Page 1 TRANSPORTATION AND INSTALLATION MANUAL Notice  Make sure that this instruction manual is delivered to the final user of Toshiba Machine’s industrial robot.  Before operating the industrial robot, read through and completely understand this manual.  After reading through this manual, keep it nearby for future reference.
Page 2 TRANSPORTATION AND INSTALLATION MANUAL This Instruction Manual applies to the following robots: THL Series: THL300, THL400, THL500, THL600, THL700, THL800, THL900, THL1000 Copyright 2011 by Toshiba Machine Co., Ltd. All rights reserved. No part of this document may be reproduced in any form without obtaining prior written permission from Toshiba Machine Co., Ltd.
Page 3 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.
Page 4 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.
Page 5 Mandatory • 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.
Page 6 TRANSPORTATION AND INSTALLATION MANUAL CAUTION • NEVER lift the robot by the arm 2 cover. Doing so will apply an excessive force on the robot's mechanism section and could lead to faults. • For the controller, secure the ample space for air vent. Prohibited Heating of controller could lead to malfunction.
Page 7: Table Of Contents
TRANSPORTATION AND INSTALLATION MANUAL Table of Contents 1. Specifications (THL300 and THL400) ..............12 1.1 Correspondence between the Robots and the Robot Controllers ....12 1.2 Robot Configuration Diagram (TSL3000) ............12 1.3 Robot Configuration Diagram (TSL3000E) ........... 13 1.4 Robot Configuration Diagram (TS3000 and TS3000E) ........14 1.5 Name of Each Part ..................
Page 8 TRANSPORTATION AND INSTALLATION MANUAL 5.4.2 Transporting the Robot ............... 51 5.4.3 Transporting the Controller ..............53 5.5 Storage ......................54 5.5.1 Storage Precautions for the Robot ............. 54 5.5.2 Storage Precautions for the Controller ..........54 6. Transportation (THL800, THL900 and THL1000) ............ 55 6.1 Unpacking (TSL3000) ..................
Page 9 TRANSPORTATION AND INSTALLATION MANUAL 9.1 Installation Environment .................. 99 9.2 Installation ....................... 99 9.2.1 External Dimensions and Working Envelope........99 9.2.2 Changing the Operating Ranges of Axes 1 and 2 ......103 9.2.3 Changing the Operating Range of Axis 3 ......... 105 9.2.4 Changing Software Limits ..............
Page 10 TRANSPORTATION AND INSTALLATION MANUAL 13.2 Controller Connector Signals ................ 141 13.2.1 Connector Signal Connection Diagrams........... 141 13.2.2 Jumpers for Safety Related Signals ..........141 14. System Connections (TSL3000E) ................. 143 14.1 Cable Wiring ....................143 14.1.1 Connector Arrangement on the Controller ........143 14.1.2 Connecting the Power Cable ............
Page 11 TRANSPORTATION AND INSTALLATION MANUAL 16.2 Tool Air Piping ....................172 16.3 Permissible Load Conditions and Program Setting ........173 16.3.1 Permissible Load Conditions ............173 16.3.2 Load Conditions and Program Setting ..........174 16.3.3 Setting Maximum Speed and Robot Acceleration/Deceleration for Load Conditions ..................
Page 12: Specifications (Thl300 And Thl400)
Correspondence between the Robots and the Robot Controllers Table 1.1 shows the correspondence between the robots and the robot controllers. There are several models of robots and controllers. The THL series robots are compatible with the THL3000, THL3000E, TH3000 and TH3000E robot controllers.
Page 13: Robot Configuration Diagram (Tsl3000E)
Personal computer TSPC (To be provided by the Communication cable customer) (obtained by customer) TSPC (option) TCPRGOS (option) Robot unit THL series Cable between robot and controller Power source 200V Teach pendant (option) Power source 24V TP cable Robot controller (TSL3000E) Fig.
Page 14: Robot Configuration Diagram (Ts3000 And Ts3000E)
TRANSPORTATION AND INSTALLATION MANUAL Robot Configuration Diagram (TS3000 and TS3000E) TSPC communication Personal computer cable (To be provided (To be provided by the by the customer) customer) TSPC (option) TCPRGOS (option) THL500/THL600/THL700 Cable between robot and controller Operation panel (separated type; option) Power source 200V Power source 24V TP cable...
Page 15: Name Of Each Part
TRANSPORTATION AND INSTALLATION MANUAL Name of Each Part Fig. 1.4 shows the name of each part of the robot (THL300 and THL400). For the names of the parts on the rear of Arm 2, see the Arm 2 rear panel. Cover Arm 1 Axis 1...
Page 16: External Dimensions
TRANSPORTATION AND INSTALLATION MANUAL External Dimensions Reference planes 4 x 9 mounting hole Reference planes * The example shows the case of TSL3000. Multiple cables are used with other controllers. Air coupler for the hand For 3 x 4 tube (The product comes with the air tube.
Page 17 TRANSPORTATION AND INSTALLATION MANUAL 4 x 9 mounting hole Reference planes Reference planes * The example shows the case of TSL3000. Multiple cables are used with other controllers. Air coupler for the hand For 3 x 4 tube (The product comes with the air tube. It needs to be installed by the customer.) Space for cable connection Fig.
Page 18: Specifications Table
TRANSPORTATION AND INSTALLATION MANUAL Specifications Table Item Specifications Structure Horizontal multi-joint type SCARA robot Model THL300 THL400 Applicable controller TSL3000, TSL3000E, TS3000, TS3000E Mass of robot body 12 kg 13 kg No. of controlled axes 300 mm 400 mm Arm length (125 mm + 175 mm) (225 mm + 175 mm) Axis 1...
Page 19 TRANSPORTATION AND INSTALLATION MANUAL CAUTION  Micro vibration may occur depending on the robot posture. If micro vibration occurs, reduce the acceleration speed to use the robot.  Put the Z-axis (axis 3) in the raised position as much as possible, when moving Axes 1, 2, and 4.
Page 20: Specifications (Thl500, Thl600 And Thl700)
TRANSPORTATION AND INSTALLATION MANUAL 2. Specifications (THL500, THL600 and THL700) 2.1 Correspondence between robot and controller, and equipment configuration diagram For the correspondence between robot and controller, and equipment configuration diagram, see the description of 1.1 through 1.4. 2.2 Name of Each Parts Fig.
Page 21 TRANSPORTATION AND INSTALLATION MANUAL For the names of the parts on the rear of Arm 2, see the Arm 2 rear panel. Eyebolt Axis 2 (rotation) Axis 2 Ball screw spline (rotation) (tool shaft) Arm 1 For the names of the parts on the rear of the base, see the wiring panel (back of base).
Page 22: External Dimensions
TRANSPORTATION AND INSTALLATION MANUAL External Dimensions Figs. 2.2 to 2.4 refer to the external dimensions of the robot (THL500, THL600 and THL700). 4 x 11 mounting hole Reference planes Reference plane Air coupler for the hand  For 3 x 6 tube * This drawing is for TSL3000.
Page 23 TRANSPORTATION AND INSTALLATION MANUAL 4 x 11 mounting hole Reference plane Reference plane Air coupler for the hand  For 3 x 6 tube * This drawing is for TSL3000. Multiple cables are used with other controllers. Space for cable connection Fig.
Page 24 TRANSPORTATION AND INSTALLATION MANUAL 4 x 11 mounting hole Reference planes Reference plane Air coupler for the hand  For 3 x 6 tube * This drawing is for TSL3000. Multiple cables are used with other controllers. Space for cable connection Fig.
Page 25: Specifications Table
TRANSPORTATION AND INSTALLATION MANUAL Specifications Table Item Specifications Structure Horizontal multi-joint type SCARA robot Model THL500 THL600 THL700 Applicable controller TSL3000, TSL3000E, TS3000, TS3000E Mass of robot body 22 kg 23 kg 24 kg No. of controlled axes 4 axis 500 mm 600 mm 700 mm...
Page 26 TRANSPORTATION AND INSTALLATION MANUAL CAUTION  Micro vibration may occur depending on the robot posture. If micro vibration occurs, reduce the acceleration speed to use the robot.  Put the Z-axis (axis 3) in the raised position as much as possible, when moving Axes 1, 2, and 4.
Page 27: Specifications (Thl800, Thl900 And Thl1000)
TRANSPORTATION AND INSTALLATION MANUAL Specifications (THL800, THL900 and THL1000) 3.1 Correspondence between robot and controller, and equipment configuration diagram For the correspondence between robot and controller, and equipment configuration diagram, see the description of 1.1 through 1.4. Name of Each Parts Fig.
Page 28 TRANSPORTATION AND INSTALLATION MANUAL For the names of the parts on the rear of Arm 2, see the Arm 2 rear panel. Axis 2 (rotation) Cover Arm 1 Axis 1 Eyebolt (rotation) For the names of the parts on the rear of the base, see the Ball screw spline wiring panel (back of base).
Page 29: External Dimensions
TRANSPORTATION AND INSTALLATION MANUAL External Dimensions Figs. 3.2 to 3.4 refer to the external dimensions of the robot (THL800, THL900 and THL1000). 6 x 13 mounting hole Reference planes Reference plane Air coupler for the hand  For 3 x 6 tube * This drawing is for TSL3000.
Page 30 TRANSPORTATION AND INSTALLATION MANUAL 6 x 13 mounting hole Reference plane Reference plane Air coupler for the hand  For 3 x 6 tube * This drawing is for TSL3000. Multiple cables are used with other controllers. Space for cable connection Fig.
Page 31 TRANSPORTATION AND INSTALLATION MANUAL 6 x 13 mounting hole Reference planes Reference plane Air coupler for the hand  For 3 x 6 tube * This drawing is for TSL3000. Multiple cables are used with other controllers.le cables are used with TS3000.
Page 32: Specifications Table
TRANSPORTATION AND INSTALLATION MANUAL Specifications Table Item Specifications Structure Horizontal multi-joint type SCARA robot Model THL800 THL900 THL1000 Applicable controller TSL3000, TSL3000E, TS3000, TS3000E Mass of robot body 33 kg 35 kg 37 kg No. of controlled axes 4 axis 800 mm 900 mm 1000 mm...
Page 33 TRANSPORTATION AND INSTALLATION MANUAL CAUTION  Micro vibration may occur depending on the robot posture. If micro vibration occurs, reduce the acceleration speed to use the robot.  Put the Z-axis (axis 3) in the raised position as much as possible, when moving Axes 1, 2, and 4.
