Toshiba TSL3000E Series Interface Manual
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Toshiba TSL3000E Series Interface Manual

Toshiba TSL3000E Series Interface Manual

Robot controller
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TSL3000E SCARA system
TSL3100E 6-Axis system
• Make sure that this instruction manual is delivered to the
final user of Toshiba Machine's industrial robot.
• Before operating the industrial robot, read through and
completely understand this manual.
• After reading through this manual, keep it nearby for future
reference.
INTERFACE MANUAL
Notice
TOSHIBA MACHINE CO., LTD.
TOKYO, JAPAN
STE 85457-0

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Summary of Contents for Toshiba TSL3000E Series

  • Page 1 INTERFACE MANUAL Notice • Make sure that this instruction manual is delivered to the final user of Toshiba Machine's industrial robot. • Before operating the industrial robot, read through and completely understand this manual. • After reading through this manual, keep it nearby for future reference.
  • Page 2 INTERFACE MANUAL Copyright 2015 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 INTERFACE MANUAL Preface This manual describes the type, function and handling method of external cables connecting the TSL3000E/TSL3100E robot controller with external equipment. This manual is intended for the system designers and manufacturing engineers. The TSL3000E/TSL3100E robot controller can work in concert with the external equipment through digital input and output signals that can be programmed by the SCOL language.
  • Page 4 INTERFACE MANUAL Cautions on Safety This manual contains the important information on the robot and controller to prevent injury to the operators and persons nearby, to prevent damages to assets and to assure correct use. Make sure that you well understand the following details (indications and symbols) before reading this manual.
  • Page 5 INTERFACE MANUAL To perform the work ranging from robot installation to operation with safety, read through and through the Safety Manual provided separately before actually starting the CAUTION work. STE 85457 – 4 –...
  • Page 6 Disassembly Prohibited • To replace parts, use the spare parts designated by Toshiba Machine. • Carry out the maintenance and inspection on a regular basis. Otherwise, the equipment may go wrong or accidents will be Mandatory caused.

  • Page 7: Table Of Contents

    INTERFACE MANUAL Table of Contents Page Section 1 Type of External Cable ................9 Layout and Name of Connectors (4-Axis Type/6-Axis Type combined) ... 9 Power Cable "AC IN" ..................10 Motor, Encoder "ROBOT" ................10 Hand I/O Cable "HAND" ................. 10 Brake Cable "BRK"...
  • Page 8 INTERFACE MANUAL Section 4 External I/O Signal Cable ................ 32 SAFE I/O Signal Cable ................... 32 Detail of SAFE Circuit ..................33 Emergency Stop Input ..................34 Safety Door and Enable Input ................ 42 SAFE Circuit Operation Timing............... 43 4.5.1 Start Method ....................
  • Page 9 INTERFACE MANUAL Section 9 Connection of Trigger Input Signal Cable (TRIG) (Option) ....114 Fabricating Trigger Input Signal Cable ............115 Attaching and Detaching Trigger Input Signal Cable ........115 Section 10 Connection of Conveyor Synchronization Signal Cable (CONV) (Option) ..................116 10.1 Fabricating Incremental Encoder Input Signal Cable ........

  • Page 10: Type Of External Cable

    INTERFACE MANUAL Section 1 Type of External Cable Layout and Name of Connectors (4-Axis Type/6-Axis Type combined) The TSL3000E/TSL3100E robot controller is connected with the robot and external equipment, using connectors and terminal blocks provided on the front and rear panels of the controller.

  • Page 11: Power Cable "Ac In

    INTERFACE MANUAL Power Cable "AC IN" Fig. 1.1– 1 (with connector) The power cable is an interface feeding the main power (single phase, 190/240 V AC, 50/60 Hz) to the TSL3000E/TSL3100E robot controller. Connector "AC IN" is used. For details, see the Installation & Transport Manual provided separately. Motor, Encoder "ROBOT"...

  • Page 12: External I/O Signal Cable

    INTERFACE MANUAL External I/O Signal Cable 1.6.1 Safety Input Signal Cable "SAFE" Fig. 1.1– 15 (with connector) The safety input signal cable is an interface connecting emergency stop input and safety door signal input to the TSL3000E/TSL3100E robot controller from the external equipment.

  • Page 13: Serial I/O Signal Cable

    INTERFACE MANUAL Serial I/O Signal Cable 1.7.1 Serial I/O Signal "COM1" Fig. 1.1– 5 Serial I/O signal cable COM1 is exclusively used for the RS232C and allows data communication with an image processing equipment or other FA equipment that can connect an RS232C interface.

  • Page 14: I/O P24V Supply And Remote I/O Cable

    INTERFACE MANUAL 1.10 I/O P24V Supply and Remote I/O Cable Fig. 1.1– 8 This is a connector for external power supply connection for setting INPUT, OUTPUT, and the INPUT and OUTPUT for HAND to ON or OFF. P24V is supplied externally.

  • Page 15: Fieldbus Cable "Fieldbus

    INTERFACE MANUAL 1.14 Fieldbus Cable "Fieldbus" Fig. 1.1– 11 (option) This supports connection with fieldbus devices, which is available as an option function in the TSL3000E/TSL3100E robot controller. PROFIBUS, DeviceNet, or CC-Link can be selected as the type of fieldbus for the slave module. "FieldBUS" is located in the top section of the front panel.

  • Page 16: Extension Output Signal Cable "Output (Tr)

    INTERFACE MANUAL 1.17.2 Extension Output Signal Cable "OUTPUT (TR)" Fig. 7.3– 15 (option) This is an interface which outputs an external signal from remote I/O module TR480DIOCN/TR48DIOC to the external equipment. Like the external output signal cable, the extension output signal cable is provided with twenty (20) digital output signals that can be programmed at the user's discretion, using the SCOL language or PLC function.

