Sony CAST-AU4, B2521E User Manual

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Page 1

Sony Desktop Robot

OPERATION MANUAL

CAST-AU4/B2521E

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About this Operation Manual

This Operation Manual is intended as a guide for users of the Sony Desktop Robot ROBOKIDS.

Before operating this system, you should first throughly read this manual. You may not understand all of the explanations the first time through, but be on the lookout for any special directions. It should be used in conjuction with the RK card manual for your specifications.

• This manual may not be replicated in whole or in part without the prior written authorization of Sony Corporation.

• The information described herein is subject to change without notice.

• The information described herein has been checked for both reliability and accuracy. However, if you have any questions, or notice any errors or omissions in this manual, please contact the following offices of Sony Corporation.

[Singapore]

Sony Electronics (Singapore) Pte. Ltd

SPEC, No.52 Tuas Avenue 9, Singapore 639193

TEL : 8615858 FAX : 8621521

[Europe]

Sony Wega Produktions GmbH Production Technology Division Europe

Hedelfinger Str. 61 D-70327 Stuttgart Germany

TEL : +49 (0)711 5858-420 FAX : +49 (0)711 574153

[Japan]

Sony Manufacturing Systems Corporation FA Service Department

1-10, Kiyoku-cho, Kuki-shi Saitama, 346-0035 JAPAN

TEL : 0480-23-1956 FAX : 0480-23-1706

CAST-AU4/B2521E

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How to Use this Operation Manual

First Time Users

Read this manual form chapter 1 through chapter 4 before starting any operation. The manual describes the procedures required in setting up ROBOKIDS for users who have little experience with FA (Factory Automation) equipment.

Routine Assembly

Follow the respective application manuals for routine assembly task operations.

Replacing the Unit or Memory Card

Remove the existing unit. Attach the new unit and replace the memory card. References of the memory card may be found in this Operation manual or the respective application manuals.

This manual describes the ROBOKIDS base machine. Details for application unit installations may be found in the operation manuals that are attached when purchasing the application units.

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Manual Configuration

This operation manual describes the procedures required to operate the desktop robot ROBOKIDS Various types of applications such as dispensing and soldering may be accomplished by exchanging the memory cards (RK card) which stores the programs required to run an application. The semi-programmable specification allows the user to modify an operation program and peripheral task program to perform a specific work. The full open programmable specification enables the use to freely write any program to perform an unique application. This manual contains the common contents between dispensing, soldering, semi-programmable and the full open programmable specification. For further details refer to the memory card (RK Card) operation manual (or the Full Open Programmable operation manual for the full open programmable specifications.)

Safety Instruction

Describes the safety precautions for user’s safety.

Unpacking

Describes the precautions during unpacking, and lists the supplied accessories.

1. Outline Outlines features, names and functions of controls, and its specifications.

2. Preparation Helps you set up the base machine. Beside the supplied accessories, you also may need to purchase the dispensing unit, soldering unit, air compressor, workpiece fixing tool (including fixing screws) depending on the configuration.

3. Maintenance Describes daily maintenance.

4. Troubleshooting Describes countermeasure (only the contents which are in common in applications) when an error occurs during operation. The Operation Manual of each memory card (RK card) describes countermeasures for dispensing errors and soldering errors.

5. Replacement Parts Shows list of main replacement parts of the base machine.

6. Appendix Described input and output specifications of each connector.

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Contents

Safety Instruction ............................................................................................................... S-1

Unpacking ........................................................................................................................... U-1

1. Outline

1-1 Nomenclature.................................................................................................................... 1-2

1-2 Outline Drawings .............................................................................................................. 1-4

1-3 Specifications.................................................................................................................... 1-9

1-3-1 Machine Specification ........................................................................................ 1-9

1-3-2 Control Specifications ...................................................................................... 1-10

2. Preparation

2-1 Attaching the Units ........................................................................................................... 2-1

2-1-1 Attaching the Z-unit ........................................................................................... 2-1

2-1-2 Attaching the ZR-unit ......................................................................................... 2-4

2-2 Connecting the External Signal ........................................................................................ 2-7

2-3 Connecting to an Electrical Outlet.................................................................................. 2-12

2-4 Starting Up the Base Machine ........................................................................................ 2-13

2-4-1 Full-open Programmable Specification ............................................................ 2-13

2-4-2 When Using Memory Card “RK card” ............................................................ 2-13

3. Maintenance

3-1 Maintaining the Machine .................................................................................................. 3-1

3-2 Greasing the Machine and Removing Fallen Materials ................................................... 3-1

3-3 Cleaning and Replacing the Air Filter .............................................................................. 3-4

3-4 Replacing the Battery ....................................................................................................... 3-6

4. Troubleshooting

4-1 Common Items.................................................................................................................. 4-1

4-1-1 Stepping Out ....................................................................................................... 4-1

4-1-2 External Noise .................................................................................................... 4-3

4-1-3 Abnormal Sound from Unit’s Motors ................................................................ 4-3

4-2 Full-open Programmable Specifications........................................................................... 4-4

4-3 When Memory Card (RK Card) is Used .......................................................................... 4-7

Trouble Check Sheet ................................................................................................................. 4-10

5. Repair Parts Lists

5-1 ROBOKIDS Body ............................................................................................................ 5-1

5-2 Z-axis Unit ........................................................................................................................ 5-1

5-3 ZR-axis Unit ..................................................................................................................... 5-2

6. Appendix .................................................................................................................................... 6-1

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Safety Instruction

Sony Corporation designs and manufactures all its equipment with strict attention to safety. However, if the machine is operated or maintained without regard to the safety guidelines, damage or injury to the machine or operator may occur. To prevent accidents, those in charge of operation and maintenance must follow the safety work rules when using the machine. Always read the safety precautions carefully before reading the Operation Manual, and carefully note the following safety rules.

Observe all precautions to ensure safety.

Read the precautions on pages 3 to 6 thoroughly.

Perform regular inspections.

Inspect the machine referring to chapter “3. Maintenance”.

In the event of accidents....

Consult with the dealer that is indicated on warranty card after filling in the trouble check sheet which is attached to the end of the Operation Manual.

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S-1

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Definition of warning symbols

Pay particular attention to the following symbols and conventions shown on the machine and on the Operation Manual. Fully understand the contents of symbols and conventions before reading the Operation Manual.

《Machine Symbols》

Indicates a protective terminal of mechanical parts to which an external protective earth wire is connected.

When the part with this mark is removed, the high voltage appears.

Check the operation manual before using the part with this mark.

Be cautious not to pinch your hands or fingers into the units moving parts. Before you perform any maintenance and/or check, disconnect the unit from the main power supply.

《Operation Manual Symbols》

Indicates that mis-operations or mis-handling may result in unexpected danger (fire, etc.,)

Warning

and the that operator is at risk (of major injury).

Indicates that mis-handling may result in unexpected danger (electric shock, etc.,) and that

Caution

the operator is at risk of injury or the equipment at risk of damage.

S-2

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■ Important Safeguards

◆

The tool driving mechanism are subject to unexpected movement. Pay attention to safety measures.

◆

Turn off the main power prior to performing maintenance or inspections. Failure to observe this may result in severe injury through electric shocks or unexpected movement of the machine.

◆

Mistakes during maintenance and inspections may result in accidents. Observe the followings prior to starting maintenance or inspections:

Warning

Read the Operation Manual thoroughly and following all instructions and warnings closely.

Implement inspections on a daily basis to prevent accidents arising from damaged equipment.

3. Pay attention so that the power cord is not pinched by the machine and the peripheral equipment when installing the machine system.

Safety Instruction

Caution

◆

Ensure to connect the primary power supply to the three-pin AC power outlet using the power cord (supplied with earth wire) supplied with the equipment. Electrical potential difference will occur with surrounding equipment if the electrical earth is not connected and may result in electrical leakage or electrical shocks.

