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Toshiba THP700 Maintenance Manual

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THP700/TS3100
1.
Make sure that this instruction manual is delivered to the final
user of this product.
2.
Before using this product robot, read through and completely
understand this manual.
3.
After reading through this manual, keep it nearby for future
reference.
MAINTENANCE MANUAL
January, 2011
TOSHIBA MACHINE CO., LTD.
Notice
STE 85321-0

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Summary of Contents for Toshiba THP700

  • Page 1 Make sure that this instruction manual is delivered to the final user of this product. Before using this product robot, read through and completely understand this manual. After reading through this manual, keep it nearby for future reference. January, 2011 TOSHIBA MACHINE CO., LTD.
  • Page 2 MAINTENANCE MANUAL 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. The information contained in this manual is subject to change without prior notice to effect improvements.
  • Page 3 MAINTENANCE MANUAL WARRANTY This product is delivered to each customer only after it is inspected very carefully to make sure that it satisfies the Toshiba Machine’s standard. Should it cause an inconvenience, we will guarantee as described below. Warranty period Toshiba Machine agrees to repair or replace as necessary all defective material or workmanship up to the period shown below, whichever comes first.
  • Page 4 Please note that the warnings, cautions and other descriptions stipulated in this manual are only those which can be assumed by Toshiba Machine as of now. (*1) The consumable parts signify the replacement parts for maintenance as listed in Section 5 of this manual.
  • Page 5 MAINTENANCE MANUAL INTRODUCTION This manual describes the maintenance of this product, THP700, and the TS3100 controller. The maintenance and inspection are essential to maintain the product performance for long years to prevent a trouble and improve the safe work. Before starting an actual operation, it is strongly recommended to read through this manual and draw up a maintenance schedule.
  • Page 6 Disassembly caused. prohibited • Always use the Toshiba Machine's designated spare parts when replacing the parts. • Maintenance and inspection should be performed regularly. Otherwise, the system may malfunction or accidents will be Mandatory caused.

  • Page 7: Table Of Contents

    MAINTENANCE MANUAL Table of Contents Page Maintenance ......................9 Maintenance Schedule ..................9 Items for Maintenance and Inspection ............10 1.2.1 Inspection at Power OFF (at Non-Operation)........10 1.2.2 Inspection at Power ON (at Operation) ..........11 1.2.3 Overhaul.................... 11 Maintenance Tools..................12 Maintenance Contract and Repair ..............12 1.4.1 Maintenance Contract ...............12 1.4.2...
  • Page 8 MAINTENANCE MANUAL 2.5.10 Mounting Axis 4 Motor...............42 Adjusting and Replacing Timing Belt .............43 2.6.1 Type of Timing Belt................43 2.6.2 Timing Belt Locations ................44 2.6.3 Replacing Axis 3 Timing Belt .............44 2.6.4 Replacing Axis 4 Timing Belt .............46 2.6.5 Adjusting Timing Belt.................49 Filling Grease to Ball Screw Spline Unit and Replacement......50 2.7.1 Type of Ball Screw Spline Unit ............50...
  • Page 9 MAINTENANCE MANUAL Robot Home Point and Position Detector Error ............86 Setting Robot Home Point ................86 Position Detector Error ..................87 Restoring Operation from Position Detector Error .........90 4.3.1 Encoder Status Display ..............90 4.3.2 Encoder Error Reset Operation............92 Restoring Home Position Data by HOME Function ........93 4.4.1 Outline of HOME Function ..............93 4.4.2...

  • Page 10: Maintenance

    MAINTENANCE MANUAL Maintenance Maintenance Schedule Maintenance comes in the two (2) types; daily inspection, and regular inspection and maintenance. For the regular inspection and maintenance, inspection items are added every 1,200 running hours. 3-month check 1200 3-month check 6-month check 2400 3-month check 3600...

  • Page 11: Items For Maintenance And Inspection

    MAINTENANCE MANUAL Items for Maintenance and Inspection This section describes the items for maintenance and inspection. For the executing procedures, see the relevant paragraph listed in the table below. 1.2.1 Inspection at Power OFF (at Non-Operation) D: Daily inspection Q: Quarterly inspection S: Semi-annual inspection A: Annual inspection Description...

  • Page 12: Inspection At Power On (At Operation)

    MAINTENANCE MANUAL 1.2.2 Inspection at Power ON (at Operation) D: Daily inspection Q: Quarterly inspection S: Semi-annual inspection A: Annual inspection Description Check position Refer to Push each arm by hand in Each joint the servo ON condition to make sure that the arm is secured.

