation and operation of the product.
A double checking of this chapter before starting to operate the product is
always a good idea.
Please do NOT proceed any actions not being mentioned in the manual.
WARNING
Improper installation or incorrectly operation may cause severe injury and

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serious threat endangering the life.
d) Do not use the product in the environment filled with inflammables or
explosives.
WARNING
The product is not designed to operate under the environment where inflammable or
explosive substances are present; use of the actuator in such environment might
result fire hazard.
e) Do not use the product in locations with possibly electromagnetic
interference.
WARNING
Avoid using the robot in locations subject to electromagnetic interference,
electrostatic discharge or radio fervency interference. Malfunctions might
otherwise occur.
f) Use caution when releasing the brake on a vertical axis actuator.
WARNING
The vertical axis will slide down when brake are released, and may cause
hazardous situation.
Use a support to prop the vertical axis before releasing the break, while
emergency stop is activated.
Be careful not to get caught between the axis and the installing base when
releasing the brake to perform direct teaching.
g) Provide safety measure for end effector (gripper)
WARNING
End effector must be designed and manufactured so that they create no hazards
(for example, a workpiece that comes loose) even if power source (electricity
or air pressure) is cut off or power fluctuation occur.
If there are possible danger that the object hold by the end effector may fly
off or drop off, please provide appropriate safety measures, taking the
consideration of the object dimension, size, weight, temperature and chemical
properties.

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h) Use caution when dissemble the motor for vertical axis actuator.
WARNING
The vertical axis will slide down when motor is dissembled, and may cause
hazardous situation.
Use a support to prop the vertical axis before disassembly of the motor,
while emergency stop is activated.
Be careful not to get caught between the vertical axis parts and the
installing base.
i) Take the following safety precaution during inspection of controller.
WARNING
When touching external parts of the controller, such as terminals or
connectors, are required for inspection, please make sure to turn off the
power switch of the controller and cut off the main power source to prevent
possible electrical shock.
Never touch internal parts of a controller.
j) Please consult with us before dealing with failure or malfunction of actuator.
WARNING
Continue on using a failure or malfunctioned actuator may cause injury to the
personals or further damage to the actuator or equipment, please contact your
TOYO’s sales office or dealer for trouble shooting.
k) The surface of motor and decelerator may get really hot after automatic
operation.
WARNING
The surface of the motor and the deceleration gearbox are extremely hot after
automatic operation, burns will be caused if touched. Please allow they to cool
down if inspection is required. Allow the surface temperature to drop down to
reasonable range after power off.
l) Do not remove, alter or damage the warning labels on the actuator.
WARNING

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Removing or altering the warning labels on the actuator may cause accident by
others.
Make sure the warning labels are not blocked or hidden by other equipment or
devices.
Make sure the warning labels are clearly visualized from outside of the
safeguard.
m) Electrical grounding
WARNING
Please ground the actuator and the controller to prevent electrostatics or
electrical shock.
n) Use correct parameter settings.
WARNING
The actuator must be operated with correct tolerable moment of inertia and
acceleration coefficients according to the manipulator tip mass and moment of
inertia. If these are not correct, drive unit service life may end prematurely,
and damage to actuator parts or may result residual vibration during position.

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1-3 Safety function required for the actuator
a) Power overload detection.
When motor overload occurs, the detection activates and cut off servo power.
b) Soft limit sensors
Soft limits can be set on each axis to limit the working envelope in manual
operation after return-to-home and during automatic operation.
NOTE. Working envelope is the area limited by soft limits.
c) Mechanical stopper
If the servo power has suddenly been shut off during high-speed operation by
emergency stop or safety functions, these mechanical stoppers prevent the axis
from exceeding the movement range. No mechanical stopper is provided on the
rotating axis.
NOTE. Movement range is the area limited by mechanical stoppers.
WARNING
Axis movement will not stop immediately after servo power supply is cut off by
emergency stop or other safety functions.
d) Brake for vertical axis
An electromagnetic brake installation is essential on the vertical axis to
prevent sliding down of the axis when servo power is cut off. This brake shall be
working when the controller is off, or when the vertical axis servo power is off
even with controller is on. The vertical axis brake can be released by means of
the programming unit or by commands in the program when controller is on.
WARNING
The vertical axis will slide down when brake are released, and may cause
hazardous situation.
Use a support to prop the vertical axis before releasing the break, while
emergency stop is activated.
Be careful not to get caught between the axis and the installing base when
releasing the brake to perform direct teaching.

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1-4 Safety measure of the system
Since the actuator is commonly in conjunction with an automated system, danger is
more likely to occur from the automated systems instead of from actuator itself.
Thus, appropriated safety measure must be taken on the part of the system
manufacturer according to the individual system. The system provider shall
provide a proper instruction manual for safe and correct operating or service of
the system.

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1-5 Trial run
After installation, adjustment, inspection or maintenance, follow below
procedures to make trial runs.
a) If a safeguard enclosure has not yet implied after installation of the
actuator, rope off or chain off around the movement area of the actuator in
place of the safeguard, and observe the following points.
Use sturdy, stable posts which will not fall over easily.
The rope or chain should be easily visible by everyone around the actuator.
Place a sign to keep personal from entering the movement range of the
actuator.
b) Check the following before turn on the controller.
If the actuator are securely and correctly installed.
If the electrical connection are correctly and properly wired.
If other connections such as pressured air supply or grounding connection
proper?
If the actuator correctly connect to peripheral equipment.
Has the safety measure been taken?
If the installation location meet the specific environmental requirement.
c) Check the following after turn on the controller from outside of the safeguard
enclosure.
If the actuator start and stop as intended, if the operation mode can be
selected correctly.
If each axis move as intended within the soft limit.
If the end effector act as intended.
If the signal transmissions to the end effector and peripheral equipment
are correct.
If emergency stop work.
If the teaching and playback function are normal.
If the safeguard enclosure and interlock are working as intended.
If the actuator move correctly during automatic operation.