◆

Heavy object. Move and transport with two or more persons, and pay attention to safety measures.

◆

To maintain safety do not make any modifications to the equipment in order.

◆

Be careful so that hands must not be pinched by the movable blocks. (Movable parts of each axis, tool attachment block, table block, belt beneath the units, tools, works, etc.)

◆

Avoid installing in the following locations:

○

In places which receive direct sunlight or which experience temperature ranges exceeding 0 degrees °C and 40 degrees °C.

○

In places which experience relative humidity ranges exceeding 35% and 90%, and

places in which condensation is generated by rapidly changing humidity.

○

In places where corrosive gas or inflammable gas exists.

○

In places where the unit will be subject to direct vibrations or impact.

○

Close to machinery which emits electrical noise, such as welders, electric dischargers or high-frequency generators.

○

In places where any obstacles are anticipated during maintenance and inspection.

◆

CAST-AU4/B2521E

Precautions during operation, movement, maintenance and inspection During operation the machine may look as if it has stopped. Be careful when certain conditions are met, the machine will resume motion automatically.

Connect the earth wiring (FG) to the tools. Electrical potential difference will occur with surrounding equipment if the electrical earth is not connected and may result in electrical shocks.

Be careful that motor gets very hot.

S-3

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Precautions on Usage

Operate on the specified voltage

Operate the ROBOKIDS only on AC power voltage as specified on the label of the machine. The power cord must be directly connected to the electrical output, and grounded. The ROBOKIDS conforms with the safety requirements of the target country to which it is shipped.

When a machine will not be used for extended period of time

If the machine is not in use for a long period, unplug the power cord from the electrical output. To unplug, pull on the plug. Never pull on the cord.

Do not drop any foreign material into the machine

Dropping any flammable liquid or metal, object into the machine can cause errors and trouble of the machine. Should any of them drop into the machine, unplug the power cord and contact your local Sony dealer.

Do not place any obstacles in front of the fans.

Heat dissipation will be insufficient and the accumulated heat can cause malfunctions.

Precautions on Transportation

• Avoid excessive shock. Excessive shock such as dropping the machine may cause damage.

• Do not hit the units or work table during operation. Also be careful so that hands and/or clothes are not pinched by the machine. It can cause unexpected physical injury.

• Be sure to hold the bottom panel when moving the machine.

S-4

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Safety Instruction

Precaution on memory cards

Before inserting or removing a memory card, always turn the power off. The data stored in the memory card may be damaged if a memory card is inserted or removed while the power is on.

Precaution on the teaching pendant

ROBOKIDS uses a teaching pendant for the CAST-PRO or SRX. The CAST-U teaching pendant and CAST-PRO teaching pendant are not compatible. Do not use the CAST-U teaching pendant with the ROBOKIDS.

If the CAST-U teaching pendant is used with the ROBOKIDS., the ROBOKIDS cannot exit the emergency stop state and can be damaged. Do not use the CAST-U teaching pendant with the ROBOKIDS.

Caution

If the SRX teaching pendant (SRX-P006) is used with the ROBOKIDS. the ROBOKIDS can be damaged. Do not use the SRX teaching pendant with the ROBOKIDS.

Precaution on maintenance

Periodic inspection of the following items is recommended once every six months.

Operation check of the fan attached to the controller

Be sure to check the operation of the fan attached to the controller before starting operation. Equipment can be seriously damaged by heat accumulated in ICs in certain operating environments in which equipment is used without sufficient heat dissipation.

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On handling batteries

The following battery is used in the base machine controller.

Lithium battery (primary battery) of type : CR17335SE-CN21 Manufactured by Sanyo Electric Co.

Incorrect handling of the battery may result in dangerous situation. Do not perform the actions as listed below for safety. Sony Corporation is not responsible for the troubles related to the operation of the following precautions. (1) Shorting

Do not short the batteries. Shorting the battery may damage the equipment or may result in thermal injury due to overheating.

(2) Disassembling

Do not disassemble the batteries. Gas will be generated irritating the throat. Lithium metal may be generated. The batteries can be heated internally resulting in explosion or fire if the batteries are subject to shock.

(3) Throwing into fire or water

The battery may explode, generate fire due to liquid leakage or internal shorting if the

Caution

battery is heated. Never throw the battery into fire. The batteries can explode if they are thrown into fire. Throwing the batteries into water may lose the battery function.

(4) Soldering

Do not make any soldering directly to the batteries. The batteries can explode or generate

fire due to liquid leakage or internal shorting inside the batteries caused by heat. (5) Do not connect the batteries with reverse polarities between (+) and (-) (6) Using the batteries for other applications

Do not use the batteries for other applications. The batteries may be damaged or the

equipment can be damaged due to specification differences. (7) Charging

Do not charge the lithium battery (primary battery). Gas will be generated inside causing

explosion and fire.

Life and replacement of batteries

The nominal life of the lithium battery (primary battery) used in the controller is 3 to 5 years. Replace it every 3 years as a guide line. (Refer to section “3-4 Replacing the Battery” for the replacement procedure.) Life, however, can be shorter than the nominal life depending upon the ambient environments. The front POWER indicator changes from green to red when a battery runs out.

S-6

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Unpacking

ds

Transport it to the installation position while taking care not to drop or fall. Pay extra

Caution

attention not to give any vibration or shock because the controller contains precision electronic parts.

Unpacking

NOTE

Be sure to use the packaging material specified by Sony Corporation when transporting the machine.

Accsesorybox

CAST-AU4/B2521E

Removebyholdinghan atthebottomasshown bythearrows.

U-1

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When the machine is unpacked, make sure the following items are in the package.

Base machine Power cable Operation box USER I/O connector

(For AC 200V to 240 V) PCR-E68FS (connector)

PCS-E68LA (connector cover)

(Honda Communications Company)

Operation Manual External supply power

connector for USER I/O

MC 1.5/2-ST-3.81

(Phoenix Contact Inc.)

U-2

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1. Outline

ROBOKIDS is a desktop assembly tool designed to automate cell production systems saving a significant amount of power consumed by assembly lines. It may be used in a variety of applications by simply exchanging the work unit and memory card. The basic operation procedures are common throughout the applications enabling a smooth migration from one work to another.

• The programs required for an application are stored in the memory card “RK Card”. Operation is started by inserting the specific memory card into the base machine and teaching the work points. The machine may be switched to perform a different application be exchanging the memory card.

• The work points and the working speed may be set by using the simple operation teaching pendant (option) even by someone who has just purchased ROBOKIDS.

• The power supply and controller are built inside the machine thus making the system transportable to the place where it is needed.

• The machine is equipped with an external switch connector and also an USER I/O connector allowing synchronous operation with external equipment. Remote operation is also possible.

NOTE

■ Product Configuration

The base machine consists of two axes X-axis and Y-axis. It may be upgraded to three and four axes by installing the optional Z-unit and ZR-unit respectively.

The external switch and connector enabling operation of the machine by two operators, must be prepared by the user.

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1-1

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1-1 Nomenclature

Front View

Work table mounting bracket (Y-axis)

X-axis

Unit or tool mounting bracket

TECH. PEN. connector (for teaching pendant of CAST-PRO)

*EJECT button

Debug station connector

*To debug station

SRX teaching pendant connector

RS 232C program transfer connector

Memory card slot

5-gang LED display (POWER, TASK, ROBOT, ONLINE, ERROR indications from the left)

PROGRAM switch

STOP button

X-axis stand

START button

Operation box

* Debug station • • • Option

Either the “SRX teaching pendant” or the program transfer cable can be directly connected to the debug station connector.