  • Page 17: Power Cable

    INTERFACE MANUAL Section 2 Power Cable Connecting the Power Cable To connect the TSL3000E/TSL3100E power cable, use the attached connector. AC IN Robot controller side User side Single-phase 190-240 VAC 50/60 Hz Fig. 2.1 Connection of power cable Plug connector model: JL04V-6A18-10SE-EB Manufacturer: JAE (Japan Aviation Electronics Industry, Limited) JL04-18CK(13)
  • Page 18 INTERFACE MANUAL A ground-fault circuit interrupter must be installed on TSL3000E/TSL3100E by the customer. Specifications: Single phase 20 A, sensitivity current 30 mA Recommended ground-fault circuit interrupter: BKW2203CCK by Panasonic Electric Works, Co., Ltd. Note the following when installing a ground-fault circuit interrupter. - A ground-fault circuit interrupter must be installed for each power supply to the machine.

  • Page 19: Robot Control Cable

    INTERFACE MANUAL Section 3 Robot Control Cable TSL3000E Motor Drive Cable (4-Axis Type) To connect the motors, use the attached cables. ROBOT Cable connecting robot and Robot controller Robot body controller MOTAP J1AS Axis 1 J2AS Axis 2 MOTBP J3AS Axis 3 J4AS Axis 4...

  • Page 20: Tsl3100E Motor Cable (6-Axis Type)

    INTERFACE MANUAL TSL3100E Motor Cable (6-Axis Type) To connect the motors, use the attached cables. ROBOT Cable connecting robot and Robot controller Robot body controller J1AS MOT1 Axis 1 J2AS Axis 2 J3AS MOT2 Axis 3 J4AS Axis 4 J5AS MOT3 Axis 5 J6AS...

  • Page 21: Tsl3000E Brake Cable (4-Axis Type)

    INTERFACE MANUAL TSL3000E Brake Cable (4-Axis Type) To connect the brakes, use the attached cables. Cable connecting robot and Robot controller Robot body controller P24V ENCBP J3DS BRAKE BRAKE P24V BRAKE S BRAKE P24G P24G Fig. 3.3 Connection of brake cables STE 85457 –...

  • Page 22: Tsl3100E Brake Cable (6-Axis Type)

    INTERFACE MANUAL TSL3100E Brake Cable (6-Axis Type) To connect the brakes, use the attached cables. Cable connecting robot and Robot controller Robot body controller J1DS BRA1 P24V BRAKE Axis 1 P24V P24V J2DS BRAKE Axis 2 P24V J3DS BRAKE Axis 3 P24V J4DS BRA2...

  • Page 23: Tsl3000E Encoder Cable

    INTERFACE MANUAL TSL3000E Encoder Cable To connect the encoders, use the attached cables. ROBOT Cable connecting controller and robot Robot controller Robot body J1BS ENCBS 1RQ/SD 1RQ/SD Axis 1 encoder 1RQ/SD* 1RQ/SD* J2BS 2RQ/SD 2RQ/SD Axis 2 encoder 2RQ/SD* 2RQ/SD* J3BS 3RQ/SD 3RQ/SD...

  • Page 24: Tsl3100E Encoder Cable (6-Axis Type)

    INTERFACE MANUAL TSL3100E Encoder Cable (6-Axis Type) To connect the encoders, use the attached cables. J1BS ROBOT Cable connecting controller Robot controller Robot body and robot ENC1 1RQ/SD 1RQ/SD Axis 1 encoder 1RQ/SD* 1RQ/SD* J2BS 2RQ/SD 2RQ/SD Axis 2 encoder 2RQ/SD* 2RQ/SD* J3BS...

  • Page 25: Connecting Hand I/O Signal Cable (Thl Series)

    INTERFACE MANUAL Connecting Hand I/O Signal Cable (THL Series) Use the supplied cable to connect the robot control signal cable. The input common signal is shared with the SYSINCOM signal (17 and 30 pins) in the INPUT connector on the front panel of the controller, and the output common signal is shared with the SYSOUTCOM signal (10 and 23 pins) in the OUTPUT connector.
  • Page 26 INTERFACE MANUAL Connection for Type P ROBOT Robot controller Cable connecting controller and robot Robot body ( ): signal name of DIN command and DOUT command JOES (201) (202) (203) (204) SYSINCOM (205) Source type (206) (- common) (207) Note: SYSINCOM is (208) connected to the 17 P24V...

  • Page 27: Connecting Hand I/O Signal Cable (Tvl Series)

    INTERFACE MANUAL Connecting Hand I/O Signal Cable (TVL Series) To use a user's special system, use the attached HAND motor drive power connections on the robot side. The cables are not attached. Appropriate cables should be used. When using this function, use of exclusive cables (option) is recommended.
  • Page 28 INTERFACE MANUAL Connection for Type P HAND HAND Cable connecting controller Robot controller Robot body User wiring and robot ( ): signal name of DIN command and DOUT command (201) (202) (203) (204) SYSINCOM P24V Sink type (- common) Note: SYSINCOM is connected to the 17, and 30 pins of the INPUT connector.

  • Page 29: Fabricating Hand I/O Signal Cable

    INTERFACE MANUAL Fabricating Hand I/O Signal Cable When fabricating a hand I/O signal cable, observe the following matters. When using this function, use of exclusive cables (option) is recommended. For details, contact our after-sale service agent in your territory. 3.9.1 THL Series Hand The CN0 connector on the robot side should be either the attached connector or equivalent connectors.

  • Page 30: Tvl Series Hand

    INTERFACE MANUAL 3.9.2 TVL Series Hand The HAND connector on the robot side should be equivalent connectors. Connector name Type of connector Maker HAND JN2FS10SL2-R Japan Aviation (plug angle type connector) Electronics Industry JN1-22-22S-PKG100 (contact) Select the cables which meet the following specifications. •...