Page 34: Transportation (Thl300 And Thl400)
TRANSPORTATION AND INSTALLATION MANUAL Transportation (THL300 and THL400) Unpacking (TSL3000) For the TSL3000E, see "4.2 Unpacking (TSL3000E) ". For the TS3000 and TS3000E, see "4.3 Unpacking (TS3000 and TS3000E)". The robot and controller are shipped separately in corrugated cardboards. Fig. 4.1 shows each packaging state.
Page 35  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.
Page 36: Unpacking (Tsl3000E)
TRANSPORTATION AND INSTALLATION MANUAL Unpacking (TSL3000E) For the TSL3000, see "4.1 Unpacking (TSL3000) ". For the TS3000 and TS3000E, see "4.3 Unpacking (TS3000 and TS3000E)". The robot and controller are shipped separately in corrugated cardboards. Fig. 4.2 shows each packaging state. Open the packages in a location easily accessible, where the equipment is to be installed.
Page 37  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.
Page 38: Unpacking (Ts3000 And Ts3000E)
TRANSPORTATION AND INSTALLATION MANUAL Unpacking (TS3000 and TS3000E) For the TSL3000, see "4.1 Unpacking (TSL3000)". For the TSL3000, see "4.2 Unpacking (TSL3000E)". The robot and controller are shipped separately in corrugated cardboards. Fig. 4.3 shows each packaging state. Open the packages in a location easily accessible, where the equipment is to be installed.
Page 39  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.
Page 40: Transportation
TRANSPORTATION AND INSTALLATION MANUAL 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.
Page 41: Transporting The Robot
TRANSPORTATION AND INSTALLATION MANUAL Mass of robot body 13kg Clamp Fig. 4.5 Packaging state (THL400) 4.4.2 Transporting the Robot In principle, the robot should be transported in the state shown in Figs. 4.4 to 4.5 above. Fold back and secure the arm with the attached clamp. (The robot is shipped in this posture.
Page 42: Transporting The Controller
TRANSPORTATION AND INSTALLATION MANUAL DO NOT hold the cover Handling areas (shaded areas) DO NOT hold the cable. DO NOT hold the ball screw spline shaft. Fig. 4.6 Robot Handling Locations (THL300 and THL400) After the installation, remove the clamp used for transport. CAUTION •...
Page 43: Storage
TRANSPORTATION AND INSTALLATION MANUAL 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. 4.5.1 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.
Page 44: Transportation (Thl500, Thl600 And Thl700)
TRANSPORTATION AND INSTALLATION MANUAL Transportation (THL500, THL600 and THL700) Unpacking (TSL3000) For information on TSL3000E, refer to Section 5.2. For information on TS3000 and TS3000E, refer to Section 5.3. The robot and controller are shipped separately in corrugated cardboards. Fig. 5.1 shows each packaging state. Open the packages in a location easily accessible, where the equipment is to be installed.
Page 45  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.
Page 46: Unpacking (Tsl3000E)
TRANSPORTATION AND INSTALLATION MANUAL Unpacking (TSL3000E) For information on TSL3000, refer to Section 5.1. For information on TS3000 and TS3000E, refer to Section 5.3. The robot and controller are shipped separately in corrugated cardboards. Fig. 5.2 shows each packaging state. Open the packages in a location easily accessible, where the equipment is to be installed.
Page 47  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.
Page 48: Unpacking (Ts3000 And Ts3000E)
TRANSPORTATION AND INSTALLATION MANUAL Unpacking (TS3000 and TS3000E) For information on TSL3000, refer to Section 5.1. For information on TSL3000E, refer to Section 5.2. The robot and controller are shipped separately in corrugated cardboards. Fig. 5.3 shows each packaging state. Open the packages in a location easily accessible, where the equipment is to be installed.
Page 49: Transportation
 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.
Page 50 TRANSPORTATION AND INSTALLATION MANUAL Mass of robot body 23kg Clamp Fig. 5.5 Packaging state (THL600) Mass of robot body 24kg Clamp Fig. 5.6 Packaging state (THL700) STE 85356...
Page 51: Transporting The Robot
TRANSPORTATION AND INSTALLATION MANUAL 5.4.2 Transporting the Robot In principle, the robot should be transported in the state shown in Figs. 5.4 to 5.6 above. Fold back and secure the arm with the attached clamp. (The robot is shipped in this posture.
Page 52 TRANSPORTATION AND INSTALLATION MANUAL 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.
Page 53: Transporting The Controller
TRANSPORTATION AND INSTALLATION MANUAL CAUTION • When lifting up the robot by workers, hold the locations (shaded areas) by hands as shown in Fig. 5.8. Holding the arm 2 cover, the cable and the ball screw spline shaft will apply excess force, possibly causing failure. •...
Page 54: Storage
TRANSPORTATION AND INSTALLATION MANUAL 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. 5.5.1 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.
Page 55: Transportation (Thl800, Thl900 And Thl1000)
TRANSPORTATION AND INSTALLATION MANUAL Transportation (THL800, THL900 and THL1000) Unpacking (TSL3000) For information on TSL3000E, refer to Section 6.2. For information on TS3000 and TS3000E, refer to Section 6.3. The robot and controller are shipped separately in corrugated cardboards. Fig. 6.1 shows each packaging state. Open the packages in a location easily accessible, where the equipment is to be installed.
Page 56  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.
Page 57  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.
Page 58: Unpacking (Ts3000 And Ts3000E)
TRANSPORTATION AND INSTALLATION MANUAL Unpacking (TS3000 and TS3000E) For information on TSL3000, refer to Section 6.1. For information on TSL3000E, refer to Section 6.2. The robot and controller are shipped separately in corrugated cardboards. Fig. 6.3 shows each packaging state. Open the packages in a location easily accessible, where the equipment is to be installed.
Page 59  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.
Page 60: Transportation
TRANSPORTATION AND INSTALLATION MANUAL 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.
Page 61 TRANSPORTATION AND INSTALLATION MANUAL Mass of robot body 35kg 固定治具 Clamp Fig. 6.5 Packaging state (THL900) Mass of robot body 37kg Clamp Fig. 6.6 Packaging state (THL1000) STE 85356...
Page 62: Transporting The Robot
TRANSPORTATION AND INSTALLATION MANUAL 6.4.2 Transporting the Robot In principle, the robot should be transported in the state shown in Figs. 6.4 to 6.6 above. Fold back and secure the arm with the attached clamp. (The robot is shipped in this posture.
Page 63 TRANSPORTATION AND INSTALLATION MANUAL 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.
Page 64: Transporting The Controller
TRANSPORTATION AND INSTALLATION MANUAL After the installation, remove the clamp and eyebolt used for transport. CAUTION • When lifting up the robot by workers, hold the locations (shaded areas) by hands as shown in Fig. 6.8. Holding the arm 2 cover, the cable and the ball screw spline shaft will apply excess force, possibly causing failure.
Page 65: Storage
TRANSPORTATION AND INSTALLATION MANUAL 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. 6.5.1 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.
Page 66: Robot Installation (Thl300 And Thl400)
In operation: 0.98 m/s or less Dust No inductive dust should exist. Consult with Toshiba Machine first if you wish to use the robot and controller in a dusty environment. No corrosive or combustible gas should exist. Degrees of protection...
Page 67: Installation
Also, high temperatures can reduce the performance and lifespan of the battery. If using the robot under high temperatures, please consult with the Toshiba Machine sales office.
Page 68 TRANSPORTATION AND INSTALLATION MANUAL Z-axis stroke Axis-2 working envelope Axis-2 working envelope Axis-1 working Axis-1 envelope working envelope Fig. 7.1 External view and working envelope (THL300) STE 85356...
Page 69 TRANSPORTATION AND INSTALLATION MANUAL Z-axis stroke Axis-2 working envelope Axis-2 working envelope Axis-1 Axis-1 working working envelope envelope Fig. 7.2 External view and working envelope (THL400) STE 85356...
Page 70: Changing The Operation Ranges Of Axes 1 And 2
TRANSPORTATION AND INSTALLATION MANUAL 7.2.2 Changing the Operation Ranges of Axes 1 and 2 Mechanical stoppers are installed to each robot to mechanically control the operation range of each axis. Changing the mechanical operation range of a robot by modifying these mechanical stoppers is referred to as "change in operating range."...
Page 71: Changing The Operating Ranges Of Axes 1 And 2
TRANSPORTATION AND INSTALLATION MANUAL As shown in Fig. 7.3, the operation range can be altered by changing the position of the mechanical stopper. Table 7.2 Operation ranges before and after change (THL300 and THL400) Before change After change + direction 125...
Page 72: Changing The Operating Range Of Axis 3
TRANSPORTATION AND INSTALLATION MANUAL 7.2.3 Changing the Operating Range of Axis 3 At the factory shipment of a robot, software limits and mechanical stoppers are preset so that the Z stroke of Axis 3 is between 0 and 160 mm. Fig. 7.4 shows the settings of operating range at the factory shipment.
Page 73 TRANSPORTATION AND INSTALLATION MANUAL 1) Remove the Arm 2 cover. The cover is fastened to Arm 2 and the harness guide with four (4) hexagon socket head bolts (M3 x 16) and ten (10) cross recessed truss head screw (M3 x 10 x 2 pcs. and M3 x 6 x 8 pcs.). It is recommended to lower Axis 3 in advance until the upper limit stopper of the ball screw enters the cover.
Page 74 TRANSPORTATION AND INSTALLATION MANUAL 2) Loosen the fixing bolts of the mechanical stoppers, move the mechanical stoppers to a desired position, and fix them again. When fixing the mechanical stoppers, be sure to apply Loctite to the fixing bolts. Upper limit mechanical stopper Upper limit mechanical stopper fixing bolt M5 x 16 x 1 pc.
Page 75 TRANSPORTATION AND INSTALLATION MANUAL 3) When the mechanical stoppers are changed, be sure to also change the software limits. Regarding how to change software limits, see Para. 7.2.4 and Fig. 7.8. After changing the software limit, while pressing the axis 3 brake release switch, move Axis 3 manually, and make sure that the software limit is correctly set.
Page 76 TRANSPORTATION AND INSTALLATION MANUAL Fig. 7.8 shows the settings of the operating range when the upper limit mechanical stopper is moved 75 mm downward. Upper limit mechanical stopper If the coordinates of Axis 3 are moved to the position of "73.0 mm," the upper limit mechanical stopper and the ball screw nut will contact each other.