* EJECT button • • • When inserting or removing the CAST-PRO teaching pendant, insert it or remove it

while pressing the EJECT button.

5-gang LED Display

The following machine conditions are indicated on the 5-gang LED display.

1. ERROR ........Illuminates during the error state.

2. ONLINE.......Illuminates during the on-line state. (Illuminates normally.)

3. ROBOT ........Illuminates while the servo is on. (Illuminates continually after home position is checked.

Turned off during stop.)

4. TASK ...........Illuminates while any of the robot task, or PLC task, or peripheral task is being executed.

5. POWER .......Illuminates in green while power is on. Illuminates in red when a battery runs out.

1-2

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Rear View

1. Outline

Internal/external selecting switch for I/O (Upper : OUTSIDE, Lower : INSIDE)

INLET (power)

POWER switch

Fan

Z- and ZR-axis connector

OPERATION BOX connector

DC24V INPUT (I/O power) connector (Up to maximum 1.5 A)

SAFETY connector

RS232C connector (Used only when the full open programmable specification is used.)

USER INPUT/OUTPUT connector (External I/O connector)

CAST-PRO Teaching Pendant SRX Teaching pendant

CAST-AU4/B2521E

CAST-P06 (option) SRX-P005/S (option)

1-3

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1-2 Outline Drawings

■ ROBOKIDS Standard Type (CAST-AU4/B2521E)

320

(35)

250

(Stroke)

(300)

+ 0.03

φ4

4-M4

(40)

(360)

(69)

105 40 105

(250)

210

203

(52)

(60)

Detailed view of "A"

(6) (78)

210

(Stroke)

(7)

(6)

1-4

(4.5)

110 150 90

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Height Adjustable Type (CAST-AU4/BT2521E)

320

(35)

250

(Stroke)

1. Outline

230

(69)

105 40 105

(250)

203

(300)

(6)

(78)

(440)

110

CAST-AU4/B2521E

210

(4.5)

(52)

210

(Stroke)

1-5

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■ 3-Axes Model Z-unit

162

■ 4-Axes Model ZR-unit

179

(13)

(202)

4-M4

162

1-6

50 Tool attachment position

φ12h7

144.5

280



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Service Tapped-Hole Position

1. Outline

50 50

128

6-M3

(250)

Side A

128

(1.6)

    

6-M3

(Side A only)

(120)



CAST-AU4/B2521E



4-φ22





1-7

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Service Tapped-Hole Position (Tall Model)







 



 



    



1-8



4-φ22





CAST-AU4/B2521E

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1-3 Specifications

1-3-1 Machine Specifications

1. Outline

Item

X-axis

Work envelope Y-axis

Z-axis R-axis X-axis

Maximum speeds Y-axis

Z-axis R-axis X-axis

Pose-repeatability Y-axis

(positioning accuracy) Z-axis

R-axis X-axis

Maximum payload Y-axis

Z-axis R-axis X-axis

Resolution (*5) Y-axis

Z-axis R-axis

Robot mass (including units)

Operating ambient temperature

Two axes specification

250 mm 210 mm

300 mm/s

(*4)

300 mm/s

±0.05 mm

± 0.05 mm

0.014 mm

About 13 kg

– –

5kg 5kg

– –

(*1)

Three axes specification

with Z-axis

250 mm 210 mm

70 mm

–

300 mm/s

100 mm/s

±0.05 mm

± 0.05 mm

±0.05 mm

0.014 mm

0.006 mm

About 15 kg

0 to 40 °C

(*2)

–

– –

5kg 2kg

–

Four axes specification

with ZR-axis

250 mm 210 mm

70 mm

0° to 360°

300 mm/s

70 mm/s

550°/s

±0.05 mm

± 0.05 mm

±0.05 mm

0.014 mm

0.003 mm

About 16 kg

(*3)

±0.1°

–

5kg

–

1.8 kg

0.04°

*1) The maximum value is subject to the payload of 4.5 kg or less. Set the speed value lower than the

maximum value when the payload exceeds 4.5 kg.

*2) The maximum value is subject to the payload of 1.5 kg or less. Set the speed value lower than the

maximum value when the payload exceeds 1.5 kg.

*3) The maximum value is subject to the payload of 1.5 kg or less. Set the speed value lower than the

maximum value when the payload exceeds 1.5 kg.

*4) The maximum value is subject to the payload of 3.0 kg or less. Set the speed value lower than the

maximum value when the payload exceeds 3.0 kg.

*5) The resolution does not indicate the absolute position accuracy. It indicates the amount of movement

(round-off function) per every pulse that is theoretically calculated from the machine structure.

This value changes especially when direction of movement or speed is changed. The resolution value can change depending on the card when the RK card is used.

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1-3-2 Control Specifications

Drive method

Movement method

Control axis count

Interpolation function

CP control speed

Teaching method

Program capacity

Point data storage capacity

Programming method

General-purpose I/O

Serial I/F

Power supply voltage

Power consumption

Ground

Pulse motor drive (open loop control) PTP, CP Up to four axes (all axes simultaneous control) 3-dimensional linear interpolation and 3-dimensioal circular interpolation 1 to 100 mm/s Direct teaching via teaching pendant (option) Point program Direct data input Full open : Total 176 Kbytes RK card : Maximum 20 work programs for one operation program. Full open : 3072 points for one program RK card : 2500 points Full open : Described by the machine language LUNA RK card : The standard software is supplied (option) 22 inputs and 22 outputs RS232C : One channel (general-purpose) Single-phase 100 to 240 V ±10% 50/60 Hz 300 VA Class 3 ground

(*)

* The 20 work programs of the program capacity item means that the 20 kinds of programs having different

point number and different position can be stored. Refer to the Operation Manual of the memory card (RK card) for the work program assignment.

1-10

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2. Preparation

2-1 Attaching the Units

2-1-1 Attaching the Z-unit

1. Fix the supplied mounting plate to the work table. (Two positions)

Hexagon socket head cap screws

M4 × 10, 2 pieces

Tightening torque 15 kgfcm

2. Preparation

2. Remove the Z-unit front cover. (The cover to which Sony logo mark is attached.) (Four positions)

3. Fix the Z-unit to the mounting plate. (Three positions)

Determine the fixing position using the positioning pin that is supplied with the equipment.

Hexagon socket head cap screw

M4 × 10, 1 piece

Hexagon socket head cap screws

M4 × 18, 2 pieces Spring washer SW4, 3 pieces Flat washer W4, 3 pieces Tightening torque 15 kgfcm

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2-1

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4. Attach the removed front cover. (Four positions)

Tightening torque 8 kgfcm

5. Connect the connectors to the Z-/ZRunit connectors.

Be sure to fix the connector by tightening the screws.

6. Attach the cable holder supplied, to the post.

Hexagon socket head cap screws

M3 × 6, 2 pieces Spring washer SW3, 2 pieces Flat washer W3, 2 pieces Tightening torque 10 kgfcm

2-2

Cable holder

(supplied)

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7. Fix the cable clamp of the cable to the cable holder.

2. Preparation

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2-1-2 Attaching the ZR-unit

1. Remove the front cover. (The cover to which Sony logo mark is attached.) (Six positions)

2. Fix the ZR-unit to the mounting plate. (Four positions)

Determine the fixing position using the positioning pin that is supplied with the equipment.

Hexagon socket head cap screw

M4 × 6, 4 pieces Spring washer SW4, 4 pieces Flat washer W4, 4 pieces Tightening torque 15 kgfcm

3. Attach the front cover. (Six positions)

Tightening torque 8 kgfcm

2-4

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4. Connect the connectors to the Z-/ZRunit connectors.

Be sure to fix the connector by tightening the screws.