  • Page 13: Maintenance Tools

    If a fault has occurred or if repair is necessary, turn off the controller power and contact the Toshiba Machine Service Department. At this time, advise us of the details of the fault and the following information stated on the robot and controller.

  • Page 14: Modification

    1.4.3 Modification The robot and controller MUST NOT be modified or disassembled without a prior consent from Toshiba Machine. CAUTION • The user must NEVER replace or modify parts other than those described in the instruction manual.

  • Page 15: Maintenance Of The Main Robot

    MAINTENANCE MANUAL Maintenance of the Main Robot Cautions on Maintenance and Inspection When performing inspection or maintenance of the robot, strictly observe the following precautions to protect yourself and coworkers. DANGER • Be sure to turn off the main power switch of the controller before approaching the robot for maintenance and inspection.
  • Page 16 MAINTENANCE MANUAL For the screws arranged on a circle for mounting the reduction gear, etc., tighten them in the diagonal order, as shown below. DO NOT tighten one (1) screw at a time. Tighten each screw in multiple steps, using a hexagonal wrench key, and secure with appropriate clamping torque by means of a torque wrench.

  • Page 17: Details Of Inspection

    MAINTENANCE MANUAL Details of Inspection 2.2.1 Check of Each Bolt (or Screw) for Clamping Tool Set Bolts Make sure, using the hexagonal wrench key, that the hexagon socket head cap screws of the tool set flange (option), which are clamped to the tool shaft are tightened completely.
  • Page 18 MAINTENANCE MANUAL Main robot installation bolt M16x4 pcs.; Recommended clamping torque 170 N·m Fig. 2.2 Robot base set bolts Bolts for each joint Make sure, using the hexagonal wrench key, that the bolts for the axis 1 and 2 joints (i.e., bolts for clamping each reduction gear and arm) are tightened completely.
  • Page 19 MAINTENANCE MANUAL Motor Set Bolts Make sure, using the hexagonal wrench key, that the bolts for securing each axis drive motor are tightened completely. If loosened, tighten them completely. Also make sure that the motor base set bolts are tightened completely. For the places where the following bolts are used, see Para.

  • Page 20: Check Of Each Cable And Air Tube For Abrasion

    MAINTENANCE MANUAL 2.2.2 Check of Each Cable and Air Tube for Abrasion Disassemble the arm 2 cover and base cover and make sure that each cable and air tube are not worn out, broken or cracked. Especially, take careful precautions to inspect the vicinity of the cable outlets of the axis 1 joint and axis 2 joint.

  • Page 21: Layout Of Robot Components And Drive Mechanism

    MAINTENANCE MANUAL Layout of Robot Components and Drive Mechanism The layout of the robot mechanical components is shown in Fig. 2.5. Axis 4 drive motor Axis 4 reduction gear Ball screw Axis 3 timing spline shaft belt Axis 2 rive motor Axis 1 reduction gear Ball screw...

  • Page 22: Dismounting And Mounting Each Cover

    MAINTENANCE MANUAL Dismounting and Mounting Each Cover This paragraph describes the dismounting and mounting of the covers, which are common to the maintenance and replacement of each unit. DANGER • When opening the cover, take careful precautions not to allow entry of moisture or contaminant into the robot.

  • Page 23: Arm 2 Cover

    MAINTENANCE MANUAL 2.4.1 Arm 2 Cover The arm 2 cover is secured to the cover set bracket with eleven (11) socket head bolts (M4x8). As the arm 2 cover is inserted into the arm 2, it can be lifted once the screws are removed.

  • Page 24: Arm 1 Covers

    MAINTENANCE MANUAL 2.4.2 Arm 1 Covers One of two arm-1 covers is provided on top of the axis 1 (the arm 1 upper cover), and the other at the bottom of the axis 2 (the arm 1 lower cover). Each cover is secured to the arm 1 with six cross truss head screws (M4x8).
  • Page 25 MAINTENANCE MANUAL Cross truss head screw Cross truss head Cover also used as battery screw Cover also serving as boxl cover connector panel cover Fig. 2.8 Base covers STE 85321 – 24 –...

  • Page 26: Replacing Motor

    MAINTENANCE MANUAL Replacing Motor The motor is to be replaced by our service engineer. If it is replaced by the customer, we will not guarantee any consequential trouble or accident. DANGER • The motor should be replaced with a new one only after the controller power is turned off with the power supply plug removed.

  • Page 27: Type Of Motor

    The motors employed in this robot are shown below. When you place an order for a replacement motor, make sure of the robot model (THP700), the serial number, the axis name, and our drawing number according to the following table.

  • Page 28: Motor Locations

    MAINTENANCE MANUAL 2.5.2 Motor Locations Axis 3 motor Axis 4 motor Axis 2 motor Axis 1 motor Fig. 2.9 Motor locations STE 85321 – 27 –...

