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Sony B2521E User's Manual

1. Error No Causes Solutions E000 E030 CPU board is defective Replace the Base board 2031 Internal memory overflows Delete the unnecessary programs E100 System task not present error full open Install the system task When the Power lamp lights up in red replace the battery E110 Object code error If it does not corresponds to any of the above contents contact Sony sales or service office E111 System task command error full open Correct the program E112 Robot command error Correct the program of system task or peripheral task E113 I O number error Correct the I O number E114 Point data not present error Load the point number Replace the CPU board E115 Error of point number specified Correct the point number E116 Parameter error Correct the variables specified E117 Array number error Correct the array number E118 Integer value out of range error Correct the integer value E119 E124 Syntax error Correct syntax E130 P D E Correct the target point to which the tool moves E131 Correct target point to which tool moves E132 ae Correct the target point to which the tool moves E133 Correct target point to which tool moves E134 X axis system limit error Correct the speed so as not to exceed the range E135 Y axis system limit error Correct the speed so as not to exceed the range E136 Z axis system limit error Correct the speed so as not to exceed the ran
2. 1 Outline 6 M3 Side only 10 250 CAST AU4 B2521E 10 280 18 220 15 30 238 30 1 7 Service Tapped Hole Position Tall Model 10 20 vA 12 3 Side only O oo x Q 250 280 18 60 128 50 42 15 220 15 30 238 30 1 8 CAST AU4 B2521E 1 Outline 1 3 Specifications 1 3 1 Machine Specifications I Three axes specification Four axes specification Two axes specification Work envelope X axis 250 mm with Z axis 250 mm with ZR axis 250 mm Y axis 210 mm 210 mm 210 mm Z axis 70 mm 70 mm R axis 0 to 360 Maximum speeds X axis 300 mm s P 300 mm s 300 mm s Y axis 9 300 mm s 300 mm s 300 mm s Z axis 100 mm s 70 mm s R axis 550 s Pose repeatability positioning accuracy X axis 0 05 mm 0 05 mm 0 05 mm Y axis 0 05 mm 0 05 mm 0 05 mm Z axis 0 05 mm 0 05 mm R axis 0 1 Maximum payload X axis 5kg Y axis 5kg 5kg 5kg Z axis 2kg R axis 1 8 kg
3. OPERATION MANUAL 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 e The information described herein is subject to change without notice e 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 How to Use this Operation Manual First Time Users Read this manual form chapter I through chapter 4 before starting any operation The man
4. rear SAFETY connector by user 125 Work program No I First digit of PROGRAM switch of operation box 1 126 Work program No 2 First digit of PROGRAM switch of operation box 2 127 Work program No 4 First digit of the PROGRAM switch of operation box 4 128 Work program No 8 First digit of the PROGRAM switch of operation box 8 129 Application program No 1 Second of the PROGRAM switch of the operation box 1 130 Application program No 2 Second digit of the PROGRAM switch of the operation box 2 131 Application program No 4 Second digit of the PROGRAM switch of operation box 4 132 Output I O names in terms of software L23 Application program No 8 Second digit of the PROGRAM switch of the operation box 8 Contents START LED White indicator L24 Stop LED Red indicator 125 RETURN indicator be connected from rear SAFETY connector by user L26 Stop indicator To be connected from the rear SAFETY connector by user L27 The barrier signal from the rear SAFETY connector becomes valid when the barrier is enabled L28 User cannot use it L29 User cannot use it User external power supply connector Power connector for I O Pin No 1 24 P CAST AU4 B2521E GND 6 3 Connector for Debug
5. Symptoms Causes Solutions START indicator does not illuminate START indicator 15 defective Replace the START indicator START button has the short circuit Replace the START button External START switch has the short circuit Replace the external START button START indicator keeps flashing Fault Finding Chart of 3 START button does not function START button is defective Replace the START button Fault Finding Chart of 4 Causes Solutions E07 appears on display Returning home failed Start operation from the very beginning Machine movement does Sensor cable is defective Confirm the sensor cable connection not stop It moves in the reverse direction Controller data is abnormal Correct the controller data from TP of the SRX 4 8 CAST AU4 B2521E Symptoms E08 appears on display Fault Finding Chart of 5 Causes TYPESET failed 4 Troubleshooting Solutions Turn on the main power of the machine system and start operation from the very beginning E09 appears on display START failed Turn on the main power of the machine system and start operation from the very beginning Symptoms START indicator keeps flashing Fault Finding Chart of 6 or 7 or 8 Causes Application program switch is defective Solutions Replace the application program switch key does not function Teaching pendant is defective Replace the