  • Page 31: Hand I/O Signal

    INTERFACE MANUAL To connect a hand I/O signal cable, completely insert the cable side connector into the robot side connector and tighten the lock screws on both sides of the connector with a screwdriver. To disconnect the cable, loosen the lock screws, then pull out the connector. At this time, DO NOT pull the cable instead of the connector.
  • Page 32 INTERFACE MANUAL Note: When the double solenoid is defined by the user parameter, two (2) hand output signals are output exclusively through the teach pendant. These two (2) output signals for the double solenoid should be programmed by the robot language, however, so that they can be exclusive during automatic operation.

  • Page 33: External I/O Signal Cable

    INTERFACE MANUAL Section 4 External I/O Signal Cable SAFE I/O Signal Cable To use a customer’s special system, use the attached connectors DFMC 1, 5/12-ST-3, 5-LR (plug type) for connecting the SAFE cable on the robot controller side. The connectors are the I/O connectors for contact inputs of the external emergency stop switch in the high-order system, safety door, etc.
  • Page 34 INTERFACE MANUAL Detail of SAFE Circuit The connection diagram of the emergency stop switch is shown below. TSL3000E/TSL3100E controller SAFE RST-1 Emergency stop latch reset input Customer-prepared RST-2 IN -E MG1 Teach pendant (TP1000) Emergency stop switch IN -E MG2 SAFE Emergency stop EMG-IN1...

  • Page 35: Emergency Stop Input

    INTERFACE MANUAL Emergency Stop Input To use the emergency stop switches externally, input two (2) b-contacts interconnected from the SAFE connector (between 2-3 and 5-6) on the controller front panel. If either of these signals is in open status, emergency stop status cannot be canceled.
  • Page 36 INTERFACE MANUAL Designation RST-1 to RST-2 (Reset inputs 1 and 2) Input terminal Between SAFE-1 and SAFE-2 (reset input for cancelling emergency stop latch) Signal logic Signal judgment Reset Normal Signal terminal  Open  Short-circuit Function The latch status of the safety relay module in the controller can be canceled by inputting reset signal from external equipment.
  • Page 37 INTERFACE MANUAL Designation EMG-IN* ~ EMG-OUT* (Emergency stop contact inputs 1 and 2) Input terminal Between SAFE-3 and SAFE-4 (emergency stop contact input 1) Between SAFE-5 and SAFE-6 (emergency stop contact input 2) Signal logic Signal judgment Emergency stop Normal Signal terminal ...
  • Page 38 INTERFACE MANUAL Cautions While this signal is open, the servo power cannot be turned on in any mode. EMG-IN* to EMG-OUT* are assumed to have two (2) b-contacts interconnected, which should be turned on and off at the same time. If there is a delay in contact input operation, the non-conformity detection function of hardware works to retain emergency stop.
  • Page 39 INTERFACE MANUAL Designation EMG-COM* ~ EMG-*a,EMG-*b (Emergency stop contact outputs 1 and 2) Input terminal Between SAFE-9 and SAFE-7 and SAFE-8 pins (c-contact output) Between SAFE-10 and SAFE-11 and SAFE-12 pins (c-contact output) Signal logic Output terminal Open Short-circuit Signal output EMG-COM* ~ EMG-COM* ~ Emergency stop...
  • Page 40 INTERFACE MANUAL Designation SAD-IN* ~ SAD-OUT* (Safety door contact inputs 1 and 2) Input terminal Between SAD-13 and SAD-14 (safety door contact input 1) Between SAD-13 and SAD-14 (safety door stop contact input Signal logic Signal judgment Emergency stop Normal Signal terminal ...
  • Page 41 INTERFACE MANUAL Designation SAD-COM* ~ SAD-*a,SAD-*b (Safety door contact outputs 1 and 2) Input terminal Between SAFE-19 and SAFE-17 and SAFE-18 pins (c contact output) Between SAFE-20 and SAFE-21 and SAFE-22 pins (c contact output) Signal logic Output terminal Open Short-circuit Signal output SAD-COM* ~...
  • Page 42 INTERFACE MANUAL Designation SVON-1a ~ SVON_COM (Servo ON contact output) Input terminal Between SAFE-23 and SAFE-24 pins (contact output) Signal logic Output terminal Open Short-circuit Signal output   Function While the servo power is turned on, the output terminals are short-circuited.

  • Page 43: Safety Door And Enable Input

    INTERFACE MANUAL Safety Door and Enable Input To connect the safety door switch, etc. from external equipment, input the signals from the SAFE connector (between 13 and 14 and between 15 and 16) on the controller front panel. When either of these signals is open, emergency stop status cannot be canceled as with the emergency stop switch.

  • Page 44: Safe Circuit Operation Timing

    INTERFACE MANUAL SAFE Circuit Operation Timing close EMG-IN1,2~ EMG-OUT1,2 Emergency stop close SAD-IN1,2~ SAD-OUT1,2 150msec RST-1,2 open 500msec 500msec none Alarm Servo power circuit open 4.5.1 Start Method While all emergency stop switches are canceled, the safety relay module in the controller is reset by pressing the switch between RST-1 and RST-2.

  • Page 45: Restart Method

    INTERFACE MANUAL circuit enters open status and the AC power to the servo power unit is turned off. The delay time of 500 ms is set by the safety relay module in the controller. 4.5.3 Restart Method When the emergency stop switch is pressed, the safety relay module in the controller enters open status and error indication takes place.

  • Page 46: Attaching And Detaching Safe Connector

    INTERFACE MANUAL Attaching and Detaching SAFE Connector Before attaching or detaching a safety I/O signal cable to or from the TSL3000E/TSL3100E robot controller, be sure to turn off the main power in the customer’s control panel. Confirm that external P24V power is also turned off. Connector lock lever (both sides) Grip and pull out the...