2. Preparation

5. Attach the cable holder supplied, to the post.

Hexagon socket head cap screws M3 × 6, 2 pieces Spring washer SW3, 2 pieces Flat washer W3, 2 pieces Tightening torque 10 kgfcm

Cable holder

(supplied)

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2-5

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5. Fix the clamp of the cable on the cable holder.

2-6

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2. Preparation

2-2 Connecting the External Signal

The base machine is equipped with the following connectors for external signal communication.

• SAFETY (for external switch) connector (rear)

• External Stop (same function as the STOP button of the main unit)

• Door, barrier

• External return (same operation as the RETURN button in the two operators line mode operation)

• USER INPUT/OUTPUT (EXTERNAL I/O) connector (rear)

• Selecting programs (same operation as the PROGRAM switch of the main unit) : (I3 ~ I10)

• Error reset (There is no switch corresponding to this function.) : (I11)

• External start (same operation as the START button of the main unit) : (I1)

1. Connect an external switch to the SAFETY connector by soldering.

Connect the wires to the corresponding pins of the external switch connector. Refer to the connector diagram for external switch, for the signals at the respective pins and type of mating connector.

How to control the stop:

• Connect pin-10 and pin-11 to the respective switches.

• Connect pin-14 to pin-15. (or to pin-7) How to control the RETURN :

• Connect pin-9 and pin-7 (or pin-15) to the respective switches.

Example of external stop switch

Switch box

Door switch

Floor mat switch

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Connector for external switch (SAFETY) Safety box

Pin No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Stop RELAY OUT (NO) Stop RELAY OUT (NC)

Contents

24 V

SA RETURN OUT

SA EMG OUT

Stop RELAY OUT (C)

SA RETURN IN

SA Stop IN (C)

SA Stop IN (NC)

BAR (C)

BAR (NC)

SA Stop ENABLE

Max 0.1 A

Connect shield of the cable

Wiring diagram of connector for external switch (SAFETY)

Applicable plug Type : DA-15PF-N (pin connector) Applicable shell Type : DA-C4-J10

RETURN indicator Stop indicator

These lines can be freely used by users because these lines are prepared for independent relay to be energized at the time of stop. (Pins-4 and -6 are normally closed. In a stop, pins-4 and -5 are closed.)

RETURN button

Stop button

Barrier switch, door switch, etc.

NOTE

2-8

◆

An external stop button can be inserted between pins-14 and –15, or between

pins-14 and –7.

◆

Be sure to use a shielded cable. The maximum length of a shielded cable is 1.5 m. The external shield must be connected to pin No. 8.

◆

The external equipment (switch, indicator, box, etc.,) to be used for external operation must be prepared by users.

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2. Preparation

2. Connect the external signals to the USERl I/O connector by soldering.

Connect the wires to the corresponding pins of the USER I/O connector. For the signal names and pin numbers of the respective pins, refer to the I/O connector input/output specifications, Operation Manual (or Operation Manual of Full Open Programmable in the case of the full open programmable specifications) of memory card (RK card).

Precautions on operating the ROBOKIDS

When using the RK card, connect the I/O connector supplied to the USER I/O connector SI1 (SYSRUN) of the machine as shown.

• USER I/O connector (supplied)

Pin No. Name

1 3

0 V

SYSRUN

Connection

Caution

• Pin arrangement

2 468

1357 9

36 38 40 42

35 37 39

* Connect a jumper wire to the USER I/O connector (supplied), with soldering, attach the

connector supplied (accessory) to the connector.

3. Controlling the program selector from external location. (RK card only)

Connect the wires to the pins of the USER I/O connector corresponding to the external signals, by soldering. (I3 to I10) Set the first digit of the PROGRAM switch to “F” when controlling the program selector from external location. If the second digit of the PROGRAM switch is set to “F”, the application program is set to external mode.

30 32 34

29 31 33

66 68

USER I/O connector

(supplied)

Pin No.1

Pin No.3

Connect a jumper wire with soldering

(AWG30 or equivalent)

PROGRAM switch Controlling the program selector from external location • • • Set to “F”

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■ Input Circuit

USER I/O power supply source selector slide switch Up position: Externally supplied 24V Down position: Internal 24V (default setting)

24V

TLP280

470Ω

680pF

3.3kΩ

Pin No.

User external power supply connector PC board side: MC1.5/2-G-3.81 (Phoenix Contact Inc.)

24V IN

Note1) 24V 0V

0V IN

I/O connector PC board side PCR-E68LMDA (Honda communication)

Direction of SI1 (SYSRUN)

current

Maximum 7mA

SW1

SI1 operates when SW1 is ON.

SI2

Reservation

(

SI3

(

SI8

(

input

Reservation

input

Reservation

input

)

I 1

2-10

Thermistor

(1A)

51 18

52 19 53

I 2

I 3 I 4 I 5

I 21

I 22

COM1

SW30

Note1) When USER I/O power supply

source selector slide switch

is set to 24V.

User sideController side

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■ Output Circuit

24V

USER I/O power supply source selector slide switch Up position:Externally supplied 24V Down position: Internal 24V (default setting)

User external power supply connector PC board side: MC1.5/2-G-3.81 (Phoenix Contact Inc.)

24V IN

0V IN

Note1) 24V 0V

I/O connector PC board side PCR-E68LMDA (Honda communication)

2. Preparation

TLP127

Thermistor (1A)

SO1 (EMC-OUT)

SO2 (ERROR)

SO3 (BARRIER) SO4 (DRIVE)

SO8

Reservation

(

output

L 1

L 2

L 22

COM1

52 19 53

Direction of

current

Maximum

0.1A

Reservation

output

)

Diode

X30

Relay coil voltage (DC 24V)

Note1) When USER I/O power supply source selector slide switch is set to 24V.

◆

NOTE

◆

CAST-AU4/B2521E

User sideController side

Add the diodes as shown when relay coils are connected as the load. Be careful that the thermistor operates to shut down the +24 V power supply when 24 V output is used and the current of 1 A or more flows. Modify the external circuit to reduce the current capacity to 1 A or less. Thermistor shuts down the +24 V power supply and returns when the main power is turned on again. (The maximum current capacity of internal power supply is 1 A.) Be careful that current capacity is maximum 0.1 A per one output point. Be sure to use a shielded cable for I/O connection. The maximum length of a shielded cable is 1.0 m. Use the core conductor of the shielded cable.

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Page 35

2-3 Connecting to an Electrical Outlet

Prepare the power cable for AC 200 V to 240 V referring to the following connection diagram. The user must provide and wire an AC power plug to connect to the AC outlet.

To the three-pin electrical outlet Power cable (supplied)

To the machine INLET

Connection diagram of the AC power cable for 200 V to 240 V

Power cable end

Brown Blue Green/Yellow

L N Earth

Plug end

2-12

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2. Preparation

2-4 Starting Up the Base Machine

Make sure that the main power is turned off. Connect the operation box.

2-4-1 Full-open Programmable Specification

Turn on the power switch on the rear panel. Subsequent operating procedure changes depending on the application created by user.

2-4-2 When Using Memory Card “RK card”

Before operation ensure that an application memory card (RK card) is inserted in the memory card slot. When you have purchased another type of optional memory card in order to use the robot in another assembly type, re-insert the new card to the memory card slot.

1. Make sure that the main power is turned off. Insert the memory card into the memory card slot.

Do not remove or insert a memory card while power is turned on. It may cause trouble.

2. Connect the USER I/O connector (in which SYSRUN is shorted) to the rear panel of the ROBOKIDS. (Refer to page 2-6.)

USER I/O connector

Operation box

Memory card slot

CAST-AU4/B2521E

Memory card

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Page 37

3. Turn the base machine on.

POWER switch · · · ON

The START indicator lights in green.

About five seconds later, the white indicator of START button starts flashing in green.