6. 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 and 40 degrees 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 45 welders electric dischargers or high frequency generators O In places where any obstacles are anticipated during maintenance and inspection 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 CAST AU4 B2521E 5 3 Precautions Usage Operate on the specified voltage Operate the ROBOKIDS only AC power voltage as specified on the label of the machine The power cord must be directly connected to the electrical
7. Resolution 5 X axis 0 014 mm 0 014 mm 0 014 mm Y axis 0 014 mm 0 014 mm 0 014 mm Z axis 0 006 mm 0 003 mm R axis 0 04 Robot mass including units About 13 kg About 15 kg About 16 kg Operating ambient temperature 0 to 40 C 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 15 changed The resolution value can change depending on the card when RK card 15 used CAST AU4 B2521E 1 9 1 3 2 Control Specifications Drive method Pulse motor drive open loop control Movement method PIP CP Control axis count Up to four axes all axes simu
8. SRX P005 S option CAST AU4 B2521E 1 3 1 2 Outline Drawings ROBOKIDS Standard Type CAST AU4 B2521E 35 320 250 Stroke 300 360 1 4 10 4 5 ed 48 6 60 Detailed view of 0 078 52 210 Stroke CAST AU4 B2521E Height Adjustable CAST AU4 BT2521E 1 Outline 300 320 35 250 Stroke 105 40 105 69 250 gt ON gt A F 110 CAST AU4 B2521E 18 52 210 Stroke 4 5 1 5 3 Model 4 Model Z unit ZR unit 179 13 10 162 50 Tool attachment position 70 97 Q o 68 58 4 4 48 162 63 97 e e 1267 30 57 CAST AU4 B2521E Service Tapped Hole Position 128 128 20
9. Station 6 4 Signal FG Contents Frame ground TP RXD Connector for SRX teaching pendant Receive data TP TXD Connector for SRX teaching pendant Transmit data TP CTS Connector for SRX teaching pendant Clear to send TP RTS Connector for SRX teaching pendant Request to send TP DTR Connector for SRX teaching pendant Data terminal ready C GND Signal ground SIO DSR Connector for program transfer Data set ready uU NI e SIO RXD Connector for program transfer Receive data C GND Signal ground NC NO C GND Signal ground Oo SIO CTS Connector for program transfer Clear to send A NC SIO RTS Connector for program transfer Request to send ON 55 Connector for SRX teaching pendant Emergency stop I EXS2 Connector for SRX teaching pendant Emergency stop SRX teaching pendant is connected TP DSR Connector for SRX teaching pendant Data set ready NO SIO TXD Connector for program transfer Transfer data NO NO PCOSV 5V for SRX teaching pendant N W SIO DTR Connector for program transfer Data terminal ready bo GND Signal ground NO PCOSV DBLC J25S
10. direction to home position has occurred Check weight of the tool and check also if there is any interfering obstacles around the point E35 appears on display Step out of the Z axis in the home position direction has occurred Check weight of the tool and check also if there is any interfering obstacles around the point E36 appears on display Step out of the R axis in the opposite direction to home position has occurred Check weight of the tool and check also if there is any interfering obstacles around the point 7 appears on display Step out of the R axis in the home position direction has occurred Check weight of the tool and check also if there is any interfering obstacles around the point The machine does not operate normally Teaching has not been done correctly Perform teaching again Machine is loaded with excessive weight Refer to section 1 3 1 Machine specifications Cover is contacting with moving object Correct the cover position Dropped parts such as screws are choking Remove anything dropped External unit is defective Repair or replace the external unit External noise is affecting 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 CAST AU4 B2521E 4 9 Trouble Check
11. saa 2 7 2 9 Connecting toan Bleetrical Outlet sou er eh aa 2 12 22 Slatine Base Machine vepser 2 13 2 4 1 Full open Programmable 5 2 13 2 4 2 When Using Memory Card RK card 2 13 3 Maintenance N rre MN PR 3 1 3 2 Greasing the Machine and Removing Fallen Materials 3 1 9 9 Cleanine and Replacing the Aim FE ee 3 4 T T TU UU TM RN 3 6 4 Troubleshooting Common en es 4 1 SEPT vase 4 1 4 3 4 1 3 Abnormal Sound from Unit s Motors 4 3 4 2 Full open Programmable 4 4 4 3 When Memory Card RK Card is Used 4 7 Trouble Check GASSER r 4 10 5 Repair Parts Lists Sl 5 1 EET eM Tren HER 5 I P FR EO T H EN 5 2 b JADDOEHOIX 6 1 CAST AU4 B2521E Safety Instruction 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 Man