  • Page 47: External Input Signal Cable

    INTERFACE MANUAL External Input Signal Cable 4.8.1 Connection of External Input Signal Cable To connect the external input signal cable, use the attached dummy connector [XM3A–3721 (plug type connector), XM2S–3711 (connector cover)]. Some system input signals (normal close contact) of this dummy connector are jumpered. Remove the jumpers, when necessary.
  • Page 48 INTERFACE MANUAL Connection for Type N Connector (INPUT) Robot controller User side INCOM, ( ) Signal name of DIN command DI _ 1 SYSINCOM DI _ 2 DI _ 3 DI _ 4 DI _ * DI _ 5 Digital input signal *In the figure, an example is shown where DI _ 6 common signals (INCOM and SYSINCOM)

  • Page 49: Digital Input Signal

    INTERFACE MANUAL Connection for Type P Connector (INPUT) Robot controller User side ( ) Signal name of DIN command DI _ 1 DI_* DI _ 2 DI _ 3 DI _ 4 INCOM, DI _ 5 SYSINCOM *In the figure, an example is shown where DI _ 6 common signals (INCOM and SYSINCOM) are connected to P24G.
  • Page 50 INTERFACE MANUAL As shown in Figs. 4.3 and 4.4 above, the external input signals are non-voltage contact inputs or open collector inputs. Some of the system inputs (STOP, CYCLE, LOW_SPD, BREAK, SVOFF) are normal close contact inputs, and the others are normal open contact inputs.
  • Page 51 INTERFACE MANUAL • Specifications of Non-voltage contact specifications non-voltage Contact rating 24 V DC, 10 mA or over contact and Circuit current: Approx. 7 mA transistor Minimum current 24 V DC, 1 mA 100  or less Contact impedance • Transistor specifications Withstand voltage between collector and emitter 30 V or over...