Page 77 TRANSPORTATION AND INSTALLATION MANUAL 4) Remove the Arm 2 cover. The cover is fastened to Arm 2 and the harness guide with four (4) hexagon socket head bolts (M3 x 16) and ten (10) cross recessed truss head screw (M3 x 10 x 2 pcs. and M3 x 6 x 8 pcs.). It is recommended to lower Axis 3 in advance until the upper limit stopper of the ball screw enters the cover.
Page 78: Changing Software Limits
TRANSPORTATION AND INSTALLATION MANUAL 7.2.4 Changing Software Limits When the mechanical stoppers are changed, be sure to also change the software limits. There are the following two types of methods to change software limits. [1] Change the setting values of the "User Parameter File (file name: USER.PAR)." There are software limits that can be set by the customer.
Page 79: Coordinate System
TRANSPORTATION AND INSTALLATION MANUAL 7.2.5 Coordinate System The robot's joint angle origin (0° or 0 mm position) is factory-calibrated according to the base reference planes. Fig. 7.10 shows the base coordinate system and origin of each axis joint angle. The coordinate system is common between the THL300 and THL400. Figure shows the THL300.
Page 80: Installing The Robot
TRANSPORTATION AND INSTALLATION MANUAL 7.2.6 Installing the Robot The robot is secured, using the mounting holes on the base (four places). Use M8 hexagon socket head cap screws. Table 7.3 lists the loads applied to the frame during horizontal operation, and Fig. 7.11 shows how to install the robot.
Page 81: Precautions For Handling The Teach Pendant
TRANSPORTATION AND INSTALLATION MANUAL Center of Axis 1 Hexagon socket head bolt 4 x 9 drill thru +0.012 2×6 H7 reamer Pin hole Reference plane Reference plane 44±0.05 Reference plane When the robot is seen from the bottom side Fig. 7.11 Installation method (THL300 and THL400) Precautions for Handling the Teach Pendant Be careful of the following matters when handling the teach pendant.
Page 82: Safety Measures
TRANSPORTATION AND INSTALLATION MANUAL Safety Measures a) When installing the robot, provide sufficient space to carry out the work safely. b) Clarify the hazard zone, and provide a safety fence so that other persons cannot enter the zone easily. The hazard zone is the zone near the robot's working space where a hazardous state could occur if a person enters.
Page 83: Robot Installation (Thl500, Thl600 And Thl700)
TRANSPORTATION AND INSTALLATION MANUAL Robot Installation (THL500, THL600 and THL700) Installation Environment For mounting environment, see "7.1 Installation Environment". Installation Before installing the robot, you should plan a layout, fully considering the working envelope (or operating range), coordinate system and space for maintenance. 8.2.1 External Dimensions and Working Envelope Figs.
Page 84 TRANSPORTATION AND INSTALLATION MANUAL Fig. 8.1 External view and working envelope (THL500) STE 85356...
Page 85 TRANSPORTATION AND INSTALLATION MANUAL Fig. 8.2 External view and working envelope (THL600) STE 85356...
Page 86 TRANSPORTATION AND INSTALLATION MANUAL Fig. 8.3 External view and working envelope (THL700) STE 85356...
Page 87: Changing The Operating Ranges Of Axes 1 And 2
TRANSPORTATION AND INSTALLATION MANUAL 8.2.2 Changing the Operating Ranges of Axes 1 and 2 Mechanical stoppers are installed to each robot to mechanically control the operation range of each axis. Changing the mechanical operation range of a robot by modifying these mechanical stoppers is referred to as "change in operating range."...
Page 88 TRANSPORTATION AND INSTALLATION MANUAL As shown in Fig. 8.4, the operation range can be altered by changing the position of the mechanical stopper. Table 8.1 Operation ranges before and after change (THL500, THL600 and THL700) Before change After change + direction 125...
Page 89: Changing The Operating Range Of Axis 3
TRANSPORTATION AND INSTALLATION MANUAL 8.2.3 Changing the Operating Range of Axis 3 At the factory shipment of a robot, software limits and mechanical stoppers are preset so that the Z stroke of Axis 3 is between 0 and 150 mm (0 through 300 mm for Z-long specifications).
Page 90 TRANSPORTATION AND INSTALLATION MANUAL 1) Remove the Arm 2 cover. The cover is fastened to Arm 2 and the harness guide with 14 hexagon socket head bolts (M3 x 16 x 4 pcs., M4 x 6 x 8 pcs. and M4 x 10 x 2 pcs.) Hexagon socket head bolts M4 x 6 x 8 pcs.
Page 91 TRANSPORTATION AND INSTALLATION MANUAL 2) Loosen the fixing bolts of the mechanical stoppers, move the mechanical stoppers to a desired position, and fix them again. When fixing the mechanical stoppers, be sure to apply Loctite to the fixing bolts. Upper limit mechanical stopper (Note that the thin head type hexagon bolt different from the lower limit mechanical stopper is used as a fixing bolt.
Page 92 TRANSPORTATION AND INSTALLATION MANUAL 3) When the mechanical stoppers are changed, be sure to also change the software limits. Regarding how to change software limits, see Para. 7.2.4 and Fig. 8.10. After changing the software limit, while pressing the axis 3 brake release switch, move Axis 3 manually, and make sure that the software limit is correctly set.
Page 93 TRANSPORTATION AND INSTALLATION MANUAL Move Axis 3 up and down. Axis 3 brake release switch Fig. 8.9 Checking Software Limit Change (THL500, THL600 and THL700) STE 85356...
Page 94 TRANSPORTATION AND INSTALLATION MANUAL Fig. 8.10 shows the settings of the operating range when the upper limit mechanical stopper was moved 75 mm downward. Upper limit mechanical stopper If the coordinates of Axis 3 are moved to the position of "71.7 mm," the upper limit mechanical stopper and the ball screw nut will contact each other.
Page 95: Changing Software Limits
TRANSPORTATION AND INSTALLATION MANUAL 4) Fasten the Arm 2 cover to Arm 2 and the harness guide with 14 hexagon socket head bolts (M3 x 16 x 4 pcs., M4 x 6 x 8 pcs. and M4 x 10 x 2 pcs.) and nylon washers.
Page 96: Coordinate System
TRANSPORTATION AND INSTALLATION MANUAL 8.2.5 Coordinate System The robot's joint angle origin (0° or 0 mm position) is factory-calibrated according to the base reference planes. Fig. 8.12 shows the base coordinate system and origin of each axis joint angle. The coordinate system is common among the THL500, THL600, and THL700.
Page 97: Installing The Robot
TRANSPORTATION AND INSTALLATION MANUAL 8.2.6 Installing the Robot The robot is secured, using the mounting holes on the base (four places). Use M10 hexagon socket head cap screws. Table 8.2 lists the loads applied to the frame during horizontal operation, and Fig. 8.13 shows how to install the robot.
Page 98: Precautions For Handling The Teach Pendant
TRANSPORTATION AND INSTALLATION MANUAL Center of Axis 1 Hexagon socket head bolt Pin hole Reference plane +0.012 2×6 H7 reamer 80±0.05 When the robot is seen from the bottom side Reference plane Fig. 8.13 Installation method (THL500, THL600 and THL700) Precautions for Handling the Teach Pendant For the teach pendant handing procedure, see "7.3 Precautions for Handling the Teach Pendant".
Page 99: Robot Installation (Thl800, Thl900 And Thl1000)
TRANSPORTATION AND INSTALLATION MANUAL Robot Installation (THL800, THL900 and THL1000) Installation Environment For mounting environment, see "7.1 Installation Environment". Installation Before installing the robot, you should plan a layout, fully considering the working envelope (or operating range), coordinate system and space for maintenance. 9.2.1 External Dimensions and Working Envelope Figs.
Page 100 TRANSPORTATION AND INSTALLATION MANUAL Fig. 9.1 External view and working envelope (THL800) STE 85356...
Page 101 TRANSPORTATION AND INSTALLATION MANUAL Fig. 9.2 External view and working envelope (THL900) STE 85356...
Page 102 TRANSPORTATION AND INSTALLATION MANUAL Fig. 9.3 External view and working envelope (THL1000) STE 85356...
Page 103 TRANSPORTATION AND INSTALLATION MANUAL 9.2.2 Changing the Operating Ranges of Axes 1 and 2 Mechanical stoppers are installed to each robot to mechanically control the operation range of each axis. Changing the mechanical operation range of a robot by modifying these mechanical stoppers is referred to as "change in operating range."...
Page 104 TRANSPORTATION AND INSTALLATION MANUAL As shown in Fig. 9.4, the operation range can be altered by changing the position of the mechanical stopper. Table 9.1 Operation ranges before and after change (THL800, THL900 and THL1000) Before change After change + direction 125...
Page 105: Changing The Operating Range Of Axis 3
TRANSPORTATION AND INSTALLATION MANUAL 9.2.3 Changing the Operating Range of Axis 3 At the factory shipment of a robot, software limits and mechanical stoppers are preset so that the Z stroke of Axis 3 is between 0 and 300 mm. Fig. 9.5 shows the settings of operating range at the factory shipment.
Page 106 TRANSPORTATION AND INSTALLATION MANUAL 1) Remove the Arm 2 cover. The cover is fastened to Arm 2 and the harness guide with 14 hexagon socket head bolts (M3 x 6 x 4 pcs., M4 x 6 x 8 pcs. and M4 x 10 x 2 pcs.) Hexagon socket head bolts Hexagon socket head bolts...
Page 107 TRANSPORTATION AND INSTALLATION MANUAL 2) Loosen the fixing bolts of the mechanical stoppers, move the mechanical stoppers to a desired position, and fix them again. When fixing the mechanical stoppers, be sure to apply Loctite to the fixing bolts. Upper limit mechanical stopper (Note that the thin head type hexagon bolt different from the lower limit mechanical stopper is used as a fixing bolt.
Page 108 TRANSPORTATION AND INSTALLATION MANUAL 3) When the mechanical stoppers are changed, be sure to also change the software limits. Regarding how to change software limits, see Para. 7.2.4 and Fig. 8.10. After changing the software limit, while pressing the axis 3 brake release switch, move Axis 3 manually, and make sure that the software limit is correctly set.
Page 109 TRANSPORTATION AND INSTALLATION MANUAL Move Axis 3 up and down. Axis 3 brake release switch Fig. 9.9 Checking Software Limit Change (THL800, THL900 and THL1000) STE 85356...
Page 110 TRANSPORTATION AND INSTALLATION MANUAL Fig. 9.10 shows the settings of the operating range when the upper limit mechanical stopper was moved 75 mm downward. Upper limit mechanical stopper If the coordinates of Axis 3 are moved to the position of "69.2 mm," the upper limit mechanical stopper and the ball screw nut will contact each other.