12. teaching pendant E10 appears on display during teaching point outside the work envelope 15 specified by INSERT DELETE Specify the point inside the area and try again appears on display during teaching The target coordinate of copy has exceeded the work envelope during COPY Perform COPY so as not to exceed the work envelope E12 appears on display during teaching Number of point storage capacity of the target point of copy is insufficient during COPY Perform COPY within the storage capacity of point E30 appears on display Step out of the X axis in the opposite direction to home position has occurred Check weight of the tool and check also if there is any interfering obstacles around the point 1 appears on display Step out of the X axis in the home position direction has occurred Check weight of the tool and check also if there is any interfering obstacles around the point E32 appears on display Step out of the Y axis in the opposite direction to home position has occurred Check weight of the work and check also if there is any interfering obstacles around the point E33 appears on display Step out of the Y axis in the home position direction has occurred Check weight of the work and check also if there is any interfering obstacles around the point E34 appears on display Step out of the Z axis in the opposite
13. the following connection diagram To the three pin electrical outlet The user must provide and wire an AC power plug Power cable supplied to connect to the AC outlet 0 0 m To the machine INLET Connection diagram of the AC power cable for 200 V to 240 V Power cable end Brown L Blue N Green Yellow Earth c oN 5 2 12 CAST AU4 B2521E 2 Preparation 2 4 Starting Up the Base Machine Make sure that the main power 15 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 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 memory card while power 15 turned on It may cause trouble 2 Connect the USER 1 connector in which SYSRUN is shorted to the rear panel of the ROBOKIDS Refer to page USER connector 2 6 Operation box Memory card slot Memory card CAST AU4 B2521E 2 13 3 Turn the base machine About five se
14. 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 key MANAGE id SHOME RETURN CONSTANT I SELECT Fi F2 F4 4 The error history is displayed ERR HISTORY lt gt 11 5 E110 1 L1045 1999 E120 2 L346 199 Date and time of occurrence Display is possible in 1998 07 01 14 43 19 format by scrolling right with gt 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 NEN 4 4 CAST AU4 B2521E 4 Troubleshooting 5 Check the error code number E on display and find 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
15. AF 10L9 Applicable plug DBSP JB25PF Applicable shell DB C8 J10 F4 1 5V for SRX teaching pendant Manufacturer JAE Manufacturer JAE Manufacturer JAE CAST AU4 B2521E Connector for Operation I O names in terms of software 6 Appendix Contents 1 125 Work program No I First digit of the PROGRAM switch 1 2 123 START LED 3 124 Stop LED 4 OV 5 132 Application program No 8 Second digit of the PROGRAM switch 8 6 123 START button P Stop button 8 Stop button 9 24 10 31 Application program No 4 Second digit of the PROGRAM switch 4 11 Work program No 2 First digit of the PROGRAM switch 2 12 Work program No 4 First digit of the PROGRAM switch 4 13 Work program No 8 First digit of the PROGRAM switch 8 14 Application program No 1 Second of the PROGRAM switch 1 15 Application program No 2 Second digit of the PROGRAM switch 2 Type 17 13150 73 Manufacturer DDK Applicable plug 17HE 23150 CD8A Manufacturer DDK Applicable shell 17H 7PCR 102 Manufacturer DDK RS232C connector Rear Panel Contents Transmit data Receive data Data set ready Signal ground Data terminal ready Clear to send Request to send CO DW NM BW NI Type CDS 3109 0122 Manufacturer SMK Applicable plug 17JE 23090 02 Manufacturer DDK Applicable s
16. AST 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 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 15 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 IC s in certain operating environments in which equipment is used without sufficient heat dissipation CAST AU4 B2521E 5 5 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 15 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 overh
17. PROGRAM switch to when controlling the program selector from external location If the second digit of the PROGRAM switch 15 set to the application program 15 set to external mode CAST AU4 B2521E 2 9 Input Circuit USER power supply source selector slide switch Up position Externally supplied 24V Down position 00 _ DLL Internal 24V default setting 51 24V User external power supply connector i PC board side OV MC1 5 2 G 3 81 Phoenix Contact Inc Notel 24V OV 1 24V IN OVIN I O connector Pin No PC board side PCR E68LMDA Honda communication EA TLP280 4700 NN SII current SW SII operates when Maximum 7mA SWI is ON Ei m area xs input 18 Reservation input PN exe o 121 i 122 SW30 Notel When USER power supply Thermistor 19 source selector slide switch 19 15 set to 24V SL NN TEEN Controller side User side N O Z 5 2 10 CAST AU4 B2521E 2 Preparation Output Circuit O USER I O power supply source selector slide switch Up position Externally supplied 24V DEN Down position Internal 24 default setting User external power supply connector S1 PC board side MC1 5 2 G 3 81 24V Phoenix Contact Ine