  • Page 52: System Input Signal

    INTERFACE MANUAL 4.8.3 System Input Signal A total of thirteen (13) system input signals are available, which control STOP, CYCLE, etc., sent from the external equipment to the TSL3000E/TSL3100E robot controller. The system input signal is provided with an exclusive input terminal for each function.
  • Page 53 INTERFACE MANUAL CAUTION The control unit pushbutton to be attached to the robot controller must be manufactured and installed in a way that unexpected system startup can be prevented (e.g., attachment of a wrong operation prevention card). CAUTION If the system contains more than one controller, specify so that the robot can operate only when the same operation mode is selected for all the controllers.
  • Page 54 INTERFACE MANUAL Designation STROBE (Strobe) Input terminal INPUT-25 pin Signal name in DIN command Signal logic Signal judgment Signal terminal  Open  Short-circuit Function Used to select an execution program for the TSL3000E/TSL3100E robot controller from the external equipment. The program number selected should use any successive "n"...
  • Page 55 INTERFACE MANUAL Cautions The STROBE signal should not be input together with the PRG_RST, CYC_RST, STEP_RST or DO_RST signal. Because the ACK signal is used in common, only the first signal which is input becomes valid and all other signals become invalid.
  • Page 56 INTERFACE MANUAL Correspondence table between [U07] set value (example) and [U08] program file name Signal name in DIN command Program file name (EXTRNSEL.PAR) "PROG1" "PROG2" "PROG3" "PROG4" "PROG5" "PROG6" "PROG7" "PROG8" "PROG9" "PROG10" "PROG11" "PROG12" "PROG13" "PROG14" "PROG15" "PROG16" When bits underlined = 1 2, two (2) external digital input signals 1 and 2 are used, and the number of program files selected is four (4) from "PROG1"...
  • Page 57 INTERFACE MANUAL Copyright(C) 2008 by TOSHIBA MACHINE CO.,LTD. ALL RIGHTS RESERVED. EXTERNAL SELECT FILE *** [ 00 - 0F ] ***** = "PROG00" = "PROG01" = "PROG02" = "PROG03" = "PROG04" = "PROG05" = "PROG06" = "PROG07" = "PROG08" = "PROG09"...
  • Page 58 INTERFACE MANUAL Designation PRG_RST (Program reset) Input terminal INPUT-7 pin signal name in DIN command Signal logic Signal judgment Signal terminal  Open  Short-circuit Function Used to reset a currently stopped program to step 1. The value of each variable is also reset to zero (0). This signal can be used only in the EXT.
  • Page 59 INTERFACE MANUAL Designation STEP_RST (Step reset) Input terminal INPUT-26 pin signal name in DIN command Signal logic Signal judgment Signal terminal  Open  Short-circuit Function Used to reset a currently stopped program to step 1. The value of each variable used in the program remains unchanged.
  • Page 60 INTERFACE MANUAL Designation CYC_RST (Cycle reset) Input terminal INPUT-8 pin Signal name in DIN command Signal logic Signal judgment Signal terminal  Open  Short-circuit Function Used to reset a currently stopped program to the step labeled "RCYCLE". The value of each variable used in the program remains unchanged.
  • Page 61 INTERFACE MANUAL Designation DO_RST (Output signal reset) Input terminal INPUT-27 pin Signal name in DIN command Signal logic Signal judgment Signal terminal  Open  Short-circuit Function Used to reset digital output signals (DO_1 ~ DO_8, DO_101 ~ DO_120, DO_133 ~ DO_152) of the TSL3000E/TSL3100E robot controller from the external equipment.
  • Page 62 INTERFACE MANUAL Designation ALM_RST (Alarm reset) Input terminal INPUT-9 pin Signal name in DIN command Signal logic Signal judgment Signal terminal  Open  Short-circuit Function Used to cancel an alarm from the external equipment, which occurred while the TSL3000E/TSL3100E robot controller was able to start.
  • Page 63 INTERFACE MANUAL Designation RUN (Start) Input terminal INPUT-28 pin Signal name in DIN command Signal logic Signal judgment Signal terminal  Open  Short-circuit Function Used to start a program registered in the TSL3000E/TSL3100E robot controller from the external equipment to execute an automatic cycle operation. This signal can be used only in the EXT.
  • Page 64 INTERFACE MANUAL Designation EX_SVON (External input servo ON) Input terminal INPUT-10 pin Signal name in DIN command Signal logic Signal judgment Signal terminal  Open  Short-circuit Function Used to turn on the servo driver main power from the external equipment.
  • Page 65 INTERFACE MANUAL Designation STOP (Stop) Input terminal INPUT-12 pin Signal name in DIN command Signal logic Signal judgment Signal terminal  Open  Short-circuit Function Used to stop executing a program registered in the TSL3000E/TSL3100E robot controller from the external equipment.
  • Page 66 INTERFACE MANUAL Designation CYCLE (Cycle operation mode) Input terminal INPUT-31 pin Signal name in DIN command Signal logic Signal judgment Signal terminal  Open  Short-circuit Function Used to stop from the external equipment a program registered in the TSL3000E/TSL3100E robot controller after current one (1) cycle operation has been executed during automatic operation.
  • Page 67 INTERFACE MANUAL Designation LOW_SPD (Low speed command) Input terminal INPUT-13 pin Signal name in DIN command Signal logic Signal judgment Signal terminal  Open  Short-circuit Function Used to cause the robot operation speed to low speed from the external equipment. The robot operates at a low speed (the low speed command is valid) while this signal is open.
  • Page 68 INTERFACE MANUAL Designation BREAK (Deceleration and stop) Input terminal INPUT-32 pin Signal name in DIN command Signal logic Signal judgment Signal terminal  Open  Short-circuit Function Used to stop the robot motion from the external equipment. The robot slows down and stops at the same time that this signal is open.
  • Page 69 INTERFACE MANUAL Designation SVOFF (Servo OFF) Input terminal INPUT-14 pin Signal name in DIN command Signal logic Signal judgment (Servo OFF) (Normal) Signal terminal  Open  Short-circuit Function Used to turn off the servo driver main power from the external equipment.
  • Page 70 INTERFACE MANUAL 4.8.4 Jumper of Safety Measure Signal Of the system input signal cables, the following signals are used for the safety measures. System input signal cables ····· INPUT-12 (STOP) INPUT-14 (SV_OFF) INPUT-32 (BREAK) INPUT-17, 35 (SYSINCOM ~ P24G) For the dummy connector provided with the TSL3000E/TSL3100E robot controller, these signals are already jumpered.