4. Press the START button.

The machine starts returning home. The green indicator of the START button turns on and changes to slow flashing after completing home return. (About 30 seconds later)

5. Press the START button again.

The green indicator of START button turns on and the machine starts assembling work.

NOTE

◆

Do not remove or insert a memory card while the power is turned on. The machine will not work if the memory card is removed.

◆

Before turning on the machine, always insert the memory card in the memory card slot first. The main assembly control program (the teaching pendant software only in the semi-programmable specification) will then be loaded automatically into the unit whenever the machine is turned on.

◆

This operation does not load the point programs: such design prevents the internal point programs (created as a result of a teaching) from being overwritten by mistake.

2-14

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3. Maintenance

3-1 Maintaining the Machine

Clean the surfaces of the machine with a soft dry cloth. If the stain is difficult to remove, use cloth moistened with a mild detergent solution, followed by using a dry cloth. Do not use volatile solvents such as alcohol, benzene or thinner, as they may mar the finish. Consult your local Sony dealer for the consumable parts, jigs and tools which are required for maintenance.

3-2 Greasing the Machine and Removing the Fallen Materials

When shipped, the machine is greased along the guide rails of the X- and Y-axes. This ensures smooth operation of the work table. To maintain the machine in top condition, grease the rails and remove the fallen materials every 6 months. Use the NSK grease No. 1 (Nippon Seiko or Multemp LRL3 equivalent).

1. Turn off the power of machine, and unplug the power cord from an electrical outlet.

When the Z unit is used, move down the Z-axis to the bottom and turn off the POWER switch.

2. Remove the screws securing the X-axis and Y-axis cover, and also the front cover of Z unit and ZR unit (also Z-axis cover for the 3 axes specification).

OFF

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3. Move the work table and the work unit to the ends by hand, remove the X-axis and Y-axis covers by pulling them, then remove the fallen materials such as screws.

Remove the front cover of the Z-unit and ZRunit also.

NOTE

If the work table and the work unit are not moved to the ends as indicated, they may cause damage to the covers.

4. Wipe of the old grease and apply grease at the center of each side of the X-axis and Y-axis guide rails.

Apply about 0.2 g of grease. Be careful not to apply grease to the drive belts.

5. Move the work table and the work unit to the left and to the right several times to spread the grease over the length of each rail.

Wipe off extra grease at the ends of each rail with a cloth. (Extra grease will be solidified causing malfunction.)

3-2

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Page 40

6. Apply grease to the Z unit and the ZR

4 axes specification model 3 axes specification model

unit as shown in the same manner.

3. Maintenance

7. Attach the covers of the X-axis, Y-axis, Z unit and ZR unit to their original positions.

◆

Be careful not to damage the covers when they are reinstalled.

◆

NOTE

After the covers are attached, move the respective axes using the teaching pendant until grease covers all necessary part.

◆

Be careful that the motors get very hot immediately after the operation is stopped.

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Page 41

3-3 Cleaning and Replacing the Air Filter

Air is circulated in the controller of the base machine to cool the controller. The cooling air is introduced through the air filter on the rear of the machine. Dust may be accumulated choking the air filter which decreases the cooling power causing serious damage such as thermal breakdown of ICs if the air filter is not properly maintained. Clean the air filter once every six months. If the air filter is heavily clogged, replace the air filter.

1. Turn off the POWER switch and unplug the power cord from an electrical outlet.

2. Remove the front cover.

Remove the bottom screws. While pulling the bottom of the cover to the front, raise the catches on the top.

Front cover

Air filter is inside the front cover.

3-4

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Page 42

3. Replace the media (filter).

3. Maintenance

4. Reinstall the front cover as before.

Replacement media

Sony Order No. .........4-761-607-01

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Page 43

3-4 Replacing the Battery

1. Turn off the POWER switch and unplug the AC power cord from the AC outlet.

The battery is located in the recess at the bottom on the rear of the Z-axis.

2. Exchange the battery with the new lithium battery.

lithium battery

NOTE

If not, internal data can be damaged.

Replacement lithium battery (primary battery)

Sony Order No. .........1-528-932-11

3-6

Battery replacement must be completed within eight hours after the main power is turned off.

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4. Troubleshooting

4-1 Common Items

4-1-1 Stepping Out (Note 1)

The machine performs open loop servo control using a pulse motor (stepping motor) without positional feedback. The machine thus continues to operate with positional error even if it steps out due to overloading of the retaining torque of the motor.

When the base machine steps out, or when it operates with positional errors, check the following items first.

(1) Overloaded The base machine has a limited carrying loading. Check whether the load exceeds the maximum payload that the respective axes can carry by referring to page 1-6, section 1-3, “Specifications.” The payload with which the machine can operate at 100% speed is smaller than the maximum payload, and varies for each axis. Check the actual load weight before operating the machine.

(2) External force External forces from cables and pipes are normally larger than anticipated, and can easily exceed the retaining torque of the motor. Be careful of unexpected external forces when using stiff wires or pipes that cannot be easily bent.

(3) Rapid speed change When a rapid speed change occurs such as an immediate returning movement while an interpolation operation is being performed, the load inertia may exceed the retaining torque of the motor, causing the motor to step out. Before performing such a movement, reduce the operating speed.

Example : Returning movement of the circular Example : Returning movement of the Z-axis

interpolation operation operation

(Movements are synthesized sometimes.)

Note 1 : What is “stepping out”? When the drive shaft of a motor is overloaded beyond the torque of the motor, the drive shaft spins (revolves swiftly without control) regardless of the control that is applied to the motor. This is called “stepping out”. This term is sometimes used incorrectly for tooth-skipping (between pulley and belt), but stepping out and tooth-skipping are actually entirely different phenomena.

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(4) Synthesis of movements in the same direction

In some programs, the machine is operated by synthesizing two movements (the FOS and PFOS with the AWAKE instruction of LUNA). When the teaching points to be synthesized are aligned on the same line, the machine can step out. When such a movement is experienced, the application program must be modified.

(5) Eccentric loading

When a load (tool, work, etc.) is very eccentric or far from the mounting surface, stepping out can occur even though the load is lower than the maximum payload. If the weight balance cannot be improved, reduce the operating speed.

(6) Mounting screw

When a mounting screw is so long that the tip of the screw touches the cover or other object, it can cause stepping out. You can detect this trouble by listening for a rubbing sound or looking for scars. Check for these before use.

(7) Belt tension

If the belt tension becomes abnormal, contact your Sony dealer from which you purchased the machine, or contact Sony Max Corporation FA Service.

(8) When the machine is operated at low temperature

In early morning during winter, the room temperature may fall to 0°C or lower. The temperature inside the machine takes time to rise even though the temperature of the room can be increased by using a heater. In this case, run the machine for half an hour at half the specified speed, or wait until the temperature of the machine rises to the temperature of the room.

4-2

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4. Troubleshooting

4-1-2 External Noise

External electrical noise is a difficult problem because it is invisible. Take the following remedial measures. If the symptom disappears, electrical noise was probably the cause of the trouble.

(1) Earthing the power supply

Always connect the earth of the AC output to ground (Class 3 ground). If the earth is not connected, the equipment is susceptible to electrical noise.

(2) Separation of AC connections

Connect the AC power of the machine to a separate AC outlet from any equipment that generates significant electrical noise.

(3) Cable length

The cables connected to the machine can function as antenna and pick up electrical wave noise. Make the cable length as short as possible, and use shielded cables where possible. The teaching pendant is connected by a long cable to the ROBOKIDS, so disconnect the teaching pendant when not in use.