18. Sheet trouble occurs check the following items before contacting your Sony dealer or the nearest Sony 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 15 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 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 Isthere any noise source near the ROBOKIDS Yes No 10 What 15 the condition of the ROBOKIDS at present The ROBOKIDS is not being used The ROBOKIDS is still being used 11 Customer Company name Dep
19. Specifications The payload with which the machine can operate at 10046 speed 15 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 15 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 I What is stepping out When the drive shaft of 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 15 sometimes used incorrectly for tooth skipping between pulley and belt but stepping out and tooth skipping are actually entirely different phenomena CAST AU4 B2521E 4 1 4 Synthesis of movements in same direction In some programs the machine is opera
20. User cannot use it 39 SI6 Reserved by system User cannot use it 6 SI7 Reserved by system User cannot use it 40 SIS Reserved by system User cannot use it 7 START User input 41 12 RETRUN User input 8 13 Work program No I User input 42 14 Work program No 2 User input 9 15 Work program No 4 User input 43 16 Work program No 8 User input 10 I7 Application program No 1 User input 44 I8 Application program No 2 User input 11 19 Application program No 4 User input 45 I10 Application program No 8 User input 12 111 Error reset User input 46 12 User input 13 I13 2 User input 47 14 ai User input 14 15 T User input 48 I16 m User input 15 117 i User input 49 I18 gt User input 16 19 User input 50 120 User input 17 I21 User input 51 122 User input allocation at 112 to 22 differs depending upon applications Refer to the Operation Manual of memory card RK card for more details The switch SII SYSRUN must always be connected The ROBOKIDS cannot be operated SFR unless the SII is turned on Turn on or off 511 as required Refer to page 2 6 CAST AU4 B2521E 6 1 Output names in terms Fon Connector pin No RK card specification Full open programmable of software including semi programmable specification specification 20 501 EMG OUT stop switch stop status output 54 502 ERROR rob
21. _ 0V 24V IN 24V OV IN gt JE 20 a M I O connector PC board side PCR E68LMDA Honda communication Direction of on d gt the a current Le n Maximum Relay coil voltage He EMC OUTY oi REO DC24V E 502 t SEE 21 lt a VIs idi E zs gt x Reservation 1 L output Ne Notel When USER I O power supply source selector slide switch 15 set to 24V DRIVE Gr Controller side User 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 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 per one output point Be sure to use a shielded cable for connection The maximum length of a shielded cable is 1 0 m Use the core conductor of the shielded cable CAST AU4 B2521E 2 11 2 3 Connecting to an Electrical Outlet Prepare the power cable for AC 200 V to 240 V referring to
22. al 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 CAST AU4 B2521E Contents Salen a ee 5 1 WIND AG KUNG Ren U 1 1 Outline Er INTC MC E E 1 2 152 Oulie Draw 1 4 EE EON 1 9 DE Machine SpectPiedblOfi AN 1 9 152 Corral ee 1 10 2 Preparation 21 Atac hne Mtt 2 1 It Mie ve 2 1 22172 RN Dd en Cup dui 2 4 2 2 Connecting the External
23. artment 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 CAST AU4 B2521E 5 Repair Parts Lists 5 Repair Parts Lists 5 1 ROBOKIDS Body Descriptions TASK board Part No 8338 047 Remarks Built in board Small BASE board A 8338 048 A Built in board Large Battery 1 528 932 11 DC switching power supply ZWS30 5 J 1 468 348 11 For DC 5 V DC switching power supply ZWS150PF 24 J 1 468 349 11 24 Circuit protector 1 576 271 11 POWER switch Fan harness 1 959 099 11 Inside the ROBOKIDS Self illuminating stop switch 1 572 977 11 Operation box Self illuminating stop switch 1 771 539 11 Operation box Digital switch 1 771 538 11 Operation box X axis motor 1 763 186 11 Y axis motor 1 763 186 11 X axis home position sensor harness 1 959 094 11 Y axis home position sensor harness 1 959 095 11 X axis liner guide 4 760 637 01 Y axis liner guide 4 760 638 01 X axis timing belt 4 760 635 02 Y axis timing belt 4 760 636 02 Media 4 761 607 01 filter Cable harness 1 959 100 11 A 8338 050 A A 8338 046 A A 8336 316 A A 8336 315 A Electrical fitting assembly Control block assembly Y axis assembly X axis assemb
24. conds later the white indicator of POWER switch 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 The START indicator lights in green 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 c 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 CAST AU4 B2521E 3 Maintenance mn 3 Maintenance 3 1 Maintaining the Machine Clean the surfaces of the machine with soft dry cloth If the stain is difficult to remove use cloth moistened with mild detergent solution followed by using dry cloth Do not use volatile solvents such as alcohol benzene or thinner as they may mar the finish Consult your local Sony dealer f