  • Page 71 INTERFACE MANUAL External Output Signal Cable 4.9.1 Connection of External Output Signal Cable To connect the external output signal cable, use the attached connector [XM3A–2521 (plug type connector), XM2S–2511 (connector cover)]. A cable with its single side soldered to the connector (TSL3000E/TSL3100E: OUTPUT cable) is provided optionally.
  • Page 72 INTERFACE MANUAL Connection for Type N Connector (OUTPUT) Robot controller User side ( ): Signal name of DOUT command DO _1 DO_* DO _2 DO _3 OUTCOM, DO _4 SYSOUTCOM Digital output signal DO _5 DO _6 DO _7 DO _8 OUTCOM OUTCOM Acknowledge...
  • Page 73 INTERFACE MANUAL Connection for Type P Connector (OUTPUT) Robot controller User side ( ): Signal name of DOUT command DO _1 DO_* DO _2 DO _3 OUTCOM, DO _4 SYSOUTCOM Digital output signal DO _5 DO _6 DO _7 DO _8 OUTCOM OUTCOM Acknowledge...
  • Page 74 INTERFACE MANUAL As shown in Figs. 4.5 and 4.6 above, all seventeen (17) digital output signals are photo MOS outputs. For the function, circuit to use, etc., see Para. 4.9.2. External output can be controlled by the TSL3000E/TSL3100E internal sequencer. For details, see the Simplified PLC Manual.
  • Page 75 INTERFACE MANUAL 4.9.3 System Output Signal Nine (9) signals are used to output the run status of the TSL3000E/TSL3100E robot controller. The system output signal is provided with an exclusive output terminal for each function. The specifications of the system output signals are as follows: •...
  • Page 76 INTERFACE MANUAL Designation ACK (Acknowledge) Output terminal OUTPUT-6 pin Signal logic Signal judgment Output terminal  High  Function This is a response signal to the STROBE, PRG_RST, STEP_RST, CYC_RST and DO_RST signals. When one of these signals is input, the ACK signal is sent back to inform that appropriate processing has finished.
  • Page 77 INTERFACE MANUAL Designation SV_RDY (Servo ready) Output terminal OUTPUT-19 pin Signal logic Signal judgment Output terminal  High  Function This signal indicates that the servo power of the TSL3000E/TSL3100E robot controller can be turned on. This signal can always be used, irrespective of the master mode selected by means of the MODE switch.
  • Page 78 INTERFACE MANUAL Designation EXTSIG (External mode ON) Output terminal OUTPUT-7 pin Signal logic Signal judgment Output terminal  High  Function This signal turns on when the MODE switch of the TSL3000E/TSL3100E robot controller is set to "EXT. SIGNAL". Signal timing MODE switch TEACH EXT.SIGNAL...
  • Page 79 INTERFACE MANUAL Designation SYS_RDY (System ready) Output terminal OUTPUT-20 pin Signal logic Signal judgment Output terminal  High  Function This signal turns on when the robot can start after the controller main power is turned on. With this signal, it is possible to confirm that the robot can be operated.
  • Page 80 INTERFACE MANUAL Designation AUTORUN (Auto mode ON) Output terminal OUTPUT-8 pin Signal logic Signal judgment Output terminal  High  Function This signal turns on when the robot is operating in the automatic operation mode. When the RUN signal is made valid after the SYS_RDY signal is turned on, automatic operation starts with this signal output.
  • Page 81 INTERFACE MANUAL Designation CYC_END (Cycle end) Output terminal OUTPUT-21 pin Signal logic Signal judgment Output terminal  High  Function This signal turns on after the stop of 1-cycle automatic operation only when the CYCLE signal is made valid in the program execution (RUN) mode and an automatic operation is executed.
  • Page 82 INTERFACE MANUAL Designation LOW_ST (Low speed mode ON) Output terminal OUTPUT-9 pin Signal logic Signal judgment Output terminal  High  Function This signal turns on while the robot is operating in the low speed mode by the input of system input signal LOW_SPD. This signal can always be used, irrespective of the master mode selected by means of the MODE switch.
  • Page 83 INTERFACE MANUAL Designation BT_ALM (Battery alarm) Output terminal OUTPUT-22 pin Signal logic Signal judgment Output terminal  High  Function This signal turns on if a battery alarm has occurred in the robot or robot controller. The battery alarm detects all encoders of axis 1 to axis 4 and axis 6 and battery level in the main control board (X8YV).
  • Page 84 INTERFACE MANUAL Designation ALARM (Alarm) Output terminal OUTPUT-11 pin Signal logic Signal judgment Output terminal  High  Function This signal turns on if an error of level 2, 4 or 8 has occurred in the robot or TSL3000E/TSL3100E robot controller. This signal is kept ON during error detection and turns off after the error has been cleared.
  • Page 85 INTERFACE MANUAL 4.10 Fabricating External I/O Signal Cable When fabricating an external I/O signal cable, observe the following matters. Connectors INPUT and OUTPUT for the TSL3000E/TSL3100E robot controller should be either the connectors attached to the controller or equivalent connectors. The equivalent of other makers (D-sub connectors) can also be used.
  • Page 86 INTERFACE MANUAL 4.11 Attaching and Detaching External I/O Signal Cable Before attaching or detaching an external I/O signal cable to or from the TSL3000E/TSL3100E robot controller, be sure to turn off the main power in the user's control panel. Connector on controller side Connector on cable side D-sub connector...
  • Page 87 INTERFACE MANUAL 4.12 Example of Controller Operation, Using External Signals (1) Normal operation sequence POWER SYS_RDY SV_RDY Approx. 2.5 sec. EX_SVON SVOFF SVON ~ SVON_COM Program selection (I)   STROBE  CYCLE STOP AUTORUN CYC_END  To include a delay time of 2.5 seconds or over between the EX_SVON signal ON and the RUN signal ON, set ON the RUN signal only after the SV_RDY signal is ON.
  • Page 88 INTERFACE MANUAL  Include a sufficient delay time before the program select signal starts between the program select signal input and STROBE signal input. (200 msec or so) Note: If the SVOFF signal remains (0), the servo cannot be turned on. Before the servo can be turned on, the SVOFF signal must be set to (1).
  • Page 89 INTERFACE MANUAL (3) Example of restarting the robot after servo OFF (emergency stop) EX_SVON SVOFF EMG_IN* * When emergency stop contacts 1 and 2 are valid ~ EMG_OUT* SVON_1a ~ SVON_COM Program selection  STROBE PRG_ STEP_ RST (I) CYC_ Approx.
  • Page 90 INTERFACE MANUAL  To restore the system while the emergency stop contact input is open, place all connected emergency stop switches in close status. The error can be cleared by short-circuiting the SAFE connector between RST-1 and RST-2 (150 ms (min.). Note 1: Signals EMG_COM* to EMG_*a and EMG_*b (emergency stop contact output) operate when emergency stop contact inputs 1 and 2 are open...