Page 111: Changing Software Limits
TRANSPORTATION AND INSTALLATION MANUAL 4) Fasten the Arm 2 cover to Arm 2 and the harness guide with 14 hexagon socket head bolts (M3 x 6 x 4 pcs., M4 x 6 x 8 pcs. and M4 x 10 x 2 pcs.) and nylon washers.
Page 112: Coordinate System
TRANSPORTATION AND INSTALLATION MANUAL 9.2.5 Coordinate System The robot's joint angle origin (0° or 0 mm position) is factory-calibrated according to the base reference planes. Fig. 9.12 shows the base coordinate system and origin of each axis joint angle. The coordinate system is common among the THL800, THL900, and THL1000.
Page 113: Installing The Robot
TRANSPORTATION AND INSTALLATION MANUAL 9.2.6 Installing the Robot The robot is secured, using the mounting holes on the base (six places). Use M12 hexagon socket head cap screws. Table 9.2 lists the loads applied to the frame during horizontal operation, and Fig. 9.13 shows how to install the robot.
Page 114: Precautions For Handling The Teach Pendant
TRANSPORTATION AND INSTALLATION MANUAL 6x13 drill thru Hexagon socket head bolt 70±0.05 +0.012 Pin hole 2×6 H7 reamer Reference plane Fig. 9.13 Installation method (THL800, THL900 and THL1000) Precautions for Handling the Teach Pendant For the teach pendant handing procedure, see "7.3 Precautions for Handling the Teach Pendant".
Page 115: Installing The Controller (Tsl3000)
TRANSPORTATION AND INSTALLATION MANUAL 10. Installing the Controller (TSL3000) 10.1 External Dimensions For information on TSL3000E, refer to Section 11. For information on TS3000 and TS3000E, refer to Section 12. External view of the controller TSL3000 is shown in Fig. 10.1.
Page 116: Precautions For Direct Installation
TRANSPORTATION AND INSTALLATION MANUAL 10.2 Precautions for Direct Installation It is necessary to provide a clearance of 50 mm or more in the horizontal direction and a clearance of 100 mm or more in the upward direction near the controller. CAUTION •...
Page 117: Rack Mounting Dimensions
TRANSPORTATION AND INSTALLATION MANUAL 10.3 Rack Mounting Dimensions When installing the robot controller TSL3000 to the control panel, attach the mounting fixtures using the screw holes for mounting the rubber legs on the bottom surface, and then fasten the controller to the control panel. Note) The mounting fixtures (2 piece set) are optional.
Page 118: Precautions For Assembling The Control Panel
TRANSPORTATION AND INSTALLATION MANUAL 10.4 Precautions for Assembling the Control Panel When installing the robot controller TSL3000 to the control panel, be careful with the following items. a) When installing the robot controller to the control panel, remove the rubber legs on the bottom surface and use the holes for installing the rubber legs to fix the controller in position.
Page 119 TRANSPORTATION AND INSTALLATION MANUAL Fig. 10.4 Removing upper cover (TSL3000) STE 85356...
Page 120 TRANSPORTATION AND INSTALLATION MANUAL Allocate a clearance of about 250 mm in front of the controller for connecting the robot cable connecto (250) (250) Fig. 10.5 Clearance of controller front side (TSL3000) CAUTION • If the control panel is completely sealed up, open air release holes, ventilate the air forcibly with a fan, or conduct indirect cooling to release heat from the control panel.
Page 121: Installing The Controller (Tsl3000E)
TRANSPORTATION AND INSTALLATION MANUAL 11. Installing the Controller (TSL3000E) 11.1 External Dimensions For information on TSL3000, refer to Section 10. For information on TS3000 and TS3000E, refer to Section 12. External view of the controller TSL3000E is shown in Fig. 11.1. Mass of controller: 13 kg Fig.
Page 122: Precautions For Direct Installation
TRANSPORTATION AND INSTALLATION MANUAL 11.2 Precautions for Direct Installation It is necessary to provide a clearance of 50 mm or more in the horizontal direction and a clearance of 100 mm or more in the upward direction near the controller. CAUTION •...
Page 123: Rack Mounting Dimensions
TRANSPORTATION AND INSTALLATION MANUAL 11.3 Rack Mounting Dimensions When installing the robot controller TSL3000E to the control panel, attach the mounting fixtures using the screw holes for mounting the rubber legs on the bottom surface, and then fasten the controller to the control panel. Note) The mounting fixtures (2 piece set) are optional.
Page 124: Precautions For Rack Mounting
TRANSPORTATION AND INSTALLATION MANUAL 11.4 Precautions for Assembling the Control Panel When installing the robot controller TSL3000E to the control panel, be careful with the following items. a) When installing the robot controller to the control panel, remove the rubber legs on the bottom surface and use the holes for installing the rubber legs to fix the controller in position.
Page 125 TRANSPORTATION AND INSTALLATION MANUAL d) Allocate a clearance of about 122 mm in front of the controller for connecting the robot cable connector. Fig. 11.5 Clearance of controller front side (TSL3000E) CAUTION • If the control panel is completely sealed up, open air release holes, ventilate the air forcibly with a fan, or conduct indirect cooling to release heat from the control panel.
Page 126: Installing The Controller (Ts3000 And Ts3000E)
TRANSPORTATION AND INSTALLATION MANUAL 12. Installing the Controller (TS3000 and TS3000E) 12.1 External Dimensions For information on TSL3000, refer to Section 10. For information on TSL3000E, refer to Section 11. External view of the controller TS3000 and TS3000E are shown in Fig. 12.1. connector for distribution I/O cable (110)
Page 127: Precautions For Direct Installation
TRANSPORTATION AND INSTALLATION MANUAL 12.2 Precautions for Direct Installation It is necessary to provide a clearance of 50 mm or more in the horizontal direction and a clearance of 100 mm or more in the upward direction near the controller. CAUTION •...
Page 128: Rack Mounting Dimensions
TRANSPORTATION AND INSTALLATION MANUAL 12.3 Rack Mounting Dimensions When mounting the robot controller TS3000 and TS3000E in a rack, mount the side brackets using the screw holes provided on both ends of the front panel, and secure the controller to the rack. The side brackets  in Fig. 12.3 are optional. ...
Page 129 TRANSPORTATION AND INSTALLATION MANUAL As the cable connectors are connected to the rear side of the controller, provide a space of 110 mm or more on the rear side. For maintenance, the upper cover should be removed. (See Fig. 12.4.) Install the controller for enabling easy access to the controller when conducting maintenance.
Page 130 TRANSPORTATION AND INSTALLATION MANUAL b) When the controller is mounted on the rack, the weight of the controller should be supported with the legs of the controller. Screw holes for rack-mounting the controller are used for securing the controller panel, and the weight of the controller cannot be supported only with these screws.
Page 131 TRANSPORTATION AND INSTALLATION MANUAL d) On the back of the controller, a clearance of approx. 110 mm should be provided for connecting the connector of the teach pendant. (110) Fig. 12.6 Clearance of controller back side (TS3000 and TS3000E) STE 85356...
Page 132: System Connections (Tsl3000)
TRANSPORTATION AND INSTALLATION MANUAL 13. System Connections (TSL3000) 13.1 Cable Wiring For information on TSL3000E, refer to Section 14. For information on TS3000 and TS3000E, refer to Section 15. This section describes the various types of cables and connectors and explains how these are to be connected. 13.1.1 Connector Arrangement on the Controller The cables connected to the robot controller are shown in Fig.
Page 133: Connecting The Power Cable "Acin" ( Of Fig. 13.1) (Plug Connector Attached)
TRANSPORTATION AND INSTALLATION MANUAL  Power cable (ACIN)  Motor cable, encoder cable, robot control signal cable, brake signal cable (ROBOT)  External input/output power cable (GNDP24V) In the subsequent paragraphs, we explain how to connect cables ,  and . For information on how to connect other cables, refer to the TSL3000 Interface Manual STE85364.
Page 134: Connecting The Motor Cable "Robot" ( Of Fig. 13.1) (Thl300 To Thl1000)
TRANSPORTATION AND INSTALLATION MANUAL DANGER • Be sure to use the designated wire. Failure to do so could lead to fires or faults. • When connecting the connector and wires, make sure not to mistake the terminal arrangement. • After making the connection, use a tester, etc., to confirm the connection. For the terminal arrangement, see Para.
Page 135: Connecting The Encoder Cable "Robot" ( Of Fig. 13.1)
TRANSPORTATION AND INSTALLATION MANUAL Connect to “ROBOT” of the controller Fig. 13.2 Robot side connector arrangement (TSL3000) 13.1.4 Connecting the Encoder Cable "ROBOT" ( of Fig. 13.1) The encoder cable is integrated with the motor cable, robot control signal cable, and brake signal cable.
Page 136: Connecting The External Input/Output Power Cable "Gndp24V" ( Of Fig. 13.1)
TRANSPORTATION AND INSTALLATION MANUAL 13.1.7 Connecting the External Input/Output Power Cable "GNDP24V" ( of Fig. 13.1) An attached connector (ML-4000-CP-2PGY) is used to connect the external input/output power cable. The P24V power is supplied from the front of the controller. The following shows the I/O using the external supply power (24 VDC).
Page 137: Connecting And Disconnecting Cables
TRANSPORTATION AND INSTALLATION MANUAL 13.1.8 Connecting and Disconnecting Cables CAUTION • Before connecting or disconnecting any controller cable, be sure to turn off the main power. • When disconnecting a cable, be sure to pull the connector and not the cord. Otherwise, you may damage the cable.
Page 138 TRANSPORTATION AND INSTALLATION MANUAL b) Square connectors: INPUT, OUTPUT, TP, HOST/TCPRG, COM1 Firstly, completely insert the cable side connector into the controller connector. Then tighten the lock screws on both ends of the cable side connector with a Phillips head screwdriver (No. 1). A loose screw can cause a contact failure or other accident.
Page 139: Examples Of Connector Terminal Arrangement (Controller Side)
TRANSPORTATION AND INSTALLATION MANUAL 13.1.9 Examples of Connector Terminal Arrangement (Controller side) a) Power cable connector "ACIN" Connects to controller. Type: 03JFAT-SAYGF-I Manufacturer: J.S.T. Mfg. Co., Ltd. DANGER 1(L) • Completely connect the grounding cable. 2(N) Single phase, 190 ~ 240 VAC, 50/60 Hz Otherwise, an electric shock or fire may be caused if a fault or electric leak occurs, or 3(FG)
Page 140 TRANSPORTATION AND INSTALLATION MANUAL d) Universal output signal cable connector "OUTPUT" Connects to controller. Type: XM3B-2522-112 Manufacturer: OMRON Corporation The mating components are attached to the controller. For details, refer to the "Instruction Manual: Interface". e) Connector for supplying power to I/O signals Connects to controller.