25. eating 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 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 15 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 environm
26. ents The front POWER indicator changes from green to red when a battery runs out 5 6 CAST AU4 B2521E Unpacking Transport it to the installation position while taking care not to drop or fall Pay extra attention not to give any vibration or shock because the controller contains precision electronic parts NOTE Be sure to use the packaging material specified by Sony Corporation when transporting the machine Accsesory box Remove by holding hands at the bottom as shown by the arrows CAST AU4 B2521E 0 1 When machine is unpacked make sure following items are in package e 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 0 2 CAST AU4 B2521E 1 Outline 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 e The programs required for an application are stored in the memory card RK Card Operation 15 s
27. ge E137 1 system limit error Correct the speed so as not to exceed the range 138 X axis point limit error Correct the speed so as not to exceed the range E139 Y axis point limit error Correct the speed so as not to exceed the range E140 Z axis point limit error Correct the speed so as not to exceed the range E141 R axis point limit error Correct the speed so as not to exceed the range Speed is too fast for the distance between E154 aod Increase distance between two points decrease The circular auxiliary point ENTER Correct the position of the circular auxiliary point or E155 and start point end point are aligned on a divide the movement into smaller segments of less then straight line during circular interpolation 360 degrees operation Circle is taught in 360 degrees E200 E204 PLC program error full open Correct the program E300 Emergency stop is triggered Cancel the emergency stop switch CAST AU4 B2521E 4 5 Causes Solutions RES Correct the speed so as not to exceed the range E301 X axis limit sensor error P 5 Replace sensor M Correct the speed so as not to exceed the range E302 Y axis limit sensor error P 5 Replace sensor UE Correct the speed so as not to exceed the range E303 Z axis limit sensor error Replace the sensor v Correct the speed so as not to exceed the range E304 R axis limit senso
28. hell 17JE O9H 1A Manufacturer DDK CAST AU4 B2521E SAFETY Connector 6 6 Signal 24V Contents 24 SA START OUT RETURN indicator SA STOP OUT Stop indicator STOP RELAY OUT Stop output common STOP RELAY OUT NO Stop output NO STOP RELAY OUT Stop output NC OV FG FG Shielded wire etc 1 2 3 4 5 6 7 8 9 SA RETURN IN RETURN switch SA Stop IN C Stop switch SA Stop IN NC Stop switch NO BAR C Barrier safety door etc O3 BAR NC Barrier safety door etc A Stop BAR RELEASE External stop switch and barrier are enabled OV DA JISPFIL9 Applicable plug DA 15PF N Applicable shell DA C4 J10 Manufacturer JAE Manufacturer JAE Manufacturer JAE CAST AU4 B2521E 6 Connector for ZR axis Cable Contents 1 Frame ground 2 Unit signal common GND 3 Z unit signal 4 ZR unit signal 5 DC 24 V for Z sensor 6 Z sensor signal 9 Ground for Z sensor 8 Z axis phase A signal 9 Z axis phase B common DC 24 V 10 Z axis phase B 11 R axis phase A 12 Z axis phase B common DC 24 V 13 R axis phase B 14 Brake 24 15 Brake ground 16 DC 24 V for R sensor 17 R sensor signal 18 Ground for R
29. hich 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 x 10 1 piece Hexagon socket head cap screws x 18 2 pieces Spring washer SW4 3 pieces Flat washer 3 pieces Tightening torque 15 CAST AU4 B2521E 2 1 4 5 2 2 Attach removed front cover Four positions Tightening torque 8 kgfcm Connect the connectors to the Z ZR unit connectors Be sure to fix the connector by tightening the screws Attach the cable holder supplied to post Hexagon socket head cap screws M3 x 6 2 pieces Spring washer SW3 2 pieces Flat washer W3 2 pieces Tightening torque 10 supplied CAST AU4 B2521E 2 Preparation 7 Fix the cable clamp of the cable to the cable holder CAST AU4 B2521E 2 3 2 1 2 Attaching 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 15 supplied with the equipment Hexagon socket head cap screw M4 x 6 4 pieces Spring washer SW4 4 pieces Flat washer W4 4 pieces Tightening torque 15 3 Attach the front cover Six positions Tighteni
30. is at risk of injury or the equipment at risk of damage 5 2 CAST AU4 B2521E Safety Instruction 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 IN Observe the followings prior to starting maintenance or inspections 1 Read the Operation Manual thoroughly and following all instructions and warnings closely 2 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 Warning 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