  • Page 29: Dismounting Axis 1 Motor

    MAINTENANCE MANUAL 2.5.3 Dismounting Axis 1 Motor Remove the rear one of the covers attached to the base. (See "Para. 2.4.3.") Disconnect the axis 1 motor connectors, J1AS (power drive cable: cannon connector) and J1BS (encoder cable). Remove the four bolts (M16) securing the robot, remove the countersink plug from the center of the arm 1, and then place the robot sideways.
  • Page 30 MAINTENANCE MANUAL CAUTION • When dismounting the input gear, DO NOT knock it with excessive force. Otherwise, the encoder may be damaged. M6x80 Stick or the like Washer Input gear Hit the head of the stick with a plastic hammer. Washer Pull out the motor when it is shifted by hitting the input gear through the stick...

  • Page 31: Mounting Axis 1 Motor

    MAINTENANCE MANUAL 2.5.4 Mounting Axis 1 Motor Mount the input gear, then secure them with the bolt (M6x80) and washer. Secure the input gear, using a vice, etc. and tighten the bolt (M6x80) at the shaft end. When securing the input gear, use a shock-resistant material such as waste cloth in such a manner that the tooth top or tooth surface is not cut or scratched.

  • Page 32: Dismounting Axis 2 Motor

    MAINTENANCE MANUAL After the axis 1 motor is replaced with a new one and before the power is turned on, move the arm 1 by hand to make sure that no abnormal noise is heard. Turn the power on and perform home setting for the axis 1. Now, the motor replacement completes.
  • Page 33 MAINTENANCE MANUAL Remove the eight bolts (M10x25) securing the arms 1 and 2. When the eight bolts are removed, the arms 1 and 2 are separated. Be careful not to drop the arm 2. The arm 2 is connected with the base through the duct. Provide a cushion near the base, and place the arm 2 sideways on the cushion.
  • Page 34 MAINTENANCE MANUAL Cover bracket Axis 2 motor assembly M6x16 M6x20 Reduction gear Axis 2 motor base Remove the bolt (M5x10) from the end of the axis while holding the protrusion on the wave generator with pliers or the likes. Use a waste cloth (or the like) as a cushion to protect the wave generator from scratches when securing it.

  • Page 35: Mounting Axis 2 Motor

    MAINTENANCE MANUAL Separate the motor from the axis 2 motor base. Liquid gasket is applied to the motor mounting surface, so the motor may be hard to remove. Be careful to not to give excessive impact to the motor when removing it. 2.5.6 Mounting Axis 2 Motor Perform key alignment, using the new motor and wave generator.
  • Page 36 MAINTENANCE MANUAL Surface to which liquid gasket is applied Align the motor lead face with a position where there is no cover bracket mounting hole. Wave generator Axis 2 motor base Washer Washer Cover bracket mounting hole M5x10 M5x16 CAUTION •...
  • Page 37 MAINTENANCE MANUAL M6x20 Axis 2 motor assembly M6x16 Washer Washer Axis 2 motor base Mount the axis 2 motor assembly with the motor lead face on the rear side of the robot. “O” ring Fit the “O” ring in the Axis 2 reduction gear groove in the top surface of the reduction...
  • Page 38 MAINTENANCE MANUAL Mount the cover bracket on the arm 2. Wiring panel M3x6 Cover bracket Keep plate M4x8 Connector panel M4x6 Connect the axis 2 motor connectors (for the power drive cable and encoder cable). Restore the cables in the arm 2 to their original routings, and mount all the covers.

  • Page 39: Dismounting Axis 3 Motor

    MAINTENANCE MANUAL 2.5.7 Dismounting Axis 3 Motor CAUTION • The axis 3 motor is provided with a brake. At replacement of the axis 3 motor, this brake becomes inoperative. Before starting the work, therefore, move down the ball screw spline to the lower limit. Otherwise, the shaft will drop due to the dead weight of the shaft or workpiece, and your hand or finger may be caught.

  • Page 40: Mounting Axis 3 Motor

    MAINTENANCE MANUAL Washer M4x8 Axis 3 motor pulley Axis 3 motor plate Washer M4x16 2.5.8 Mounting Axis 3 Motor Perform key alignment, using the new motor and pulley. At this time, no clearance should exist between the motor shaft and pulley. CAUTION •...
  • Page 41 MAINTENANCE MANUAL M4x8 Washer Axis 3 motor pulley Axis 3 motor plate Washer M4x16 Temporarily clamp the axis 3 motor plate to the arm 2 with four (4) flange head bolts (M4x12). Pass the axis 3 timing belt to the axis 3 motor pulley, then exert a tension, using the axis 3 tension adjustment bolts (M4x16).