Page 141: Controller Connector Signals
TRANSPORTATION AND INSTALLATION MANUAL 13.2 Controller Connector Signals For information on TSL3000E, refer to Section 14. For information on TS3000 and TS3000E, refer to Section 15. 13.2.1 Connector Signal Connection Diagrams Diagrams showing which signals correspond to which terminals are shown in Section 2 of the TSL3000 Interface Manual STE85364.
Page 142 TRANSPORTATION AND INSTALLATION MANUAL CAUTION • Unless the signals of SVOFF and emergency stop contacts 1, 2 are jumpered, the controller servo power cannot be turned on. • Unless the CYCLE signal is jumpered, the controller enters the cycle operation mode. •...
Page 143: System Connections (Tsl3000E)
TRANSPORTATION AND INSTALLATION MANUAL 14. System Connections (TSL3000E) 14.1 Cable Wiring This section describes the various types of cables and connectors and explains how these are to be connected. 14.1.1 Connector Arrangement on the Controller The cables connected to the robot controller are shown in Fig. 14.1. Fig.
Page 144: Connecting The Power Cable
TRANSPORTATION AND INSTALLATION MANUAL 14.1.2 Connecting the Power Cable The power cable (“ACIN” ( of Fig. 14.1)) is used to supply the main AC power to the controller. AC IN Robot controller side ロボットコントローラ側 Customer side お客様側 Single phase 単相　AC190～240V 190 –...
Page 145: Connecting The Motor Cable/Encorder Cable
TRANSPORTATION AND INSTALLATION MANUAL CAUTION • Unless the main power is normally supplied to the controller due to phase defect or voltage drop, an error of "8–027 Slow Charge error" occurs. When this happens, make sure that the maser power voltage at the controller power connector satisfies the specified input power of the controller, and that the same voltage is stabilized.
Page 146: Connecting The Brake Signal Cable And The Robot Control Signal Cable
TRANSPORTATION AND INSTALLATION MANUAL 14.1.4 Connecting the Brake Signal Cable and the Robot Control Signal Cable The brake cable is used to input and output an ON/OFF signal for the brake to lock the motor shaft. The brake signal cable used to lock the motor shaft is connected to the connector BRK (...
Page 147: Connecting And Disconnecting Cables
TRANSPORTATION AND INSTALLATION MANUAL CAUTION Be sure to supply external power (24 DVC). Otherwise, the safety signal will not be enabled and the controller servo power cannot be turned on. 14.1.6 Connecting and Disconnecting Cables CAUTION • Before connecting or disconnecting any controller cable, be sure to turn off the main power.
Page 148 TRANSPORTATION AND INSTALLATION MANUAL b) Square connectors: INPUT, OUTPUT, TP, HOST/TCPRG, COM1, BRK, HAND Firstly, completely insert the cable side connector into the controller connector. Then tighten the lock screws on both ends of the cable side connector with a screwdriver.
Page 149 TRANSPORTATION AND INSTALLATION MANUAL c) Circular connector: ACIN To connect the connector, align the key position, securely insert the connector on the cable side into the connector on the robot controller body side, and then tighten by rotating the lock screw on the cable side clockwise. If the connector is loose, it may cause accidents due to connector contact failure, so be sure to check that the connector is securely inserted.
Page 150: Examples Of Connector Terminal Arrangement (For The Tsl3000E)
TRANSPORTATION AND INSTALLATION MANUAL 14.1.7 Examples of Connector Terminal Arrangement (for the TSL3000E) a) TSL3000E Power cable connector "ACIN" Connects to controller. Type: JL04V-2E18-10PE-B Manufacturer: Japan Aviation Electronics Industry, Ltd Single phase, 190 ~ 240 VAC, 50/60 Hz Grounding (Class D or higher level) DANGER •...
Page 151 TRANSPORTATION AND INSTALLATION MANUAL b) Motor/Encoder cable connector "ROBOT" Connects to controller. Manufacturer: Harting Co., Ltd. For encoder For motor power c) Universal input signal cable connector "INPUT" Connects to controller. Type: XM3B-3722-112 Manufacturer: Omron Corporation The counterpart is attached to the controller. For details, see Part STE85364 TSL3000 Interface or Part STE85457 TSL3000E Interface.
Page 152 TRANSPORTATION AND INSTALLATION MANUAL e) TSL3000E Input/output signal power supply and Distributed I/O connector EXT I/O connector Connects to controller. Type: ML-4000-CWJH 05PGY Manufacturer: Sato Parts Co., Ltd. The counterpart is attached to the controller. For details, see Part STE85364 TSL3000 Interface Manufacturer: Sato Parts Co., Ltd.
Page 153: Controller Connector Signals
TRANSPORTATION AND INSTALLATION MANUAL 14.2 Controller Connector Signals 14.2.1 Connector Signal Connection Diagrams Diagrams showing which signals correspond to which terminals are shown in Section 2 of the TSL3000 Interface Manual STE85364 or the TSL3000E Interface Manual STE85457. 14.2.2 Jumpers for Safety Related Signals The following system input signals are provided to serve for the safety purpose.
Page 154 TRANSPORTATION AND INSTALLATION MANUAL CAUTION • Unless the signals of SVOFF and emergency stop contacts 1, 2 are jumpered, the controller servo power cannot be turned on. • Unless the CYCLE signal is jumpered, the controller enters the cycle operation mode. •...
Page 155: System Connections (Ts3000 And Ts3000E)
TRANSPORTATION AND INSTALLATION MANUAL 15. System Connections (TS3000 and TS3000E) 15.1 Cable Wiring For information on TSL3000, refer to Section 13. For information on TSL3000E, refer to Section 14. This section describes the various types of cables and connectors and explains how these are to be connected.
Page 156: Connecting The Power Cable "Acin" ( Of Fig. 15.1) (Plug Connector Attached)
TRANSPORTATION AND INSTALLATION MANUAL  Brake signal cable (BRK)  Distribution I/O cable (EXT-I/O)  External input/output power cable "EMS" In the subsequent paragraphs, we explain how to connect cables  to  and  inclusive. For information on how to connect cables  to , refer to the TS3000 Interface Manual STE80729.
Page 157: Connecting The Motor Cable "Motor" ( Of Fig. 15.1) (Thl300 To Thl1000)
TRANSPORTATION AND INSTALLATION MANUAL DANGER • Be sure to use the designated wire. Failure to do so could lead to fires or faults. • When connecting the connector and wires, make sure not to mistake the terminal arrangement. • After making the connection, use a tester, etc., to confirm the connection. For the terminal arrangement, see Para.
Page 158: Connecting The Encoder Cable "Enc" ( Of Fig. 15.1)
TRANSPORTATION AND INSTALLATION MANUAL Connect to “ROBOT” of the controller Fig. 15.2 Robot side connector arrangement (TS3000 and TS3000E) 15.1.4 Connecting the Encoder Cable "ENC" ( of Fig. 15.1) The encoder cable is integrated with the motor cable, robot control signal cable, and brake signal cable.
Page 159: Connecting The Brake Signal Cable "Brk" ( Of Fig. 15.1)
TRANSPORTATION AND INSTALLATION MANUAL 15.1.6 Connecting the Brake Signal Cable "BRK" ( of Fig. 15.1) The brake signal cable is integrated with the motor cable, encoder cable, and robot control signal cable. This integrated cable is further integrated with the robot. The brake signal cable is used for motor brake ON and OFF.
Page 160: Connecting And Disconnecting Cables
TRANSPORTATION AND INSTALLATION MANUAL CAUTION Be sure to supply external power (24 VDC). If not, power cannot be turned on, independently of safety measures. 15.1.8 Connecting and Disconnecting Cables CAUTION • Before connecting or disconnecting any controller cable, be sure to turn off the main power ("POWER") switch.
Page 161 TRANSPORTATION AND INSTALLATION MANUAL b) Square connectors: ENC, HAND, SYSTEM, INPUT, OUTPUT, TRIG, CONV Firstly, completely insert the cable side connector into the controller connector. Then tighten the lock screws on both ends of the cable side connector with a screwdriver.
Page 162: Examples Of Connector Terminal Arrangement (Controller Side)
TRANSPORTATION AND INSTALLATION MANUAL 15.1.9 Examples of Connector Terminal Arrangement (Controller Side) a) Power cable connector ACIN Connects to controller. Type: JL04V–2E18–10PE–B DANGER Manufacturer: Japan Aviation Electronics • Completely connect the grounding Industry, Ltd cable. Single phase, 200 - 240 VAC, Otherwise, an electric shock or fire may be caused if a fault or electric 50/60 Hz...
Page 163 TRANSPORTATION AND INSTALLATION MANUAL e) General-purpose input signal cable connector INPUT Connects to controller. Type: DHA-RC36-R132N-FA 17 16 15 14 13 12 11 28 27 26 25 24 23 22 21 20 19 36 35 34 33 32 31 30 29 Manufacturer: DDK General-purpose output signal cable connector OUTPUT Connects to controller.
Page 164 TRANSPORTATION AND INSTALLATION MANUAL Emergency stop, safety input, and external P24V supply connector EMS Connects to controller. Type: ML-4000CWJH-10PGY 10 9 8 Manufacturer: SATO PARTS k) Brake connector BRK Connects to controller. Type: 1-1827876-6 A1 A2 A3 A4 A5 A6 Manufacturer: Tyco Electronics AMP STE 85356...
Page 165: Controller Connector Signals
TRANSPORTATION AND INSTALLATION MANUAL 15.2 Controller Connector Signals For information on TSL3000, refer to Section 13. For information on TSL3000E, refer to Section 14. 15.2.1 Connector Signal Connection Diagrams Diagrams showing which signals correspond to which terminals are shown in Section 2 of the TS3000 Interface Manual STE80729.
Page 166 TRANSPORTATION AND INSTALLATION MANUAL CAUTION • Unless the signals of SVOFF and emergency stop contacts 1, 2 are jumpered, the controller servo power cannot be turned on. • Unless the CYCLE signal is jumpered, the controller enters the cycle operation mode. •...