  • Page 91 INTERFACE MANUAL (4) Example of restarting the robot after error correction To resume the automatic operation after an error has occurred (i.e., processing of automatic operation after error correction): EX_SVON Error has been cleared. ALARM ALM_RST SVON-1a ~ SVON-COM SYS_RDY Approx.
  • Page 92 INTERFACE MANUAL 4.13 Definition of Colors for Operation Buttons and Indicator Lamps If the switches or the likes to operate the TSL3000E/TSL3100E robot controller are to be placed out of the controller by the customer, it is requested that the colors of operation buttons be defined as follows: - Operation buttons Red - Emergency...
  • Page 93 INTERFACE MANUAL Section 5 Serial I/O Signal Cable Connecting Serial I/O Signal Cables The TSL3000E/TSL3100E robot controller is provided with two (2) channels of RS-232C serial I/O signals COM1 and 2. For the connection, see the figure below. It is recommended to use commercially available cables. Using a surge protector is also recommended in order to protect serial I/O signals from an electrostatic discharge-induced surge or switching surge.
  • Page 94 INTERFACE MANUAL Attaching and Detaching Serial I/O Signal Cables Before attaching or detaching the serial I/O cables to or from the TSL3000E/TSL3100E robot controller, be sure to turn off the main power in the user's control panel. The procedures for attaching and detaching serial I/O signal cables HOST/TCPRG and COM1 are the same as in Para.
  • Page 95 INTERFACE MANUAL Section 6 Teach Pendant Cable External View and Functional Names of the TP1000 Display screen Emergency stop switch Servo-ON pushbutton Guidance condition indicator lamp Enable switch Guidance buttons STE 85457 – 94 –...
  • Page 96 INTERFACE MANUAL Connecting Teach Pendant (TP) Cable Connector TP1000 Robot controller (TP) TP cable teach pendant P24V P24V To TP control power circuit P24G P24G EMS1A EMS1A Emergency stop contact 1 EMS1B EMS1B RXDG RXDG TXDG TXDG P24V ENABLE1A Enable 1 ENABLE1B ENABLE1 P24V...
  • Page 97 INTERFACE MANUAL Unless the teach pendant or dummy plug is connected with the TP connector of the TSL3000E/TSL3100E CAUTION robot controller, the servo power cannot be turned on. As shown in Fig. 6.1, the teach pendant I/O signals include the I/O signals for data transmission between the teach pendant and controller, signals for identifying servo ON, emergency stop and enable input from the teach pedant, and P24V and P24G signals for supplying the power to the teach pendant.
  • Page 98 INTERFACE MANUAL How to Operate the Enable Switch The TP1000 (Teach Pendant) is equipped with a 3-position Enable switch. Use the Enable switch to turn on the servo in teach mode or guide the robot in teach mode. Enable switch To turn on the Enable switch, gently hold the switch.
  • Page 99 Connecting External I/O Cable The external I/O cable is used to connect the TR48DIOCN/TR48DIOC module (option) or Toshiba Machine's designated remote I/O module (option) serving as the slave station. Power (24 V, 0 V) is supplied to TR48DIOCN/TR48DIOC by an external power supply provided by the customer.
  • Page 100 INTERFACE MANUAL Use the cable attached to the TR48DIOCN/TR48DIOC module, or the cable which satisfies the following specifications. • Core wires 0.3 mm to 0.75 mm twisted wires • Twisted pair Required. • Cable outer diameter Max. 7 mm • Shield Batch braided shield •...
  • Page 101 INTERFACE MANUAL When connecting two (2) TR48DIOCN/TR48DIOC modules for I/O extension, be sure to branch from the terminal block of slave station 0, as shown in Fig. 7.2. (For the I/O extension, up to two (2) TR48DIOCN/TR48DIOC modules can be connected.) +24V External 24 V power supply...
  • Page 102 TR48DIOCN/TR48DIOC module to the slave station, inputs and outputs can be controlled via the RS485 serial communication. In addition to the TR48DIOCN/TR48DIOC module, a distribution I/O module designated by Toshiba Machine, which can serve as the slave station, can be used also. ⑭...
  • Page 103 INTERFACE MANUAL To designate the slave station number of the TSL3000E/TSL3100E, observe the following steps. Under [U12] of the USER.PAR (user parameter) file, you can find the following parameter setting related to the extension input and output. [U12] Extend I/O setting {Use/Not Use} (0: Not Use, 1: Use) {Not Use} {Not Use}...
  • Page 104 INTERFACE MANUAL Make sure that the slave station number set in "USER.PAR" (User parameter) coincides with the station number setting of the TR48DIOC module. When the TR48DIOC module or modules are connected, set ON the terminator setting switch equipped on the TR48DIOC module which is located on the extreme right side in terms of cable wiring when seen from the controller front side.
  • Page 105 INTERFACE MANUAL Attaching and Detaching External I/O Cable For the external I/O cable, use the cable attached to the TR48DIOCN/TR48DIOC module, or a cable which meets the specifications. Before attaching or detaching the external I/O cable to or from the TSL3000E/TSL3100E robot controller, be sure to turn off the main power.
  • Page 106 INTERFACE MANUAL Section 8 Extension I/O Signal Cable The TR48DIOCN/TR48DIOC is an extension I/O module having 28 inputs and 20 outputs. The TSL3000E/TSL3100E can be expanded up to a maximum of two stations. The output specifications are different between the TR48DIOCN and TR48DIOC (Source type/Sink type).
  • Page 107 INTERFACE MANUAL INPUT Station 0/Station 1: Signal name of DIN TR48DIOCN User side command Station 0/Station 1 DI_101 to DI_108 DI_101/DI_133 DI_133 DI_140 (101/133) DI_102/DI_134 (102/134) DI_103/DI_135 (103/135) DI_104/DI_136 (104/136) INCOM1 DI_105/DI_137 (105/137) DI_106/DI_138 (106/138) Note 1: The DI_101 to DI_107/DI_139 DI_108/DI_131 to DI_140 in the (107/139)
  • Page 108 INTERFACE MANUAL Source type (+ common) Sink type　(- common) User side User side TR48DIOCN TR48DIOCN P24V P24V Contact or transistor DI_101to DI_128 (DI_133 to DI_160) DI_101to DI_128 (DI_133 to DI_160) INCOM1 to 3 Contact or INCOM1 to 3 transistor P24G P24G ...
  • Page 109 INTERFACE MANUAL 8.1.2 Connecting the Extension Output Signal Cable The connection of the extension output signal cable uses the connector XM3A-2521 (plug type) and XM2S-2511 (connector cover) supplied with the TR48DIOCN. The TR48DIOCN outputs (DO_101 to DO_120 (Station 0) and DO_133 to DO_152 (Station 1), are connected to the connector OUTPUT on the module panel.