  • Page 42: Dismounting Axis 4 Motor

    MAINTENANCE MANUAL 2.5.9 Dismounting Axis 4 Motor Remove the arm 2 cover. (See Para. 2.4.1.) Disconnect connectors J4AS and J4AP (power drive cables) and connectors J4BS and J4BP (encoder cables) of the axis 4 motor. For the connector layout, see Para. 2.5.7. Cut the Ty-Raps used to secure the axis 3 and axis 4 motor cables.

  • Page 43: 2.5.10 Mounting Axis 4 Motor

    MAINTENANCE MANUAL 2.5.10 Mounting Axis 4 Motor Mount the new motor on the axis 4 reduction gear with four (4) bolts (M4x16). Tighten the coupling of the axis 4 reduction gear by means of the attached bolt (M4x12) to mount the cap. (Recommended clamping torque: 4.3 N·m) Axis 4 reduction gear M4x16 Washer...

  • Page 44: Adjusting And Replacing Timing Belt

    Type of Timing Belt The timing belts used in this robot are shown below. When you place an order for a replacement belt, specify the robot model (THP700), the serial number, the axis name, and our drawing number. For the location where the serial number plate is attached, see the "Safety Manual."...

  • Page 45: Timing Belt Locations

    MAINTENANCE MANUAL 2.6.2 Timing Belt Locations Axis 3 timing belt Axis 4 timing belt Fig. 2.11 Timing belt locations 2.6.3 Replacing Axis 3 Timing Belt Remove the arm 2 cover. (See Para. 2.4.1.) Disconnect the axis 3 motor assembly. For the disconnecting procedures, see Steps 1) through 4) of Para.
  • Page 46 MAINTENANCE MANUAL Stopper M4x12 Shaft Tap for disassembly M4 Ball screw nut Axis 3 timing belt Stopper Mount the new timing belt. Insert the ball screw shaft into the ball spline nut, and mount the stoppers. (For the insertion of the ball screw shaft, see "Para. 2.7.5.") Temporarily secure the axis 3 motor assembly (which was removed in step 2) to the arm 2 with the four flange head bolts (M4x12).

  • Page 47: Replacing Axis 4 Timing Belt

    MAINTENANCE MANUAL Connect the connectors, mount the arm 2 cover, and perform home setting for the axes 3 and 4. This completes the replacement of the timing belt. Carry out a test operation of the axes 3 and 4 and make sure that each part operates properly.
  • Page 48 MAINTENANCE MANUAL Remove the six (6) bolts (M4x12) securing the ball screw nut, then carefully draw out the ball screw nut integrated with the shaft upward. If the ball screw nut integrated with the shaft is drawn out diagonally with an unusually large force, the ball in the ball screw nut may drop.
  • Page 49 MAINTENANCE MANUAL Ball screw spline shaft M4x12 Axis 4 motor assembly Axis 4 motor plate M4x12 Axis 3 timing belt Ball screw nut Axis 4 timing belt Axis 3 nut pulley Stopper Align the phases and insert. While pushing the axis 4 motor plate by means of the axis 4 tension adjustment bolt, measure the tension on the tension meter.

  • Page 50: Adjusting Timing Belt

    MAINTENANCE MANUAL Arrange the connectors and cables as originally set. (See the pictures you took beforehand.) Perform home setting for the axes 3 and 4. Carry out a test operation of the axes 3 and 4 and make sure that the belt tension is appropriate.

  • Page 51: Filling Grease To Ball Screw Spline Unit And Replacement

    MAINTENANCE MANUAL Filling Grease to Ball Screw Spline Unit and Replacement The ball screw spline unit is to be replaced by our service engineer. If it is replaced by the customer, we will not guarantee any consequential trouble or accident. DANGER •...

  • Page 52: Ball Screw Spline Unit Location

    • Be sure to use the grease designated by Toshiba Machine. Fill the grease to the ball screw spline unit every three (3) months. At daily inspection also, make sure that the ball screw spline unit is filled with a sufficient volume of grease.
  • Page 53 MAINTENANCE MANUAL Recommended grease Maker AFF grease Turn on the controller power and turn off the servo system. Move the arm to a position where the axis 3 can be moved over the full stroke. Remove the arm 2 cover (see Para. 2.4.1). Push down the ball screw spline shaft to the lower limit while pressing the axis 3 brake OFF switch.