Page 167: Separating Control Panel From Controller
TRANSPORTATION AND INSTALLATION MANUAL 15.3 Separating Control Panel from Controller Separate control panel option is not available for TSL3000 and TS3000E. 15.3.1 Removing Control Panel Remove the control panel in the following manner. a) Loosen the four (4) screws at the four (4) corners, which secure the control panel. b) Remove these screws, then carefully draw out the control panel toward your side.
Page 168: Control Panel Mounting Dimensions
TRANSPORTATION AND INSTALLATION MANUAL 15.3.3 Control Panel Mounting Dimensions The dimensions of mounting the control panel are shown in Fig. 15.6. Cross truss head screws (3 x 6, ZN3–B) are used. 4-M3 Hole for control panel Fig. 15.6 Control panel mounting dimensions STE 85356...
Page 169: Mounting Dummy Panel On Controller (Option)
TRANSPORTATION AND INSTALLATION MANUAL 15.3.4 Mounting Dummy Panel on Controller (option) When the control panel has been disengaged from the controller, mount a dummy panel on the place where the control panel was set before, as shown in Fig. 15.7. The dummy panel, mounting parts, etc.
Page 170: Dimensions When Separating Control Panel
TRANSPORTATION AND INSTALLATION MANUAL 15.3.5 Dimensions when Separating Control Panel Fig. 15.8 shows the connections of the control panel and dummy panel. Provide a clearance of 50 mm or more (with cover, 60 mm or more) on the rear side of the separated control panel.
Page 171: Tool Interface (Thl300 And Thl400)
TRANSPORTATION AND INSTALLATION MANUAL 16. Tool Interface (THL300 and THL400) 16.1 Mounting Tool The tool is mounted on the end of the tool shaft. Dimensions of the tool shaft section are shown in Fig. 16.1. As shown in Fig. 16.1, the tool is centered with the 12H7 mating section.
Page 172: Tool Air Piping
TRANSPORTATION AND INSTALLATION MANUAL 16.2 Tool Air Piping The customer is requested to install the tool air piping using the following accessories.  Air tube x3 (red, white, blue) Fig. 16.2 shows an installation example of tool air piping for your reference. 3 x 4 air tube Make holes on the metal plate cover, and fasten...
Page 173: Permissible Load Conditions And Program Setting
TRANSPORTATION AND INSTALLATION MANUAL 16.3 Permissible Load Conditions and Program Setting This paragraph describes the permissible load conditions of the robot and how to set up the program according to the load. 16.3.1 Permissible Load Conditions The robot load conditions are defined by the tool mass, moment of inertia and offset value of tool gravity center from the center of the tool shaft, as shown in Fig.
Page 174: Load Conditions And Program Setting
TRANSPORTATION AND INSTALLATION MANUAL 16.3.2 Load Conditions and Program Setting This robot can automatically change the maximum speed, acceleration/deceleration and servo gain by using the PAYLOAD command in the program according to the load conditions. Be sure to use the PAYLOAD command. The specific method for using this function is explained below.
Page 175 TRANSPORTATION AND INSTALLATION MANUAL (Program example 2) When the hand mass is 3 kg and the gravity center offset is 30 mm, and the mass is 5 kg and gravity center offset is 50 mm when the workpiece is grasped. Pick-and-place operation is executed under the above conditions.
Page 176 TRANSPORTATION AND INSTALLATION MANUAL c) Setting of PAYLOAD command In the default state, or when the PAYLOAD command is not used, the maximum speed and acceleration/deceleration are set to 100 % and the servo gain is set to the value under the minimum load. See "Setting Maximum Speed and Robot Acceleration/Deceleration for Load Conditions"...
Page 177 TRANSPORTATION AND INSTALLATION MANUAL CAUTION • When guiding manually, the robot may vibrate if the load mass or gravity center offset is large. This is because the servo gain is not appropriate. When this happens, perform the following operation while setting the load conditions in the test run mode.
Page 178: Setting Maximum Speed And Robot Acceleration/Deceleration For Load Conditions
TRANSPORTATION AND INSTALLATION MANUAL 16.3.3 Setting Maximum Speed and Robot Acceleration/Deceleration for Load Conditions When the PAYLOAD command is used, the maximum speed and acceleration/deceleration of the robot are automatically changed according to the load conditions. The maximum speed and acceleration/deceleration change with the load mass, as shown in Figs.
Page 179 TRANSPORTATION AND INSTALLATION MANUAL Acceleration/ Acceleration/ Deceleration Deceleration Maximum speed Maximum speed Load (kg) Load (kg) Setting of maximum speed and acceleration/deceleration in Setting of maximum speed and acceleration/deceleration in relation to load mass (Axis 1) relation to load mass (Axis 2) Acceleration/ Acceleration/ Deceleration...
Page 180 TRANSPORTATION AND INSTALLATION MANUAL Additionally, if there is an offset of load gravity center, the maximum speed and acceleration/deceleration change as shown in Fig. 16.6 to Fig. 16.9. Load mass  2 (kg) Load mass  2 (kg) 2 (kg) < Load mass  5 (kg) 2 (kg) <...
Page 181 TRANSPORTATION AND INSTALLATION MANUAL Load mass  2 (kg) Load mass  2 (kg) 2 (kg) < Load mass  5 (kg) 2 (kg) < Load mass  3.5 (kg) Load mass > 3.5 (kg) Load mass > 5 (kg) Offset (mm) Offset (mm) Setting of acceleration/deceleration in relation to offset (Axis 3)
Page 182 TRANSPORTATION AND INSTALLATION MANUAL Load mass  2 (kg) Load mass  2 (kg) 2 (kg) < Load mass  5 (kg) 2 (kg) < Load mass  3.5 (kg) Load mass > 5 (kg) Load mass > 3.5 (kg) Offset (mm) Offset (mm) Setting of acceleration/deceleration in relation to offset (Axis 1)
Page 183 TRANSPORTATION AND INSTALLATION MANUAL Load mass  2 (kg) Load mass  2 (kg) 2 (kg) < Load mass  5 (kg) 2 (kg) < Load mass  3.5 (kg) Load mass > 3.5 (kg) Load mass > 5 (kg) Offset (mm) Offset (mm) Setting of acceleration/deceleration in relation to offset (Axis 3)
Page 184: Tool Interface (Thl500, Thl600 And Thl700)
TRANSPORTATION AND INSTALLATION MANUAL 17. Tool Interface (THL500, THL600 and THL700) 17.1 Mounting Tool The tool is mounted on the end of the tool shaft. Dimensions of the tool shaft section are shown in Fig. 17.1. As shown in Fig. 17.1, the tool is centered with the 12H7 mating section.
Page 185: Tool Air Piping
TRANSPORTATION AND INSTALLATION MANUAL 17.2 Tool Air Piping The customer is requested to install the tool air piping using the following accessories.  Air tube x3 (red, white, blue) Fig. 17.2 shows an installation example of tool air piping for your reference. Make holes on the metal plate cover, and fasten the air tubes with bolts...
Page 186: Permissible Load Conditions And Program Setting
TRANSPORTATION AND INSTALLATION MANUAL 17.3 Permissible Load Conditions and Program Setting This paragraph describes the permissible load conditions of the robot and how to set up the program according to the load. 17.3.1 Permissible Load Conditions The robot load conditions are defined by the tool mass, moment of inertia and offset value of tool gravity center from the center of the tool shaft, as shown in Fig.
Page 187: Load Conditions And Program Setting
TRANSPORTATION AND INSTALLATION MANUAL 17.3.2 Load Conditions and Program Setting For load conditions and program setting, see "16.3.2 Load Conditions and Program Setting". 17.3.3 Setting Maximum Speed and Robot Acceleration/Deceleration for Load Conditions When the PAYLOAD command is used, the maximum speed and acceleration/ deceleration of the robot are automatically changed according to the load conditions.
Page 188 TRANSPORTATION AND INSTALLATION MANUAL Acceleration/ Acceleration/ Deceleration Deceleration Maximum speed Maximum speed Load (kg) Load (kg) Setting of maximum speed and acceleration/deceleration in Setting of maximum speed and acceleration/deceleration in relation to load mass (Axis 1) relation to load mass (Axis 2) Acceleration/ Acceleration/ Deceleration...
Page 189 TRANSPORTATION AND INSTALLATION MANUAL Acceleration/ Acceleration/ Deceleration Deceleration Maximum speed Maximum speed Load (kg) Load (kg) Setting of maximum speed and acceleration/deceleration in Setting of maximum speed and acceleration/deceleration in relation to load mass (Axis 1) relation to load mass (Axis 2) Acceleration/ Acceleration/ Deceleration...
Page 190 TRANSPORTATION AND INSTALLATION MANUAL Acceleration/ Acceleration/ Deceleration Deceleration Maximum speed Maximum speed Load (kg) Load (kg) Setting of maximum speed and acceleration/deceleration in Setting of maximum speed and acceleration/deceleration in relation to load mass (Axis 1) relation to load mass (Axis 2) Acceleration/ Acceleration/ Deceleration...
Page 191 TRANSPORTATION AND INSTALLATION MANUAL Additionally, if there is an offset of load gravity center, the maximum speed and acceleration/deceleration change as shown in Fig. 17.7 to Fig. 17.12. Load mass  2 (kg) Load mass  2 (kg) 2 (kg) < Load mass  5 (kg) 2 (kg) <...
Page 192 TRANSPORTATION AND INSTALLATION MANUAL Load mass ( 2 (kg) Load mass ( 2 (kg) 2 (kg) < Load mass  5 (kg) 2 (kg) < Load mass ( 5 (kg) Load mass > 5 (kg) Load mass > 5 (kg) Offset (mm) Offset (mm) Setting of acceleration/deceleration in relation to offset (Axis 3)
Page 193 TRANSPORTATION AND INSTALLATION MANUAL Load mass  2 (kg) Load mass  2 (kg) 2 (kg) < Load mass  5 (kg) 2 (kg) < Load mass  5 (kg) Load mass > 5 (kg) Load mass > 5 (kg) Offset (mm) Offset (mm) Setting of acceleration/deceleration in relation to offset (Axis 1)
Page 194 TRANSPORTATION AND INSTALLATION MANUAL Setting of acceleration/deceleration in relation to offset (Axis 2) Setting of maximum speed in relation to offset (Axis 2) Load mass  2 (kg) Load mass  2 (kg) 2 (kg) < Load mass  5 (kg) 2 (kg) <...