31. ltaneous control Interpolation function 3 dimensional linear interpolation and 3 dimensioal circular interpolation CP control speed 1 to 100 mm s Teaching method Direct teaching via teaching pendant option Point program Direct data input Program capacity Full open Total 176 Kbytes RK card Maximum 20 work programs for one operation program Point data storage capacity Full open 3072 points for one program RK card 2500 points Programming method Full open Described by the machine language LUNA RK card The standard software is supplied option General purpose I O 22 inputs and 22 outputs Serial I F RS232C One channel general purpose Power supply voltage Single phase 100 to 240 10 50 60 Hz Power consumption 300 VA Ground 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 CAST AU4 B2521E 2 Preparation 2 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 x 10 2 pieces Tightening torque 15 2 Remove the Z unit front cover The cover to w
32. ly 5 2 Z axis Unit Descriptions Z axis motor Part No 1 763 187 11 Remarks Z axis home position sensor harness 1 959 096 11 Z axis linear guide 4 760 643 01 Z axis timing belt 4 760 641 01 Z axis relay cable harness 1 790 017 11 Z axis timing belt 4 760 642 01 Bearing 4 760 650 01 Mechanism block assembly CAST AU4 B2521E A 8336 325 A 5 3 Z R axis Unit 5 2 Descriptions Z axis motor Part No 1 763 187 11 Remarks R axis motor 1 763 187 11 Z axis home position sensor harness 1 959 101 11 R axis home position sensor harness 1 959 097 12 Spline ball screw 4 760 605 01 Z axis timing belt 4 760 645 01 R axis timing belt 4 760 644 01 Z R axis relay cable harness 1 959 098 12 Bearing 4 760 650 01 Mechanism block assembly A 8336 314 A CAST AU4 B2521E 6 6 Appendix B User Input Output Specifications of USER I O Connector Input I O names in terms Connector pin No RK card specification Full open programmable of software including semi programmable specification specification 3 SII SYSRUN 37 512 Reserved by system User cannot use it 4 513 Reserved by system User cannot use it 38 514 Reserved by system User cannot use it 5 515 Reserved by system
33. ng 5 START indicator flashes slowly Application program switches are set Work program switches are set Application program Application program 0 11 pr E 6 8 HOME key of START button is pressed teaching pendant is pressed 7 9 teaching mode To running mode CAST AU4 B2521E 4 7 Fault Finding Chart of 1 Symptoms Causes Solutions Connect the SYSRUN OFF LINE is selected Set the machine system to ONLINE from the TP of the SRX Internal PC board is defective Exchange the internal PC board The simple operation teaching pendant keeps displaying 666 E01 appears on the m Card is not inserted Insert the memory card securely simplified TP The card has no program Insert a memory card in which program is stored E02 appears on the ODE The CAST specification setting is set to Set the CAST specification setting to YES from simplified TP NO the TP of the SRX The main power cannot The main AC power is not turned on Connect the AC main power be turned on Exchange the POWER switch The POWER switch is broken The stop indicator keeps The STOP button is kept locked Release the lock turning on Including the teaching pendant TN Release the external emergency stops The external stop signal is being Alternatively short pin 1 and pin 2 of connected external switch connector Fault Finding Chart of 2
34. ng torque 8 kgfcm 2 4 CAST AU4 B2521E 2 Preparation 4 Connect the connectors to the Z ZR unit connectors Be sure to fix the connector by tightening the screws 5 Attach the cable holder supplied to the post Hexagon socket head cap screws M3 x 6 2 pieces Spring washer SW3 2 pieces Flat washer W3 2 pieces Tightening torque 10 supplied CAST AU4 B2521E 2 5 5 Fix the clamp of the cable on cable holder 2 6 CAST AU4 B2521E 2 Preparation 2 2 Connecting the External Signal The base machine 15 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 e USER INPUT OUTPUT EXTERNAL connector rear e Selecting programs same operation as the PROGRAM switch of the main unit I3 Error reset There is no switch corresponding to this function I11 External start same operation as the START button of the main unit 11 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 con
35. nt connector Operation box STOP button 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 15 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 battery runs out 1 2 CAST AU4 B2521E 1 Outline Rear View 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 USER INPUT OUTPUT connector External I O connector SAFETY connector RS232C connector Used only when the full open programmable specification 15 used CAST PRO Teaching Pendant SRX Teaching pendant CAST P06 option