  • Page 54: Dismounting Ball Screw Spline Unit

    MAINTENANCE MANUAL Move the shaft up and down repeatedly while pressing the axis 3 brake OFF switch to fill the grease uniformly. Wipe out the surplus grease. Now the work completes. 2.7.4 Dismounting Ball Screw Spline Unit DANGER • The ball screw spline unit should be replaced with a new one only after the controller power is turned off with the power supply plug removed.
  • Page 55 MAINTENANCE MANUAL Remove the six bolts (M4x12) securing the ball screw nut, and lift off the ball screw nut and the ball screw spline shaft all together. Caution should be taken when lifting them off. If they cannot be removed by hand, use a tap for disassembly.
  • Page 56 MAINTENANCE MANUAL M4x12 Ball spline nut Tap for disassembly Axis 4 nut pulley Washer M5x12 Insert the disconnected ball spline nut into the ball screw spline shaft. A marking for phase adjustment is stamped on both the ball screw spline shaft and the ball spline nut.

  • Page 57: Mounting Ball Screw Spline Unit

    MAINTENANCE MANUAL 2.7.5 Mounting Ball Screw Spline Unit DANGER • The ball screw spline unit should be replaced with a new one only after the controller power is turned off with the power supply plug removed. If the work is done while the power is turned on, you may get an electric shock or the robot may malfunction, which is very dangerous.
  • Page 58 MAINTENANCE MANUAL M4x12 Ball spline nut Ball spline nut Ball screw spline shaft Axis 4 nut pulley Ball screw nut M5x12 Mount the axis 4 timing belt and axis 4 motor, then adjust the belt tension. Mount the axis 3 nut pulley with the four bolts (M5x20). Put the axis 3 timing belt through the clearance in the fixed surface of the ball screw nut.
  • Page 59 MAINTENANCE MANUAL Stopper split line Align the top surface of the stopper with the top surface of the spline Stopper shaft. Ball screw nut M4x12 The bolt head must be on the right side. Ball screw groove Axis 3 nut pulley M5x20 Arm 2 Spline...

  • Page 60: Filling Grease To Reduction Gear And Replacement

    Type of Reduction Gear The reduction gears used in this robot are shown below. When you place an order for the reduction gear for replacement, specify the robot model (THP700), axis name, type and our drawing number. Description Axis name Our drawing No.

  • Page 61: Reduction Gear Locations

    Caution should be taken to avoid shortage of grease. • Be sure to use the grease designated by Toshiba Machine. Increase in internal pressure will adversely affect the starting torque and damage the internal seal. To avoid this, be sure to observe the grease filling volume.
  • Page 62 MAINTENANCE MANUAL Grease filling volume Grease filling volume for axis 1 reduction gear 246 g When you wish to place an order for the grease, contact us at the Service Department. Filling grease to axis 1 reduction gear Remove the top cover of the arm 1, and supply grease through the nipple. Grease of 82 g should be supplied at each of the operating angles +90°, 0°, and -90°...

  • Page 63: Dismounting Axis 1 Reduction Gear

    MAINTENANCE MANUAL 2.8.4 Dismounting Axis 1 Reduction Gear Remove the arm 1 top cover. (See Para. 2.4.2.) Remove the base cover and pull out the cables (J1AS and J1BS). (See Para. 2.4.3.) CAUTION • The arm should always be mounted and dismounted by three (3) or more persons.

  • Page 64: Mounting Axis 1 Reduction Gear

    MAINTENANCE MANUAL M8x40 Axis 1 reduction gear (RV-40E) Remove the input gear. For the removal of the input gear, see "Para. 2.5.3." The input gear is used in combination with the reduction gear, so it must be replaced when the reduction gear is replaced. An input gear is provided as an accessory with a new reduction gear.
  • Page 65 MAINTENANCE MANUAL Mount the reduction gear with the sixteen (16) bolts (M8 × 40). Be sure to apply the Loctite adhesives to the threaded area of each bolt. Before mounting the reduction gear, set the “O” ring in the “O” ring groove on the bottom of the reduction gear.

  • Page 66: Dismounting Axis 2 Reduction Gear

    MAINTENANCE MANUAL M14×35 Washer M4×8 Arm 1 2.8.6 Dismounting Axis 2 Reduction Gear Remove the arm 2 cover. (See Para. 2.4.1.) Remove the arm 2 from the arm 1. For the disconnecting procedures, see Steps 1) through 8) of Para. 2.5.5. Remove the ten bolts (M6x20) securing the axis 2 motor base and the arm 2, and pull out the axis 2 motor assembly from the arm 2.
  • Page 67 MAINTENANCE MANUAL Remove the bolt (M5x10) from the end of the axis while holding the protrusion on the wave generator with pliers or the likes. In doing so, use a waste cloth (or the like) as a cushion to protect the wave generator from scratches. It is recommended that the wave generator should also be replaced when the reduction gear is replaced.