Page 195 TRANSPORTATION AND INSTALLATION MANUAL Load mass  2 (kg) Load mass  2 (kg) 2 (kg) < Load mass  5 (kg) 2 (kg) < Load mass  5 (kg) Load mass > 5 (kg) Load mass > 5 (kg) Offset (mm) Offset (mm) Setting of acceleration/deceleration in relation to offset (Axis 1)
Page 196 TRANSPORTATION AND INSTALLATION MANUAL Load mass  2 (kg) Load mass  2 (kg) 2 (kg) < Load mass  5 (kg) 2 (kg) < Load mass  5 (kg) Load mass > 5 (kg) Load mass > 5 (kg) Offset (mm) Offset (mm) Setting of acceleration/deceleration in relation to offset (Axis 3)
Page 197: Tool Interface (Thl800, Thl900 And Thl1000)
TRANSPORTATION AND INSTALLATION MANUAL 18. Tool Interface (THL800, THL900 and THL1000) 18.1 Mounting Tool The tool is mounted on the end of the tool shaft. Dimensions of the tool shaft section are shown in Fig. 18.1. As shown in Fig. 18.1, the tool is centered with the 12H7 mating section.
Page 198: Tool Air Piping
TRANSPORTATION AND INSTALLATION MANUAL 18.2 Tool Air Piping The customer is requested to install the tool air piping using the following accessories.  Air tube x3 (red, white, blue) Fig. 18.2 shows an installation example of tool air piping for your reference. Make holes on the metal plate cover, and fasten the air tubes with bolts...
Page 199: Permissible Load Conditions And Program Setting
TRANSPORTATION AND INSTALLATION MANUAL 18.3 Permissible Load Conditions and Program Setting This paragraph describes the permissible load conditions of the robot and how to set up the program according to the load. 18.3.1 Permissible Load Conditions The robot load conditions are defined by the tool mass, moment of inertia and offset value of tool gravity center from the center of the tool shaft, as shown in Fig.
Page 200: Load Conditions And Program Setting
TRANSPORTATION AND INSTALLATION MANUAL 18.3.2 Load Conditions and Program Setting For load conditions and program setting, see "16.3.2 Load Conditions and Program Setting". 18.3.3 Setting Maximum Speed and Robot Acceleration/Deceleration for Load Conditions When the PAYLOAD command is used, the maximum speed and acceleration/ deceleration of the robot are automatically changed according to the load conditions.
Page 201 TRANSPORTATION AND INSTALLATION MANUAL Acceleration/ Acceleration/ Deceleration Deceleration Maximum speed Maximum speed Load (kg) Load (kg) Setting of maximum speed and acceleration/deceleration in Setting of maximum speed and acceleration/deceleration in relation to load mass (Axis 1) relation to load mass (Axis 2) Acceleration/ Acceleration/ Deceleration...
Page 202 TRANSPORTATION AND INSTALLATION MANUAL Acceleration/ Acceleration/ Deceleration Deceleration Maximum speed Maximum speed Load (kg) Load (kg) Setting of maximum speed and acceleration/deceleration in Setting of maximum speed and acceleration/deceleration in relation to load mass (Axis 1) relation to load mass (Axis 2) Acceleration/ Acceleration/ Deceleration...
Page 203 TRANSPORTATION AND INSTALLATION MANUAL Acceleration/ Acceleration/ Deceleration Deceleration Maximum speed Maximum speed Load (kg) Load (kg) Setting of maximum speed and acceleration/deceleration in Setting of maximum speed and acceleration/deceleration in relation to load mass (Axis 1) relation to load mass (Axis 2) Acceleration/ Acceleration/ Deceleration...
Page 204 TRANSPORTATION AND INSTALLATION MANUAL Additionally, if there is an offset of load gravity center, the maximum speed and acceleration/deceleration change as shown in Fig. 18.7 to Fig. 18.12. Load mass  2 (kg) Load mass  2 (kg) 2 (kg) < Load mass  5 (kg) 2 (kg) <...
Page 205 TRANSPORTATION AND INSTALLATION MANUAL Load mass ( 2 (kg) Load mass ( 2 (kg) (kg) < Load mass ( 5 2 (kg) < Load mass (kg) ( 5 (kg) Load mass > 5 (kg) Load mass > 5 (kg) Offset (mm) Offset (mm) Setting of acceleration/deceleration in relation to offset (Axis 3) Setting of maximum speed in relation to offset (Axis 3)
Page 206 TRANSPORTATION AND INSTALLATION MANUAL Load mass ( 2 (kg) Load mass ( 2 (kg) 2 (kg) < Load mass ( 5 (kg) 2 (kg) < Load mass ( 5 (kg) Load mass > 5 (kg) Load mass > 5 (kg) Offset (mm) Offset (mm) オフセット量に対する加減速度の設定(第1軸)
Page 207 TRANSPORTATION AND INSTALLATION MANUAL Setting of acceleration/deceleration in relation to offset (Axis 2) Setting of maximum speed in relation to offset (Axis 2) Load mass  2 (kg) Load mass  2 (kg) 2 (kg) < Load mass ( 5 2 (kg) <...
Page 208 TRANSPORTATION AND INSTALLATION MANUAL Load mass ( 2 (kg) Load mass ( 2 (kg) 2 (kg) < Load mass  5 (kg) 2 (kg) < Load mass ( 5 (kg) Load mass > 5 (kg) Load mass > 5 (kg) Offset (mm) Offset (mm) Setting of acceleration/deceleration in relation to offset (Axis 1)
Page 209 TRANSPORTATION AND INSTALLATION MANUAL Load mass ( 2 (kg) Load mass  2 (kg) 2 (kg) < Load mass  5 (kg) (kg) < Load mass ( 5 (kg) Load mass > 5 (kg) Load mass > 5 (kg) Offset (mm) Offset (mm) Setting of acceleration/deceleration in relation to offset (Axis 3) Setting of maximum speed in relation to offset (Axis 3)
Page 210: Tool Interface (Tsl3000)
TRANSPORTATION AND INSTALLATION MANUAL 19. Tool Interface (TSL3000) 19.1 Tool Wiring Eight (8) input signals are provided for sensors, etc. and eight (8) control signals for solenoid valves, etc. A supply power signal of 24 VDC is also provided. They are connected to the controller.
Page 211 TRANSPORTATION AND INSTALLATION MANUAL D-SUB 25 pin connector types Connector type (male) <Hood> XM2S-2511 (maker: OMRON) <Body> XM3A-2521 (maker: OMRON) Connector type (female) <Body> XM3D-2521 (maker: OMRON) Cable inlet Brake release Grommet switch Inner diameter 13 mm Base rear cover JOEP JOFP JOES...
Page 212 TRANSPORTATION AND INSTALLATION MANUAL Cable inlet D-SUB 25 pin Grommet installation position Inner diameter 9 mm Base rear cover JOEP JOFP JOES JOFS From PLC etc. JOFS Disconnect (HAND side) JOES Fig. 19.3 Wiring to PLC, etc. (THL800, THL900, THL1000 and TSL3000) STE 85356...
Page 213 Input/output circuit and example of connections (D-SUB) D-IN1 Input signal 1 Input Customer’s side D-IN2 Input signal 2 THL series (Arm 2 or P24V the rear side of base) D-IN3 Input signal 3 D-IN4 Input signal 4 D-IN5 Input signal 5...
Page 214 Input/output circuit and example of connections (D-SUB) D-IN1 Input signal 1 Input D-IN2 Input signal 2 Customer’s side THL series (Arm 2 or the rear side of base) D-IN3 Input signal 3 P24V D-IN4 Input signal 4 D-IN5 Input signal 5...
Page 215 TRANSPORTATION AND INSTALLATION MANUAL Transistor specifications: Withhold voltage between collector and emitter: 30 V or over Current between collector and emitter: 10 mA or over (circuit current: approx. 7 mA) Leak current between collector and emitter: 100 A or less By using P24V power of the controller, a relay, solenoid valve, etc., can be driven.
Page 216 TRANSPORTATION AND INSTALLATION MANUAL Brake release switch JOFS Wiring connector for CN0 hand JOES JOEP JOFP JOFP JOEP JOES JOFS Fig. 19.5 Tool wiring (THL500, THL600 and THL700) JOFS Brake release switch JOES Wiring connector for CN0 hand JOEP JOFP JOFP JOEP JOES...
Page 217 TRANSPORTATION AND INSTALLATION MANUAL Fig. 19.7 Tool wiring (Common to Type-N, Type-P and TSL3000) STE 85356...
Page 218 TRANSPORTATION AND INSTALLATION MANUAL Hand wiring connector (D-SUB) * Use mount bases or similar to prevent the cable from hanging down. Ball screw shaft (hollow) Fixed stay (Prepared by the customer) Hand 2 x M3 tap hole Penetration depth 6 mm Fig.
Page 219 TRANSPORTATION AND INSTALLATION MANUAL Hand wiring connector (D-SUB) Ball screw shaft (hollow) Fixed stay (Prepared by the customer) * Use mount bases or similar to prevent the cable from hanging down. Hand 2 x M4 tap hole Penetration depth 4 mm (penetrated) Fig.
Page 220 TRANSPORTATION AND INSTALLATION MANUAL Ball screw shaft (hollow) Hand wiring connector (D-SUB) Fixed stay (Prepared by the * Use mount bases or similar to prevent customer) the cable from hanging down. Hand 4 x M4 tap hole Penetration depth 7 mm Fig.
Page 221: Tool Signals (Controller Side)
TRANSPORTATION AND INSTALLATION MANUAL 19.2 Tool Signals (Controller Side) The controller is provided with the tool signals of eight input signals for sensors, eight control signals for solenoid valves, DC24 V (P24V) signal, and DC24 V GND (P24G) signal. The signals enable connection from the controller to external equipment. Table 19.3 Input signal connector HAND (TSL3000, Type-N) Signal Signal name...
Page 222 TRANSPORTATION AND INSTALLATION MANUAL Table 19.4 Input signal connector HAND (TSL3000, Type P) Signal Input circuit and example of Signal name connections Input D-IN1 signal 1 Customer's side お客様側 TSL3000 (Cable between the robot Input and the controller) D-IN2 signal 2 P24V Input D-IN3...
Page 223 TRANSPORTATION AND INSTALLATION MANUAL Table 19.5 Output signal connector HAND (TSL3000, Type N) Output circuit and example of Signal name Signal No. connections Output TSL3000 D-OUT1 signal 1 Customer's side (Cable between the robot and Output the controller) D-OUT2 signal 2 P24V DC relay Output...
Page 224 TRANSPORTATION AND INSTALLATION MANUAL Table 19.6 Output signal connector HAND (TSL3000, Type P) Output circuit and example of Signal name Signal No. connections Output TSL3000 D-OUT1 Customer's side signal 1 (Cable between the robot and the controller) Output P24V D-OUT2 signal 2 ●...