4-1-3 Abnormal Sound from Unit’s Motors

The Z unit motor and the ZR unit motor are equipped with brakes; these motors may occasionally produce abnormal sounds such as scratching or crunching noises. These sounds are caused by the structure of the brakes and are not a problem. Also, a squeaking or creaking sound may be heard when the emergency stop switch is pressed during AUTO operation. These are the stepping out sound that is generated when the Z-axis is forcibly stopped by stepping it out in order to prevent the Z-axis from moving down during an emergency stop. These sounds cause no problem in terms of reliability.

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Page 47

4-2 Full-open Programmable Specifications



Connect the SRX teaching pendant via a debug station and check the error codes and error history using the following procedure.

1 Connect a debug station. 2 Connect the SRX teaching pendant. 3 Press the MANAGEMENT key and select “Error History” with the F4 key by scrolling the cursor using

↑ ↓

the

MANAGE ↑ ↓

sHOME RETURN

CONSTANT ❙ SELECT

F1 F2 F3 F4

4 The error history is displayed.

key.

ERR HISTORY← →↑ ↓

s E110 R1 L1045 199 E120 R2 L346 199 



Date and time of occurrence Display is possible in a 1998/07/01 14:43:19 format by scrolling right with the → key.

Program line number in which the error occurred

Task name in which the error occurred

Error number

A list of errors is displayed starting from the most recent occurrence. When an error occurs, it is registered in the top (the topmost line) and the oldest error is deleted.

4-4

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4. Troubleshooting

5 Check the error code number E*** on display and find out causes and countermeasures referring to the

following table. When the machine does not operate normally, check the error contents referring to the following table. For the contents that are unique to the respective applications, refer to the Operation Manual of the memory card (RK card), and take the appropriate measures.

Error No.

E000 ~ E030

E031 E100

E110

E111 E112 E113 E114 E115 E116 E117 E118

E119 ~ E124

E130

E131

E132

E133

E134 E135 E136 E137 E138 E139 E140 E141

E154

E155

E200 ~ E204

E300

Causes CPU board is defective Internal memory overflows System task not present error (full open)

Object code error

System task command error (full open) Robot command error I/O number error Point data not present error Error of point number specified Parameter error Array number error Integer value out of range error Syntax error X-axis (tool axis) out of operation range error Y-axis (work axis) out of operation range error Z-axis (tool axis) out of operation range error R-axis (tool axis) out of operation range error X-axis system limit error Y-axis system limit error Z-axis system limit error R-axis system limit error X-axis point limit error Y-axis point limit error Z-axis point limit error R-axis point limit error Speed is too fast for the distance between the two points during interpolation operation The circular auxiliary point (ENTER B) and start point/end point are aligned on a straight line during circular interpolation operation. Circle is taught in 360 degrees PLC program error (full open) Emergency stop is triggered

Solutions Replace the Base board Delete the unnecessary programs Install the system task When the Power lamp lights up in red, replace the battery. If it does not corresponds to any of the above contents, contact Sony sales or service office. Correct the program Correct the program of system task or peripheral task Correct the I/O number Load the point number. Replace the CPU board Correct the point number Correct the variables specified Correct the array number Correct the integer value Correct syntax

Correct the target point to which the tool moves

Correct the speed so as not to exceed the range Correct the speed so as not to exceed the range Correct the speed so as not to exceed the range Correct the speed so as not to exceed the range Correct the speed so as not to exceed the range Correct the speed so as not to exceed the range Correct the speed so as not to exceed the range Correct the speed so as not to exceed the range

Increase the distance between the two points, or decrease the speed

Correct the position of the circular auxiliary point, or divide the movement into smaller segments of less then 360 degrees

Correct the program Cancel the emergency stop switch

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Page 49

Error No.

E301

E302

E303

E304

E314

E315

E316

E317

Causes

X-axis limit sensor error

Y-axis limit sensor error

Z-axis limit sensor error

R-axis limit sensor error

X-axis command position error

Y-axis command position error

Z-axis command position error

R-axis command position error

Solutions Correct the speed so as not to exceed the range. Replace the sensor Correct the speed so as not to exceed the range. Replace the sensor Correct the speed so as not to exceed the range. Replace the sensor Correct the speed so as not to exceed the range. Replace the sensor Correct the speed so as not to exceed the range. Correct the target point Correct the speed so as not to exceed the range. Correct the target point Correct the speed so as not to exceed the range. Correct the target point Correct the speed so as not to exceed the range. Correct the target point

4-6

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4. Troubleshooting

4-3 When Memory Card (RK Card) is Used

The operational flow starting from turning on the main power of the machine until the programmed operation or teaching is started, is shown as follows. Causes and countermeasures when trouble occurs in the respective state from 1) to 9) are shown on the next page. Use these tables for troubleshooting. There may be a case when an error number is displayed on the teaching pendant. When “EEE” and “error number” appear alternately, it indicates that the trouble is the robot error. The robot errors which can occur in the ROBOKIDS are shown as follows. When any error number other than those listed below appears, consult your Sony dealer for more details.

Main power of

ROBOKIDS is turned on

System task number appears

START indicator flashes

START button is pressed

Performed Homing

START indicator flashes slowly

Application program switches are set

CAST-AU4/B2521E

Work program switches are set

Application program

"0"

HOME key of

teaching pendant is pressed

To teaching mode

Application program

"1" ~ "E"

START button is pressed

To running mode

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Page 51

Fault-Finding Chart of 1)

Symptoms

The simple operation teaching pendant keeps displaying “666”

“E01” appears on the simplified TP.

“E02” appears on the simplified TP.

The main power cannot be turned on.

The stop indicator keeps turning on.

Causes

OFF LINE is selected

Internal PC board is defective

Card is not inserted

The card has no program The CAST specification setting is set to NO The main AC power is not turned on

The POWER switch is broken The STOP button is kept locked. (Including the teaching pendant)

The external stop signal is being connected

Solutions Connect the SYSRUN Set the machine system to “ONLINE” from the TP of the SRX Exchange the internal PC board

Insert the memory card securely

Insert a memory card in which program is stored Set the CAST specification setting to “YES” from the TP of the SRX Connect the AC main power Exchange the POWER switch

Release the lock

Release the external emergency stops Alternatively, short pin-1 and pin-2 of the external switch connector

Fault-Finding Chart of 2)

Symptoms

START indicator does not illuminate

START indicator keeps flashing

Fault-Finding Chart of 3)

Symptoms

START button does not function

Fault-Finding Chart of 4)

Symptoms “E07” appears on display Machine movement does not stop (It moves in the reverse direction.)

Causes START indicator is defective START button has the short circuit External START switch has the short circuit

Causes START button is defective

Causes Returning home failed

Sensor cable is defective

Controller data is abnormal

Replace the START indicator Replace the START button Replace the external START button

Replace the START button

Start operation from the very beginning

Confirm the sensor cable connection

Correct the controller data from TP of the SRX

Solutions

4-8

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Fault-Finding Chart of 5)

4. Troubleshooting

Symptoms

“E08” appears on display

“E09” appears on display

TYPESET failed

START failed

Fault-Finding Chart of 6) or 7) or 8)

Symptoms

START indicator keeps flashing

“HOME” key does not function “E10” appears on display

during teaching “E11” appears on display during teaching “E12” appears on display during teaching

“E30” appears on display

“E31” appears on display

“E32” appears on display

“E33” appears on display

“E34” appears on display

“E35” appears on display

“E36” appears on display

“E37” appears on display

The machine does not operate normally

Application program switch is defective Teaching pendant is defective A point outside the work envelope is specified by INSERT/DELETE The target coordinate of copy has exceeded the work envelope during COPY. Number of point storage capacity of the target point of copy is insufficient during COPY Step-out of the X-axis in the opposite direction to home position has occurred Step-out of the X-axis in the home position direction has occurred Step-out of the Y-axis in the opposite direction to home position has occurred Step-out of the Y-axis in the home position direction has occurred Step-out of the Z-axis in the opposite direction to home position has occurred Step-out of the Z-axis in the home position direction has occurred Step-out of the R-axis in the opposite direction to home position has occurred Step-out of the R-axis in the home position direction has occurred Teaching has not been done correctly Machine is loaded with excessive weight Cover is contacting with moving object Dropped parts such as screws are choking. External unit is defective External noise is affecting