  • Page 68: Mounting Axis 2 Reduction Gear

    MAINTENANCE MANUAL 2.8.7 Mounting Axis 2 Reduction Gear CAUTION • Handle the reduction gear with extreme care. If it drops or an unusually large external force is exerted on it, the reduction gear cannot function any further. • Use the wave generator which is attached to the new reduction gear. •...
  • Page 69 MAINTENANCE MANUAL M6x16 M5x10 Washer Washer Protrusion on the wave generator “O” ring Fit the “O” ring in the groove in Wave generator the lower surface of the reduction gear. Axis 2 reduction gear Secure the axis 2 motor assembly to the arm 2 with the ten bolts (M6x20). While lifting the cover bracket, secure the axis 2 motor assembly.

  • Page 70: Replacing Axis 4 Reduction Gear

    MAINTENANCE MANUAL Mount the cover bracket on the arm 2. For the mounting procedure, see steps 6) to 9) in "Para. 2.5.6." Mount the arm 2 cover and perform home setting for the axes 2, 3 and 4. Now replacement of the axis 2 reduction gear completes. (Check the axis 1 for the coordinates and perform home setting as necessary.) Carry out a test operation of the axis 2 and make sure that each part operates properly.
  • Page 71 MAINTENANCE MANUAL M4x16 Axis 4 motor pulley Washer M4x16 Axis 4 motor M5x16 Washer Remove the cap and loosen the Axis 4 Axis 4 motor plate coupling bolt. reduction gear Assemble the new reduction gear, motor and pulley in the reverse order of Steps 4), 5) and 6) above.

  • Page 72: Replacing Position Detector (Or Encoder) Batteries

    MAINTENANCE MANUAL Replacing Position Detector (or Encoder) Batteries CAUTION • The batteries should be disposed of according to the user’s in-house regulations. NEVER drop the battery into fire. NEVER short-circuit, charge, disassemble or heat it. Otherwise, liquid leakage or rupture may be caused. To keep the data of the position detector attached to the motor, they are backed up by batteries.

  • Page 73: Battery Box Location

    MAINTENANCE MANUAL 2.9.1 Battery Box Location The battery box for the position detector is provided inside the battery box cover of the base unit. Battery box Battery box cover Fig. 2.14 Battery box location 2.9.2 Replacing Batteries DANGER • Only after assuring the safe work, replace the batteries with new ones while the power is turned on and an emergency stop is effected on the robot.

  • Page 74: Battery Error Code

    MAINTENANCE MANUAL Battery box Battery box cover M4x6 Battery box cover Attach the battery box cover to the base unit. Now replacement of the batteries completes. 2.9.3 Battery Error Code When a position detector error including battery error has occurred, the following error code is shown on the error display.

  • Page 75: Maintenance Of Controller

    MAINTENANCE MANUAL Maintenance of Controller Cautions on Maintenance and Inspection When performing maintenance and inspection of the controller, follow the items given below so that the work can be carried out safely. CAUTION • Before removing the controller cover for maintenance or inspection, be sure to turn off the main power switch of the controller.

  • Page 76: Layout Of Controller Parts

    MAINTENANCE MANUAL Layout of Controller Parts X8GM X8G1 to X8G3 X8GN(X8GI) X8GC X8GL Bottom of capacitor Fig. 3.1 Layout of controller parts Part name Descriptions P5V, P24V output switching power supply X8GC Main control printed board X8GN (X8GI) I/O output printed board X8GL Servo logic printed board X8G1 to X8G3...

  • Page 77: Maintenance Procedures

    MAINTENANCE MANUAL Maintenance Procedures 3.3.1 Check of Controller Air Vent Holes If the air vent holes are blocked, the controller may overheat and malfunction. To avoid this, perform check on the air vent holes to make sure that air is flowing freely through them.

  • Page 78: Check Of Safety Devices For Function

    MAINTENANCE MANUAL 3.3.2 Check of Safety Devices for Function Make sure that the EMERGENCY stop pushbutton switches equipped on the control panel and teach pendant work properly. Also make sure that the safety devices controlled by the external operation input signals work correctly. Fig.
  • Page 79 MAINTENANCE MANUAL Turn the EMERGENCY switch clockwise and make sure that the same switch turns off. Make sure that the EMERGENCY STOP switch provided on the teach pendant functions properly. Press the SERVO ON switch [4] on the teach pendant to turn on the servo power, and make sure that the SERVO ON LED [5] is illuminated.
  • Page 80 MAINTENANCE MANUAL At this time, make sure that the EMERGENCY STOP switch [6] remains depressed. Turn the EMERGENCY STOP switch clockwise and make sure that the same switch turns off. Make sure that the safety devices controlled by the external operation input signals work properly.