36. o pin No 6 The external equipment switch indicator box etc to be used for external operation must be prepared by users 2 8 CAST AU4 B2521E 2 Preparation 2 Connect the external signals to the USERI connector by soldering Connect the wires to the corresponding pins of the USER connector For the signal names and pin numbers of the respective pins refer to the 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 connector supplied to the USER I O connector 511 SYSRUN of the machine as shown USER I O connector supplied USER I O connector me 1 OV D a pA 9 SYSRUN Pin arrangement 12 1416181 130132134 N Connect jumper wire with solderin 113 1517 29 31 33 Jump 35 37 39141 163165 67 Connect 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 PROGRAM switch Connect the wires to the pins of the USER Controlling the program selector connector corresponding to the external from external location e e Set to F signals by soldering 13 to Set the first digit of
37. or the consumable parts jigs and tools which are required for maintenance 3 2 Greasing the Machine and 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 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 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 CAST AU4 B2521E 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 ZR unit also NOTE If the work table and the work unit are not moved to the ends as indicated they may cause 4 3 2 damage to the covers 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 Move the work table and the work unit to the left and to the right several times to spread the grea
38. ot error signal 21 503 Reserved by system User cannot use it 55 504 Drive ON signal 22 505 ONLINE signal 56 506 Reserved by system User cannot use it 23 507 Reserved by system User cannot use it 34 SOS Reserved by system User cannot use it 24 L1 End of cycle output User output 58 L2 Standby output User output 25 L3 Error output User output 59 LA During operation output User output 26 155 Unloading position output during line mode User output 60 L6 User output 27 L7 User output 61 18 G User output 28 L9 2 User output 62 110 User output 20 L11 User output 63 112 User output 30 L13 User output 64 114 T User output 31 1 15 User output 65 L16 T User output 32 L17 User output 66 18 i User output 33 L19 User output 67 L20 gt User output 34 L21 i User output 68 L22 User output The allocation at L6 to 122 differs depending upon applications Refer to the Operation Manual of memory card RK card for more details B Pin assignment 121416181 _ 30132134 113517 9 1293133 361 381 401 42 1641661 68 13513713914 163165 67 6 2 CAST AU4 B2521E 6 Appendix Specifications of the Connected I O Used only in the semi programmable specifications and the full open programmable specifications Input I O names in terms of software 123 Contents START button White button of operation box 124 RETURN button be connected from
39. ottom of the cover to the front raise the catches on the top 3 4 CAST AU4 B2521E 3 Maintenance 3 Replace the media filter 4 Reinstall the front cover as before Replacement media Sony Order No 4 761 607 01 CAST AU4 B2521E 3 5 3 4 Replacing Batter 1 Turn off the POWER switch and unplug the AC power cord from the AC outlet The battery 15 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 Battery replacement must be completed within eight hours after the main power is turned off If not internal data can be damaged Replacement lithium battery primary battery Sony Order No 1 528 932 11 3 6 CAST AU4 B2521E 4 Troubleshooting 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
40. output and grounded The ROBOKIDS conforms with the safety requirements of the target country to which it is shipped When machine will not be used for extended period of time If the machine 15 not in use 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 5 4 CAST AU4 B2521E Safety Instruction Precaution on memory cards Before inserting or removing memory card always turn the power off The data stored in the memory card may be damaged if memory card is inserted removed while power IS on Precaution on the teaching pendant ROBOKIDS uses a teaching pendant for the CAST PRO or SRX The C
41. r error P 5 Replace sensor Correct speed so as not to range E314 X axis command position error p 5 Correct target point Correct the speed so as not to exceed the range E315 Y axis command position error j B Correct the target point Correct the speed so as not to exceed the range E316 Z axis command position error 5 Correct target point T Correct the speed so as not to exceed the range E317 R axis command position error B Correct target point 4 6 CAST AU4 B2521E 4 Troubleshooting 4 3 When Memory RK is Used The operational flow starting from turning on the main power of the machine until the programmed operation or teaching 15 started 1 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 case when an error number 15 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 1 System task number appears 2 START indicator flashes START button is pressed 4 Performed Homi