Page 225: Tool Interface (Tsl3000E)
TRANSPORTATION AND INSTALLATION MANUAL 20. Tool Interface (TSL3000E) 20.1 Tool Wiring Eight (8) input signals are provided for sensors, etc. and eight (8) control signals for solenoid valves, etc. A supply power signal of 24 VDC is also provided. They are connected to the controller.
Page 226 TRANSPORTATION AND INSTALLATION MANUAL D-SUB 25 pin connector types Connector type (male) <Hood> XM2S-2511 (maker: OMRON) <Body> XM3A-2521 (maker: OMRON) Connector type (female) <Body> XM3D-2521 (maker: OMRON) Cable inlet Brake release Grommet switch Inner diameter 13 mm Base rear cover JOEP JOFP JOES...
Page 227 TRANSPORTATION AND INSTALLATION MANUAL Cable inlet D-SUB 25 pin Grommet installation position Inner diameter 9 mm Base rear cover JOEP JOFP JOES JOFS From PLC etc. JOFS Disconnect (HAND side) JOES Fig. 20.3 Wiring to PLC, etc. (THL800, THL900, THL1000 and TSL3000E) STE 85356...
Page 228 Input signal 1 Input Customer’s side D-IN2 Input signal 2 Arm 2 (1) Customer side TSL3100E お客様側 THL series (Arm 2 or the rear side of base) D-IN3 Input signal 3 SYSINCOM ● D-IN4 Input signal 4 ● D-IN5...
Page 229 Input/output circuit and example of connections (D-SUB) D-IN1 Input signal 1 Input Arm 2 (1) Customer’s side D-IN2 Input signal 2 THL series (Arm 2 or Customer’s side TSL3100E TS3100 the rear side of base) D-IN3 Input signal 3 D-IN4 Input signal 4...
Page 230 TRANSPORTATION AND INSTALLATION MANUAL When the external power is used, GND of the external power should be common to GND (P24G) of the robot controller. Output specifications: Rated voltage 24 VDC (max. 30 VDC) Rated current 100 mA • If the P24V power supplied from the robot controller is used, the total current should be 2 A or less.
Page 231 TRANSPORTATION AND INSTALLATION MANUAL Brake release switch JOFS Wiring connector for CN0 hand JOES JOEP JOFP JOFP JOEP JOES JOFS Fig. 20.5 Tool wiring (THL500, THL600 and THL700) JOFS Brake release switch JOES Wiring connector for CN0 hand JOEP JOFP JOFP JOEP JOES...
Page 232 TRANSPORTATION AND INSTALLATION MANUAL Fig. 20.7 Tool wiring (Common to Type-N, Type-P and TSL3000E) STE 85356...
Page 233 TRANSPORTATION AND INSTALLATION MANUAL Hand wiring connector (D-SUB) * Use mount bases or similar to prevent the cable from hanging down. Ball screw shaft (hollow) Fixed stay (Prepared by the customer) Hand 2 x M3 tap hole Penetration depth 6 mm Fig.
Page 234 TRANSPORTATION AND INSTALLATION MANUAL Hand wiring connector (D-SUB) Ball screw shaft (hollow) Fixed stay (Prepared by the customer) * Use mount bases or similar to prevent the cable from hanging down. Hand 2 x M4 tap hole Penetration depth 4 mm (penetrated) Fig.
Page 235 TRANSPORTATION AND INSTALLATION MANUAL Ball screw shaft (hollow) Hand wiring connector (D-SUB) Fixed stay (Prepared by the * Use mount bases or similar to prevent customer) the cable from hanging down. Hand 4 x M4 tap hole Penetration depth 7 mm Fig.
Page 236: Tool Signals (Controller Side)
TRANSPORTATION AND INSTALLATION MANUAL 20.2 Tool Signals (Controller Side) The controller is provided with the tool signals of eight input signals for sensors, eight control signals for solenoid valves, DC24 V (P24V) signal, and DC24 V GND (P24G) signal. The signals enable connection from the controller to external equipment. Table 20.3 Input signal connector HAND (TSL3000E, Type-N) Signal Signal name...
Page 237 TRANSPORTATION AND INSTALLATION MANUAL Table 20.4 Input signal connector HAND (TSL3000E, Type P) Signal Input circuit and example of Signal name connections Input D-IN1 signal 1 TSL3000E Customer's side TSL3100E お客様側 Input D-IN2 signal 2 P24V Input D-IN3 signal 3 Input D-IN4 signal 4...
Page 238 TRANSPORTATION AND INSTALLATION MANUAL Table 20.5 Output signal connector HAND (TSL3000E, Type N) Output circuit and example of Signal name Signal No. connections Output Customer's side D-OUT1 TSL3000E signal 1 お客様側 [P24G (minus) common Output connection] D-OUT2 【P24G(-) ｺﾓﾝ接続】 P24V signal 2 ●...
Page 239 TRANSPORTATION AND INSTALLATION MANUAL Table 20.6 Output signal connector HAND (TSL3000E, Type P) Output circuit and example of Signal name Signal No. connections Output D-OUT1 Customer’s side TSL3000E signal 1 お客様側 Output 【P24V(+)ｺﾓﾝ接続】 D-OUT2 P24V [P24V (plus) common ●...
Page 240: Tool Interface (Ts3000 And Ts3000E)
TRANSPORTATION AND INSTALLATION MANUAL 21. Tool Interface (TS3000 and TS3000E) 21.1 Tool Wiring Eight (8) input signals are provided for sensors, etc. and eight (8) control signals for solenoid valves, etc. A supply power signal of 24 VDC is also provided. They are connected to the controller.
Page 241 TRANSPORTATION AND INSTALLATION MANUAL D-SUB 25 pin connector types (THL500 to THL1000) Connector type (male) <Hood> XM2S-2511 (maker: OMRON) <Body> XM3A-2521 (maker: OMRON) Connector type (female) <Body> XM3D-2521 (maker: OMRON) Cable inlet Brake release Grommet switch Inner diameter 13 mm Base rear cover JOEP JOFP...
Page 242 TRANSPORTATION AND INSTALLATION MANUAL Cable inlet D-SUB 25 pin Grommet installation position Inner diameter 9 mm Base rear cover JOEP JOFP JOES JOFS From PLC etc. JOFS Disconnect (HAND side) JOES Fig. 21.3 Wiring to PLC, etc. (THL800, THL900, THL1000 and TS3000/TS3000E) STE 85356...
Page 243 Input/output circuit and example of connections (D-SUB) D-IN1 Input signal 1 Input D-IN2 Input signal 2 Customer’s side THL series (Arm 2 or P24V the rear side of base) D-IN3 Input signal 3 D-IN4 Input signal 4 D-IN5 Input signal 5...
Page 244 Input/output circuit and example of connections (D-SUB) D-IN1 Input signal 1 Input D-IN2 Input signal 2 Customer’s side THL series (Arm 2 or Customer’s side the rear side of base) D-IN3 Input signal 3 P24V D-IN4 Input signal 4 D-IN5...
Page 245 TRANSPORTATION AND INSTALLATION MANUAL Transistor specifications: Withhold voltage between collector and emitter: 30 V or over Current between collector and emitter: 10 mA or over (circuit current: approx. 7 mA) Leak current between collector and emitter: 100 A or less By using P24V power of the controller, a relay, solenoid valve, etc., can be driven.
Page 246 TRANSPORTATION AND INSTALLATION MANUAL Brake release switch JOFS Wiring connector for CN0 hand JOES JOEP JOFP JOFP JOEP JOES JOFS Fig. 21.5 Tool wiring (THL500, THL600 and THL700) JOFS Brake release switch JOES Wiring connector for CN0 hand JOEP JOFP JOFP JOEP JOES...
Page 247 TRANSPORTATION AND INSTALLATION MANUAL Fig. 21.7 Tool wiring (TS3000 and TS3000E, Type-N) STE 85356...
Page 248 TRANSPORTATION AND INSTALLATION MANUAL Fig. 21.8 Tool wiring (TS3000 and TS3000E, Type-P) STE 85356...
Page 249 TRANSPORTATION AND INSTALLATION MANUAL Hand wiring connector (D-SUB) * Use mount bases or similar to prevent the cable from hanging down. Ball screw shaft (hollow) Fixed stay (Prepared by the customer) Hand 2 x M3 tap hole Penetration depth 6 mm Fig.
Page 250 TRANSPORTATION AND INSTALLATION MANUAL Hand wiring connector (D-SUB) Ball screw shaft (hollow) Fixed stay (Prepared by the customer) * Use mount bases or similar to prevent the cable from hanging down. Hand 2 x M4 tap hole Penetration depth 4 mm (penetrated) Fig.
Page 251 TRANSPORTATION AND INSTALLATION MANUAL Ball screw shaft (hollow) Hand wiring connector (D-SUB) Fixed stay (Prepared by the * Use mount bases or similar to prevent customer) the cable from hanging down. Hand 4 x M4 tap hole Penetration depth 7 mm Fig.
Page 252: Tool Signals (Controller Side)
TRANSPORTATION AND INSTALLATION MANUAL 21.2 Tool Signals (Controller Side) The controller is provided with tool signals (i.e., eight (8) input signals for sensor, etc., eight (8) control signals for solenoid valve, etc., 24 VDC(P24V) and 24 VDC GND (P24G) signals), which can be connected also from the controller side. The relevant signals are described below.
Page 253 TRANSPORTATION AND INSTALLATION MANUAL Table 21.4 Input signal connector HAND (TS3000 and TS3000E, Type P) Signal Input circuit and example of Signal name connections Input D-IN1 signal 0 Customer's side Input TS3000 TS3000/TS3000E D-IN2 signal 1 P24V Input D-IN3 signal 2 Input D-IN4 signal 3...
Page 254 TRANSPORTATION AND INSTALLATION MANUAL Table 21.5 Output signal connector HAND (TS3000 and TS3000E, Type N) Output circuit and example of Signal name Signal No. connections Output D-OUT0 signal 0 TS3000 Customer's TS3000/TS3000E side Output D-OUT1 signal 1 P24V DC relay Output D-OUT2 signal 2...
Page 255 TRANSPORTATION AND INSTALLATION MANUAL Table 21.6 Output signal connector HAND (TS3000 and TS3000E, Type P) Output circuit and example of Signal name Signal No. connections Output D-OUT0 signal 0 TS3000/TS3000E Customer's Output TS3000 D-OUT1 side signal 1 Output P24V D-OUT2 signal 2 Output DC relay...

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