  • Page 81: Battery Replacement

    MAINTENANCE MANUAL 3.3.3 Battery Replacement The memory equipped on the X8GC printed board of the robot controller is backed up by a lithium battery to save the data. Replace the battery every five (5) years. The lithium battery will turn its life when used for a predetermined time. If it is used, neglecting the life, the battery voltage will drop to below the voltage required for keeping the memory data, resulting in the data being lost and faults caused by leakage of the battery liquid.
  • Page 82 (5) years. Only the battery shown in the table above should be used. As this is an exclusive battery, contact Toshiba Machine at order entry. [Battery replacement procedures] If the battery is to be kept removed for more than one (1) minute, copy all programs and various parameters stored in the internal memory to the personal computer.

  • Page 83: Replacement Of Switching Power Supply Unit

    MAINTENANCE MANUAL CAUTION • Waste battery should be disposed of according to the user's in-house regulations. NEVER drop the battery into fire. NEVER short-circuit, charge, disassemble or heat it. Otherwise, liquid leakage or rupture may be caused. 3.3.4 Replacement of Switching Power Supply Unit The life of the switching power supply unit (5 VDC/24 VDC) used in the robot controller differs with the operating conditions.

  • Page 84: Replacement Of Fuse (X8Gn, X8Gi Printed Board)

    MAINTENANCE MANUAL 3.3.5 Replacement of Fuse (X8GN, X8GI Printed Board) If the current exceeding the specified current has run through the I/O unit, the fuse of the front of the TS3100 controller is blown out. If the alarm saying “I/O Fuse Broken (8–273)”...

  • Page 85: Replacement Of Output Ics (X8Gn, X8Gi Printed Board)

    MAINTENANCE MANUAL 3.3.6 Replacement of Output ICs (X8GN, X8GI Printed Board) If the current exceeding the specified current has run through the output unit, the ICs on the X8GC, X8GN (X8GI) printed board is damaged. When this happens, replace the ICs. Before the replacement, examine and identify an fault circuit, remedy the cause, then replace the ICs.
  • Page 86 Connector: SYSTEM Main Board (X8GC) Name of board Type of IC Manufacturer X8GN TD62082AP Toshiba Corp. X8GI M54562P Mitsubishi Electric [Replacement procedures] Turn off the controller main power. Remove the cover from the controller. Disconnect all connectors connected to the X8GC, X8GN (X8GI) printed boards in the controller.

  • Page 87: Robot Home Point And Position Detector Error

    MAINTENANCE MANUAL Robot Home Point and Position Detector Error Setting Robot Home Point Before delivery from our plant, home point setting is performed for the robot after its arm is secured with clamp for home point setting. At the time of home point setting, position data of the motor position detector (i.e., encoder) is backed up by batteries, and coordinates of the robot need not be set each time the power is turned on.

  • Page 88: Position Detector Error

    MAINTENANCE MANUAL Position Detector Error If a position detector error (encoder error) occurs, either of the following errors is shown on the error display of the robot controller. Error code Error content 8–401 Axis1 Encoder abnormal 8–402 Axis2 Encoder abnormal 8–403 Axis3 Encoder abnormal 8–404...
  • Page 89 MAINTENANCE MANUAL When the mechanical connecting position with the motor has changed after motor or belt replacement: A position detector error may occur after replacement and adjustment of the servo motor or timing belt. When this happens, execute the following restoring operation.
  • Page 90 MAINTENANCE MANUAL DANGER • When moving the robot by hand while the power is turned on, be sure to assure the safe work and effect an emergency stop beforehand. • In the above situation, if the work is to be done while the axis 3 motor brake OFF switch is pressed, be sure to perform the work by two (2) persons.

  • Page 91: Restoring Operation From Position Detector Error

    MAINTENANCE MANUAL Restoring Operation from Position Detector Error Make sure on the error display that a position detector error is generated. Identify the type of the position detector error and position data on the encoder status display, then perform each restoring operation. 4.3.1 Encoder Status Display Call the encoder status screen on the teach pendant display, and make sure of the...
  • Page 92 MAINTENANCE MANUAL Press the “UTILITY” key provided on the teach pendant. Press the [NEXT] key until [ENC] is displayed on the function menu. Press the [ENC] (F5) key, and the encoder status screen appears on the display. M U L T I S I N G L E E r r –...