  • Page 110 INTERFACE MANUAL TR48DIOC The TR48DIOC output specifications are Source type. Because the input specifications use bidirectional photocouplers in the input circuit, the selection of INCOM* enables switching between Source type and Sink type. 8.2.1 Connecting the Extension Input Signal Cable The connection of the extension input signal cable uses the connector XM3A-3721 (plug type) and XM2S-3711 (connector cover) supplied with the TR48DIOC.
  • Page 111 INTERFACE MANUAL INPUT (Station 0/Station 1): User side TR48DIOC Signal name of DOUT (Station 0/Station 1) command DI_101 to DI_108 DI_101/ DI_133 DI_133 DI_140 (101 /133 ) DI_102/ DI_134 (102 /134 ) DI_103/ DI_135 (103 /135 ) DI_104/ DI_136 (104 /136 ) INCOM1 DI_105/ DI_137 (105 /137 )
  • Page 112 INTERFACE MANUAL 8.2.2 Connecting Extension Output Signal Cable The connection of the extension output signal cable uses the connector XM3A-2521 (plug type) and XM2S-2511 (connector cover) supplied with the TR48DIOC. The TR48DIOC outputs (DO_101 to DO_120 (Station 0) and DO_133 to DO_152 (Station 1), are connected to the connector OUTPUT on the module panel.
  • Page 113 INTERFACE MANUAL Electrical rating Electrical rating Notes Rated voltage 24 V DC Select the optimum external power supply based on the system specifications (power Rated current 100 mA (Max.) capacity) of the customer. If a current exceeding the rated output flows, the output elements can be damaged or the board can be burned.
  • Page 114 INTERFACE MANUAL c. The INPUT and OUTPUT connectors are solder cup type where the wires are joined by soldering. For further information about the methods of joining wires to a connector and shielding processes, see Appendix 2, "Fabricating Cable Using D-sub Connector".
  • Page 115 INTERFACE MANUAL Section 9 Connection of Trigger Input Signal Cable (TRIG) (Option) The TSL3000E/TSL3100E has eight optional trigger input points. A 0.22-ms (calculated value) filter is embedded for usual input, but a mere 2.2-s (calculated value) filter is embedded for trigger input. To prevent a robot controller malfunction, input non-chattering, low-noise signals.
  • Page 116 INTERFACE MANUAL Fabricating Trigger Input Signal Cable Follow the points below when fabricating the trigger input signal cable. a. Use either the connectors supplied with the robot controller TSL3000E/TSL3100E or your-prepared connectors of the same type. Equivalent products (D-sub connectors) of other manufacturers can also be used.
  • Page 117 INTERFACE MANUAL Section 10 Connection of Conveyor Synchronization Signal Cable (CONV) (Option) The TSL3000E/TSL3100E has optional encoder input points for two-channel conveyor synchronization. Use encoders provided with A- and B-phase signals having 90° phase and the output circuit having RS-422 differential output (line driver). To connect the encoder signal cables, use the connectors [PCR-E20FS+ (connector), PCR-V20LB (hood)] supplied with the robot controller.
  • Page 118 INTERFACE MANUAL CONV User side Robot controller CH1AH Conveyor-1 CH1AL encoder CH1BH CH1BL CH AH Conveyor-2 CH2AL encoder CH2BH CH2BL CASE Fig. 10.2 Connection between incremental encoders (with internal power supplies used) 10.1 Fabricating Incremental Encoder Input Signal Cable Follow the points below when fabricating the incremental encoder input signal cables. a.
  • Page 119 INTERFACE MANUAL c. The CONV connectors are of a solder cup type which joins cables by soldering. For how to join cables to connectors and how to shield cables, see Appendix 2. 10.2 Attaching and Detaching Incremental Encoder Input Signal Cable See the following for how to attach and detach the incremental encoder input signal cables.
  • Page 120 INTERFACE MANUAL CAUTION Be sure to turn off the main power before attaching or detaching the cables. Attaching or detaching the cables with the main power turned on may cause damage on the substrate ICs. STE 85457 – 119 –...
  • Page 121 INTERFACE MANUAL Section 11 LAN Signal Cable "LAN" The TSL3000E/TSL3100E has a single LAN port channel as standard. The LAN communication function enables communication with computers or visual equipment on the Ethernet in the same local area through the TCP/IP. The function also enables the creation and editing of programs using the computer programmer TSPC, debugging start assistance, and maintenance.
  • Page 122 INTERFACE MANUAL Section 12 MEM Cable "MEM" The TSL3000E/TSL3100E has a single USB port as standard. A commercially available USB memory device can be used to transfer and save various parameters and back up programs and other data. For details on USB memory operation, see the "Operation Manual". STE 85457 –...
  • Page 123 INTERFACE MANUAL Section 13 Connecting External I/O Power Supply Cable The connection of the external I/O power supply cable uses the supplied connector ML-4000-CP-5PGY (connector). The connector is shared with the connector for connecting the I/O function extension unit, and supplies P24V power from the EXT I/O on the controller front panel.
  • Page 124 INTERFACE MANUAL Appendix 1 System Signal Table Name Function Signal judgment STROBE Selects an execution program file from Short-circuit the external equipment. OFF: Open PRG_RST Resets a program currently stopped to Short-circuit step 1. The value of each variable is OFF: Open also reset to "0".
  • Page 125 INTERFACE MANUAL Name Function Signal judgment EMG-IN* Emergency-stops the robot. Open ~ EMG-OUT* OFF: Short-circuit SAD-IN* Emergency-stops the robot. Open ~ SAD-OUT* OFF: Short-circuit Serves as a response signal to input High signals STROBE, PRG_RST, OFF: Low STEP_RST, CYC_RST and DO_RST. SV_RDY This signal is output when the servo High...
  • Page 126 INTERFACE MANUAL Name Function Signal judgment EMG-COM* Used to detect the EMERGENCY stop c-contact ~ EMG-*a, switch equipped on the teach pendant, Non-voltage contact EMG-*b and system input signal of emergency stop. SAD-COM* Used to detect the enable switch c-contact ~ SAD-*a, equipped on the teaching pendant, and Non-voltage contact...
  • Page 127 INTERFACE MANUAL Appendix 2 Fabricating Cable Using D-sub Connector The cables to TSL3000E/TSL3100E external I/O signal connectors INPUT, OUTPUT, TR48DIOC module INPUT (TR), OUTPUT (TR), serial I/O signal connectors and hand I/O signal connector CN0 (robot side connections) should be fabricated as shown below.
  • Page 128 INTERFACE MANUAL STE 85457 – z. –...

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