42. se over the length of each rail Wipe off extra grease at the ends of each rail with cloth Extra grease will be solidified causing malfunction CAST AU4 B2521E 3 Maintenance 6 Apply grease to the Z unit and the ZR unit as shown in the same manner 4 axes specification model 3 axes specification model 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 After the covers are attached move the respective axes using the teaching pendant until NOTE grease covers all necessary part Be careful that the motors get very hot immediately after the operation is stopped CAST AU4 B2521E 3 3 3 3 Cleaning and Replacing Air Filter Air is circulated in the controller of the base machine to cool the controller The cooling air 15 introduced through the air filter on the rear of the Front cover 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 filter Air filter is inside the front cover 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 b
43. sensor 19 Frame ground 20 Z axis phase common DC 24 V 21 Z axis phase A 22 Z axis phase B 23 R axis phase A common DC 24 V 24 R axis phase A 25 R axis phase B Model DBLC J25SAF 10L9 Manufacturer JAE Applicable plug DB 25PF IN Manufacturer JAE Applicable shell DB C4 J11 Manufacturer JAE CAST AU4 B2521E 6 7 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 15 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 Singaporef 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 Ist Edition November 1998 3rd Edition October 2001 Sony Manufacturing Systems Corporation Printed in Japan 2001 10 3 864 811 13
44. tarted by inserting the specific memory card into base machine and teaching the work points The machine may be switched to perform a different application be exchanging the memory card e 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 e 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 connector allowing synchronous operation with external equipment Remote operation is also possible The external switch and connector enabling operation of the machine by two operators must NOTE be prepared by the user 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 CAST AU4 B2521E 1 1 1 1 Nomenclature Front View X axis Unit or tool mounting bracket Work table mounting bracket Y axis TECH PEN connector for teaching pendant of CAST PRO EJECT button Debug station connector debug station Memory card slot RS 232C program 5 gang LED display transfer connector POWER TASK ROBOT ONLINE ERROR indications PROGRAM switch from the left SRX teaching penda
45. ted 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 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 15 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 CAST AU4 B2521E 4 Troubleshooting 4 1 2 External Noise External electrical noise 15 a diffic
46. trol the stop Connect pin 10 and pin 11 to the respective switches Connect pin 14 to pin 15 to 7 How to control the RETURN Connect pin 9 and pin 7 or pin 15 to the respective switches Example of external Switch box stop switch Door switch F Floor mat switch amp CAST AU4 B2521E 2 7 Connector for external switch SAFETY Safety box 1 24 V Max01A I xe JAM SA RETURN OUT RETURN indicator Sop indicator to be energized at the time of stop 2 3 5 Stop RELAY OUT NO 6 Stop RELAY OUT NC Pins 4 and 6 are normally closed OV mn 77 Jna stop pins 4 and 5 are closed O SA OUT Stop RELAY OUT E These lines can be freely used by users because 1 these lines are prepared for independent relay 1 Connect shield FG RETURN butt of the cable ee SA RETURN IN O k Sop button Barrier switch door switch etc Q 10 SA Stop IN C SA Stop IN NC gt 12 BAR C I 13 BAR 14 SAStop ENABLE oy Wiring diagram of connector for external switch SAFETY Applicable plug 15 pin connector Applicable shell Type DA C4 J10 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 t
47. ual 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 CAST AU4 B2521E 5 1 EE 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 15 removed the high voltage appears Check the operation manual before using the part with this mark A cauTion cautious not to pinch your hands or fingers into the units moving parts an Before you perform any maintenance and or check disconnect the unit from the main power supply Operation Manual Symbols Warnina Indicates that mis operations or mis handling may result in unexpected danger fire etc and the that operator is at risk of major injury Indicates that mis handling may result in unexpected danger electric shock etc and that the operator
48. ual 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 found in the operation manuals that are attached when purchasing the application units CAST AU4 B2521E 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 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 manu
49. ult 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 1 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 15 generated when the Z axis 15 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 CAST AU4 B2521E 4 3

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