  • Page 93: Encoder Error Reset Operation

    MAINTENANCE MANUAL 4.3.2 Encoder Error Reset Operation When the mechanical connecting position of the servo motor and mechanical unit remains unchanged, that is, after battery replacement due to battery voltage drop or cable replacement due to cable breakage, execute this operation. Call the encoder status screen on the teach pendant display, referring to Para.

  • Page 94: Restoring Home Position Data By Home Function

    MAINTENANCE MANUAL Restoring Home Position Data by HOME Function Batteries for backing up the position information of the position detector are housed in the base unit of the robot. Unless the robot has been used for a long term, the battery voltage drops and the home position data will be lost.

  • Page 95: Setting Home1 And Home2

    MAINTENANCE MANUAL Caution: This function is used to restore the machine home point of each axis. NEVER use the function at other than the setting for restoration. 4.4.2 Setting HOME1 and HOME2 Guide the robot to secure the tool shaft at a desired position. Turn off the servo power.

  • Page 96: How To Restore Data By Home1 Or Home2

    MAINTENANCE MANUAL 4.4.3 How to Restore Data by HOME1 or HOME2 Guide the robot and secure it at the position set in HOME1 or HOME2 above. Turn off the servo power. Press the “UTILITY” key equipped on the teach pendant. Press the [NEXT] key until the [REORG] menu appears, then press the [REORG] key.

  • Page 97: Locations Of Robot Home Point Match-Marks

    MAINTENANCE MANUAL 4.4.4 Locations of Robot Home Point Match-Marks Axis 4 home point match-mark Axis 2 home point match-mark Axis 1 home point match-mark Fig. 4.1 Locations of home point match-marks 4.4.5 How to Restore Data by HOME3 or HOME4 The plus (+) side mechanical stopper positions and minus (–) side mechanical stopper positions of the axes 1 to 3 are factory-set in HOME3 and HOME4, respectively.
  • Page 98 MAINTENANCE MANUAL S Y S T E M H O M E 3 H O M E 4 ( J 1 ) 1 1 8 3 4 6 8 – 1 1 8 0 4 7 4 [ d e g ] ( J 2 ) 1 4 5 0 7 1 6 –...

  • Page 99: Restoring Home Position Data By Zerop Function

    MAINTENANCE MANUAL Restoring Home Position Data by ZEROP Function Batteries for backing up the position information of the position detector are housed in the base unit of the robot. Unless the robot has been used for a long term, the battery voltage drops and the home position data will be lost.

  • Page 100: Setting New Home Position Data

    MAINTENANCE MANUAL 4.5.2 Setting New Home Position Data Select the TEACHING mode by means of the master mode switch. Press the “UTILITY” key equipped on the teach pendant. Press the [NEXT] (F6) key on the teach pendant twice. Turn off the servo power. Press the [F3] key on the teach pendant to select the ZEROP mode.
  • Page 101 MAINTENANCE MANUAL Z E R O P O S I T O N E 1 : – 7 5 0 0 0 E 2 : 1 3 9 9 8 0 0 E 3 : 5 8 0 9 E 4 : 2 9 0 0 0 0 E 5 : : –...

  • Page 102: Confirming Home Position

    MAINTENANCE MANUAL 4.5.3 Confirming Home Position Make sure of the robot current position according to the POS data of the UTILITY mode. Guide the robot to the approximate home position by manual operation and confirm the position. Unless it could be located at the home point match-mark, make sure that the approximate position is the reference position marked in advance.

  • Page 103: Restoring Home Position Data By Multi-Turn Data Clear

    MAINTENANCE MANUAL Restoring Home Position Data by Multi-Turn Data Clear Home point match-marks are provided for the axes 1, 2 and 4. When only the multi-turn data of these axes has been cleared, move the robot to each home point match-mark. For the axis 3, move it to the position shown in Fig. 4.2 above.

  • Page 104: Replacement Parts For Maintenance

    Toshiba Machine specifications. Contact Toshiba Machine at order entry. • Parts replacement work must be done by Toshiba Machine service engineer. Toshiba Machine’s warranty does not cover failures, accidents or any damages. STE 85321...

  • Page 105: List Of Replacement Parts - Controller

    MAINTENANCE MANUAL List of Replacement Parts – Controller Part name Type Q'ty Remarks PS1 (Switching power supply) LEB100F-0524 Main power switch IR-11-A8-25-1BF Lithium battery ER6C WK27 51NM030H For X8GC Fuse printed board X8GC (Main control) Y610A4000 Type N X8GC (Main control) Y610A4020 Type P X8GN (I/O board)
  • Page 106 MAINTENANCE MANUAL APPROVED BY: CHECKED BY: PREPARED BY: STE 85321 – 105 –...

This manual is also suitable for:

Ts3100

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