Causes

Solutions

Turn on the main power of the machine system and start operation from the very beginning Turn on the main power of the machine system and start operation from the very beginning

Solutions Replace the application program switch Replace the teaching pendant Specify the point inside the area and try again

Perform COPY so as not to exceed the work envelope Perform COPY within the storage capacity of point Check weight of the tool and check also if there is any interfering obstacles around the point Check weight of the tool and check also if there is any interfering obstacles around the point Check weight of the work and check also if there is any interfering obstacles around the point Check weight of the work and check also if there is any interfering obstacles around the point Check weight of the tool and check also if there is any interfering obstacles around the point Check weight of the tool and check also if there is any interfering obstacles around the point Check weight of the tool and check also if there is any interfering obstacles around the point Check weight of the tool and check also if there is any interfering obstacles around the point Perform teaching again. Refer to section “1-3-1 Machine specifications”. Correct the cover position Remove anything dropped Repair or replace the external unit Remove the source of noise

The belt tension adjustment

Consult your Sony dealer from which you purchased the machine or the nearest Sony FA offices for the actual adjustment of the belt tension.

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Page 53

Trouble Check Sheet

If a trouble occurs, check the following items before contacting your Sony dealer or the nearest Sony FA offices.

1) Name of dealer from which you purchased the ROBOKIDS Company name : Person in charge : Tel:

2) What is the serial number of your ROBOKIDS? (It is marked on the sticker of the rear cover.) M No. R No.

3) What type of memory card are you using ? (It is marked on the memory card.) TYPE NAME

4) When did the trouble occur?

1. Has the trouble occurred since you purchased the ROBOKIDS?

2. The ROBOKIDS ran normally, but then troubles suddenly occurred.

3. The machine has gradually become worse.

4. Others In case of 1, what was the condition of the ROBOKIDS?

1. How was the condition during initial operation after purchase?

2. The main power has not been turned on for a long time (for days).

3. The main power has not been turned on for a short time (for days).

4. What was the condition when the main power was turned on?

5) Describe the details of the trouble (such as error code, etc.).

6) Compared with normal operation, at what timing does the error occur?

7) If you have two or more ROBOKIDS, compare them. What are the results of the comparison?

8) What happens if you replace parts (such as the memory card)?

9) Is there any noise source near the ROBOKIDS? Yes / No

10) What is the condition of the ROBOKIDS at present?

• The ROBOKIDS is not being used.

• The ROBOKIDS is still being used.

11) Customer Company name : Department : Person in charge :

Tel :

Fax :

Fill in the above items, and send this form to your Sony dealer or the nearest Sony FA offices by fax.

4-10

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5. Repair Parts Lists

5-1 ROBOKIDS Body

5. Repair Parts Lists

Descriptions TASK board BASE board Battery DC switching power supply ZWS30-5/J DC switching power supply ZWS150PF-24/J Circuit protector Fan harness Self-illuminating stop switch Self-illuminating stop switch Digital switch X-axis motor Y-axis motor X-axis home position sensor harness Y-axis home position sensor harness X-axis liner guide Y-axis liner guide X-axis timing belt Y-axis timing belt Media Cable harness Electrical fitting assembly Control block assembly Y-axis assembly X-axis assembly

Part No. A-8338-047-A A-8338-048-A

1-528-932-11 1-468-348-11 1-468-349-11 1-576-271-11 1-959-099-11 1-572-977-11 1-771-539-11 1-771-538-11 1-763-186-11 1-763-186-11 1-959-094-11 1-959-095-11 4-760-637-01 4-760-638-01 4-760-635-02 4-760-636-02 4-761-607-01

1-959-100-11 A-8338-050-A A-8338-046-A A-8336-316-A A-8336-315-A

Remarks Built-in board “Small” Built-in board “Large”

For DC 5 V For DC 24 V POWER switch Inside the ROBOKIDS Operation box Operation box Operation box

Air filter

5-2 Z-axis Unit

Z-axis motor Z-axis home position sensor harness Z-axis linear guide Z-axis timing belt Z-axis relay cable harness Z-axis timing belt Bearing Mechanism block assembly

CAST-AU4/B2521E

Descriptions

Part No. 1-763-187-11 1-959-096-11 4-760-643-01 4-760-641-01 1-790-017-11 4-760-642-01 4-760-650-01

A-8336-325-A

Remarks

Long

Short

5-1

Page 55

5-3 Z/R-axis Unit

Descriptions Z-axis motor R-axis motor Z-axis home position sensor harness R-axis home position sensor harness Spline ball screw Z-axis timing belt R-axis timing belt Z/R-axis relay cable harness Bearing Mechanism block assembly

Part No. 1-763-187-11 1-763-187-11 1-959-101-11 1-959-097-12 4-760-605-01 4-760-645-01 4-760-644-01 1-959-098-12 4-760-650-01

A-8336-314-A

Remarks

5-2

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6. Appendix

■ User Input/Output Specifications of USER I/O Connector Input

6. Appendix

Connector pin No.

9 43 10 44 11 45 12 46 13 47 14 48 15 49 16 50 17 51

I/O names in terms

of software

SI1 SI2 SI3 SI4 SI5 SI6 SI7 SI8

I1 I2 I3 I4 I5 I6 I7 I8

I9 I10 I11 I12 I13 I14 I15 I16 117 I18 I19 I20 I21 I22

Contents RK card specification (including semi-programmable specification)

SYSRUN Reserved by system (User cannot use it.) Reserved by system (User cannot use it.) Reserved by system (User cannot use it.) Reserved by system (User cannot use it.) Reserved by system (User cannot use it.) Reserved by system (User cannot use it.) Reserved by system (User cannot use it.)

START

RETRUN Work program No. 1 Work program No. 2 Work program No. 4 Work program No. 8

Application program No. 1 Application program No. 2 Application program No. 4 Application program No. 8

Error reset

* * * * * * * * * * *

Full-open programmable

specification

User input User input User input User input User input User input User input User input User input User input User input User input User input User input User input User input User input User input User input User input User input User input

* The allocation at I12 to I22 differs depending upon applications. Refer to the Operation Manual of

memory card (RK card) for more details.

The switch SI1 (SYSRUN) must always be connected. The ROBOKIDS cannot be operated

NOTE

unless the SI1 is turned on. Turn on or off SI1 as required. (Refer to page 2-6.)

CAST-AU4/B2521E

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Output

Connector pin No.

20 54 21 55 22 56 23 57 24 58 25 59 26 60 27 61 28 62 29 63 30 64 31 65 32 66 33 67 34 68

I/O names in terms

of software

SO1 SO2 SO3 SO4 SO5 SO6 SO7 SO8

L1 L2 L3 L4 L5 L6 L7 L8

L9 L10 L11 L12 L13 L14 L15 L16 L17 L18 L19 L20 L21 L22

Contents RK card specification (including semi-programmable specification)

EMG-OUT, stop switch, stop status output

ERROR, robot error signal

Reserved by system (User cannot use it.)

Drive servo ON signal

ONLINE signal Reserved by system (User cannot use it.) Reserved by system (User cannot use it.) Reserved by system (User cannot use it.)

End of cycle output

Standby output

Error output

During operation output

Unloading position output (during line mode)

* * * * * * * * * * * * * * * * *

Full-open programmable

specification

User output User output User output User output User output User output User output User output User output User output User output User output User output User output User output User output User output User output User output User output User output User output

* The allocation at L6 to L22 differs depending upon applications. Refer to the Operation Manual of

memory card (RK card) for more details.