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1-6 When working inside the safeguard enclosure.
a) When working inside the safeguard enclosure is required, always turn off the
controller and place a clear visual indication showing that the actuator is
been adjusted or serviced. This is to prevent others from touching the
controller switch or operation panel.
b) With the following two cases where powering off is not an option:
1. Soft limit settings, please follow the precautions and procedures for each
section.
2. Teaching
When performing teaching inside the safeguard enclosure, comply with the
instructions listed below.
(1)Before entering the safeguard enclosure.
Visual check if there is any hazard inside the safeguard enclosure.
Check that that programming unit MPB or DPB operate correctly.
Make sure there is no failure within actuator.
Double check if emergency stop work correctly.
Select teaching mode and prohibit automatic operation.
(2)Never enter the movement range of the actuator while inside the
safeguard enclosure.

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1-7 Automatic operation
a) Before start, please check the following:
There is no one inside the safeguard enclosure.
The programming unit and tools are in their specified locations.
The alarm or the error lamps of the actuator and the equipment has not been
triggered.
The safeguard enclosure is securely installed with safety interlock active.
b) Observe the following during automatic operation or in case there are errors
occurred.
After the automatic operation has started, check the operation status and
warning lamps to ensure that the actuator is in automatic operation.
Never enter the safeguard enclosure while automatic operation is active.
In case an error has occurred within the actuator or peripheral equipment,
obey the following procedure before entering the safeguard enclosure.
1. Activate the emergency stop to stop the actuator completely.
2. Place a sign on the starting switch, indicating that the actuator is
been inspected, this is to prevent others from touching the start switch
or restart the actuator.

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1-8 Adjustment and inspection.
Please do not attempt any installation, adjustment, inspection or maintenance of
the actuator unless it is stated within this manual.
Please refer to the following chapters for details.

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1-9 Repair and modification.
Please do not attempt any repair, part replacement or modification of the
actuator unless it is stated within this manual. The involved actions required
qualified technician with professional knowledge and skills, proceed without the
knowledge and skills may result hazards.

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Warranty Period
The warranty period is effective for:
18 Months (one year and half) after shipment from Taiwan factory.
12 Months (one year) after installation.
Whichever period meets first.
Exceptions to warranty
The warranty will not apply in the following cases:
Fatigue arising due to the passage of time, nature wear or tear occurring
during operation (nature fading of painted or plated surfaces, deterioration
of parts subjects to wear)
Consumables.
Damage due to earthquake, storms, floods, thunderbolts, fire or any other
natural or man-made calamities.
Trouble caused by actions prohibited by this manual.
Modifications of the product not approved by TOYO or TOYO’s sales
representative.
Use of any other than genuine parts or specified lubricant or grease.
Insufficient or incorrect maintenance or inspection.
Repair or service done by non-authorized dealer.
In addition, we will be responsible for repairing our own product, but are not
responsible for other losses caused by the failure of our product.
Service coverage
We will provide the following service.
Guide for installation and trial operation.
Guide for maintenance.
Guide or training on technical operation and wiring.
Guide on programming.
2.Warranty

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①Motor end
②Motor Opposite Side
③Carriage
④Main Body
⑤Dust proof cover
⑥Side cover
⑦Top Cover
⑧Coupling cover
3.Part’s Name
○
1
○
1
○
1
○
2
○
2
○
2
○
3
○
3
○
3
○
4
○
4
○
5
○
5
○
8
○
7
○
6

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4-1 Transportation
All personal shall bare safety measure while transporting the actuator
regardless the method used, proper gears such as safety helmets and gloves shall
be equipped. The weight of the product is stated in the specification sheet,
please select suitable means to transport.
In case transported by hoists, make sure to use the ropes which can handle
the weight. Please also make sure the rope is properly positioned where the
product is balanced while lifted.
In case transported by folk lifter or cart, make sure the product is properly
positioned to keep its balance and the parts which stands out of the folk or
cart will not collide into any other objects.
The following parts of the actuator are not suitable part to apply force for
transportation.
Carriage.
End plates either sides.
Top Cover.
Any cables whether power cable or signal signals, if the motor is
installed.
4. Installation

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4-2 Installation environment and base requirement
The environmental requirement or restriction for Toyo’s actuator is:
Item
ETH
ECH
Surrounding
temperature while
operating.
0~45℃
0~45℃
Surrounding
humidity while
operating.
35~85% RH
35~85% RH
Maximum
installation
height.
0~1000m above sea level.
0~1000m above sea level.
Surrounding
Avoid the following environment:
Near water, cutting liquid, dust, metal chips or solvents.
Environment filled with corrosive gas or liquid.
Environment filled with flammable materials in any forms.
Locations where surrounded by electro-magnetic
disturbance, statistic or radio-wave emitting.
Locations where there are vibration sources nearby or
easily collided.
Please provide enough space for service.
Installation base requirement:
Correct installation base
Incorrect installation base
a) The installation base should be solid and rigid to sustain the vibration
from operation, also must be able to sustain the weight of the actuator
plus the working piece.
b) The installation base must be even, within the range of±0.05mm/500mm.
c) The installation base must be bigger than the mounting surface, and has