■ Pin assignment

30 32 34

29 31 33

66 68

CAST-AU4/B2521E

6-2

2 468

1357 9

36 38 40 42

35 37 39

Page 58

■ Specifications of the Connected I/O (Used only in the semi-programmable specifications and the full open programmable specifications)

Input

6. Appendix

I/O names in terms

of software

I23 I24 I25 I26 I27 I28 I29 I30 I31 I32

Output

I/O names in terms

of software

L23 L24 L25 L26 L27 L28 L29

Contents

START button (White button of operation box) RETURN button (To be connected from the rear SAFETY connector by user) Work program No. 1 (First digit of the PROGRAM switch of the operation box (1)) Work program No. 2 (First digit of the PROGRAM switch of the operation box (2)) Work program No. 4 (First digit of the PROGRAM switch of the operation box (4)) Work program No. 8 (First digit of the PROGRAM switch of the operation box (8)) Application program No. 1 (Second digit of the PROGRAM switch of the operation box (1)) Application program No. 2 (Second digit of the PROGRAM switch of the operation box (2)) Application program No. 4 (Second digit of the PROGRAM switch of the operation box (4)) Application program No. 8 (Second digit of the PROGRAM switch of the operation box (8))

Contents

START LED (White indicator) Stop LED (Red indicator) RETURN indicator (To be connected from the rear SAFETY connector by user) Stop indicator (To be connected from the rear SAFETY connector by user) The barrier signal from the rear SAFETY connector becomes valid when the barrier is enabled. User cannot use it. User cannot use it.

■ User external power supply connector

Power connector for I/O

Pin No. Name

1 24 V 2GND

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■ Connector for Debug Station

Pin No.

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Signal

FG TP-RXD TP-TXD

TP-CTS TP-RTS

TP-DTR

C GND

SIO-DSR

SIO-RXD

C GND

SIO-CTS

SIO-RTS

EXS5 EXS2

/TP CN1

NC TP-DSR

SIO-TXD

PC05V

SIO-DTR

C GND PC05V

Contents

Frame ground

Connector for SRX teaching pendant (Receive data)

Connector for SRX teaching pendant (Transmit data)

Connector for SRX teaching pendant (Clear to send)

Connector for SRX teaching pendant (Request to send)

Connector for SRX teaching pendant (Data terminal ready)

Signal ground

Connector for program transfer (Data set ready)

Connector for program transfer (Receive data)

Signal ground

–

Signal ground

Connector for program transfer (Clear to send)

–

Connector for program transfer (Request to send) Connector for SRX teaching pendant (Emergency stop) Connector for SRX teaching pendant (Emergency stop)

SRX teaching pendant is connected or not

–

Connector for SRX teaching pendant (Data set ready)

Connector for program transfer (Transfer data)

+5V for SRX teaching pendant

Connector for program transfer (Data terminal ready)

Signal ground

+5V for SRX teaching pendant

Type : DBLC-J25SAF-10L9 Manufacturer : JAE Applicable plug : DBSP-JB25PF Manufacturer : JAE Applicable shell : DB-C8-J10-F4-1 Manufacturer : JAE

6-4

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■ Connector for Operation Box

6 7 8

6. Appendix

Pin No.

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

I/O names in terms

of software

I25 L23 L24

– I32 I23

–

– I31 I26 I27 I28 I29 I30

Contents

Work program No. 1 (First digit of the PROGRAM switch (1))

START LED

Stop LED

0 V

Application program No. 8 (Second digit of the PROGRAM switch (8))

START button

Stop button

24 V

Application program No. 4 (Second digit of the PROGRAM switch (4))

Work program No. 2 (First digit of the PROGRAM switch (2)) Work program No. 4 (First digit of the PROGRAM switch (4))

Work program No. 8 (First digit of the PROGRAM switch (8)) Application program No. 1 (Second digit of the PROGRAM switch (1)) Application program No. 2 (Second digit of the PROGRAM switch (2))

Type : 17HE-13150-73 Manufacturer : DDK Applicable plug : 17HE-23150-CD8A Manufacturer : DDK Applicable shell : 17H-7PCR-102 Manufacturer : DDK

■ RS232C connector (Rear Panel)

Pin No.

1 2 3 4 5 6 7 8

Signal

NC TXD RXD DSR

DTR

CTS RTS

Type : CDS-3109-0122 Manufacturer : SMK Applicable plug : 17JE-23090-02 Manufacturer : DDK Applicable shell : 17JE-09H-1A Manufacturer : DDK

CAST-AU4/B2521E

Contents

−

Transmit data

Receive data Data set ready Signal ground

Data terminal ready

Clear to send

Request to send

−

1 2 3 4

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■ SAFETY Connector

Pin No.

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

STOP RELAY OUT (C) STOP RELAY OUT (NO) STOP RELAY OUT (NC)

Stop BAR RELEASE

Signal

24V

SA START OUT

SA STOP OUT

0V FG

SA RETURN IN

SA Stop IN (C)

SA Stop IN (NC)

BAR (C)

BAR (NC)

Contents

+24 V

RETURN indicator

Stop indicator Stop output common Stop output (NO)

Stop output (NC)

–

FG (Shielded wire, etc.)

RETURN switch

Stop switch Stop switch

Barrier (safety door, etc.) Barrier (safety door, etc.)

External stop switch and barrier are enabled

–

Type : DA-J15PF1L9 Manufacturer : JAE Applicable plug : DA-15PF-N Manufacturer : JAE Applicable shell : DA-C4-J10 Manufacturer : JAE

6-6

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■ Connector for ZR-axis Cable

6. Appendix

Pin No.

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Signal

ZR_COM

Z_DET

ZR_DET

Z_24V

Z_LIM

Z_GND

Z_A

Z_B_C

Z_/B R_A

R_B_C

R_/B BRK+ BRK–

R24V

R_LIM

R_GND

Z_A_C

Z_/A

Z_B

R_A_C

R_/A

R_B

Contents

Frame ground

Unit signal common (GND)

Z-unit signal

ZR-unit signal

DC 24 V for Z sensor

Z-sensor signal

Ground for Z-sensor

Z-axis phase A signal

Z-axis -phase B common (DC 24 V)

Z-axis phase/B R-axis phase A

Z-axis -phase B common (DC 24 V)

R-axis phase/B

Brake (+, DC 24 V)

Brake (-, ground)

DC 24 V for R sensor

R sensor signal

Ground for R sensor

Frame ground

Z-axis phase A common (DC 24 V)

Z-axis phase /A

Z-axis phase B

R-axis phase A common (DC 24 V)

R-axis phase/A R-axis phase B

Model : DBLC-J25SAF-10L9 Manufacturer : JAE Applicable plug : DB-25PF-IN Manufacturer : JAE Applicable shell : DB-C4-J11 Manufacturer : JAE

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Supply Period of Repair Parts

The functional repair parts (parts needed to maintain product performance) of this machine will be supplied for up to seven years in principle after production is discontinued. Because it may be possible to repair the machines depending upon the location of the problem even after this period, consult the service or sales representative from where you purchased the machine.

〔Singapore〕

Sony Electroncs (Singapore) Pte. Ltd

TEL : 8615858 FAX : 8621521

〔Europe〕

Sony Wega Produktions GmbH Production Technology Division Europe

TEL : +49 (0)711 5858-420 FAX : +49 (0)711 574153

〔Japan〕

Sony Manufacturing Systems Corporation, FA service Department.

TEL : 0480-23-1956 FAX : 0480-23-1706

Page 64

1st Edition November, 1998

3rd Edition October, 2001

Page 65

Sony Manufacturing Systems Corporation