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1-2

CAST-AU4/B2521E

1-1 Nomenclature

Front View

* Debug station • • • Option

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

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

while pressing the EJECT button.

5-gang LED Display

The following machine conditions are indicated on the 5-gang LED display.
1. ERROR ........Illuminates during the error state.
2. ONLINE .......Illuminates during the on-line state. (Illuminates normally.)
3. ROBOT ........Illuminates while the servo is on. (Illuminates continually after home position is checked.

Turned off during stop.)

4. TASK ...........Illuminates while any of the robot task, or PLC task, or peripheral task is being executed.
5. POWER .......Illuminates in green while power is on. Illuminates in red when a battery runs out.

Work table mounting bracket (Y-axis)

X-axis

Unit or tool mounting bracket

X-axis stand

START button

Operation box

PROGRAM switch

STOP button

Memory card slot

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

RS 232C program
transfer connector

SRX teaching
pendant connector

*To debug station

Debug station connector

*EJECT button

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

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Содержание B2521E

Страница 1: ...OPERATION MANUAL Sony Desktop Robot GA CAST AU4 B2521E ...

Страница 2: ...ed herein is subject to change without notice The information described herein has been checked for both reliability and accuracy However if you have any questions or notice any errors or omissions in this manual please contact the following offices of Sony Corporation Singapore Sony Electronics Singapore Pte Ltd SPEC No 52 Tuas Avenue 9 Singapore 639193 TEL 8615858 FAX 8621521 Europe Sony Wega Pr...

Страница 3: ...ive application manuals for routine assembly task operations Replacing the Unit or Memory Card Remove the existing unit Attach the new unit and replace the memory card References of the memory card may be found in this Operation manual or the respective application manuals This manual describes the ROBOKIDS base machine Details for application unit installations may be found in the operation manua...

Страница 4: ...rammable operation manual for the full open programmable specifications Safety Instruction Describes the safety precautions for user s safety Unpacking Describes the precautions during unpacking and lists the supplied accessories 1 Outline Outlines features names and functions of controls and its specifications 2 Preparation Helps you set up the base machine Beside the supplied accessories you als...

Страница 5: ...chine 2 13 2 4 1 Full open Programmable Specification 2 13 2 4 2 When Using Memory Card RK card 2 13 3 Maintenance 3 1 Maintaining the Machine 3 1 3 2 Greasing the Machine and Removing Fallen Materials 3 1 3 3 Cleaning and Replacing the Air Filter 3 4 3 4 Replacing the Battery 3 6 4 Troubleshooting 4 1 Common Items 4 1 4 1 1 Stepping Out 4 1 4 1 2 External Noise 4 3 4 1 3 Abnormal Sound from Unit ...

Страница 6: ... maintenance must follow the safety work rules when using the machine Always read the safety precautions carefully before reading the Operation Manual and carefully note the following safety rules Observe all precautions to ensure safety Read the precautions on pages 3 to 6 thoroughly Perform regular inspections Inspect the machine referring to chapter 3 Maintenance In the event of accidents Consu...

Страница 7: ...mark is removed the high voltage appears Check the operation manual before using the part with this mark Be cautious not to pinch your hands or fingers into the units moving parts Before you perform any maintenance and or check disconnect the unit from the main power supply Operation Manual Symbols Indicates that mis operations or mis handling may result in unexpected danger fire etc and the that ...

Страница 8: ...more persons and pay attention to safety measures To maintain safety do not make any modifications to the equipment in order Be careful so that hands must not be pinched by the movable blocks Movable parts of each axis tool attachment block table block belt beneath the units tools works etc Avoid installing in the following locations In places which receive direct sunlight or which experience temp...

Страница 9: ...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 Pr...

Страница 10: ...d 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 is recommended once every six months Ope...

Страница 11: ...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 betwee...

Страница 12: ...op or fall Pay extra attention not to give any vibration or shock because the controller contains precision electronic parts Be sure to use the packaging material specified by Sony Corporation when transporting the machine Caution NOTE Accsesory box Remove by holding hands at the bottom as shown by the arrows ...

Страница 13: ...tems are in the package Base machine Power cable Operation box USER I O connector For AC 200V to 240 V PCR E68FS connector PCS E68LA connector cover Honda Communications Company Operation Manual External supply power connector for USER I O MC 1 5 2 ST 3 81 Phoenix Contact Inc ...

Страница 14: ...to perform a different application be exchanging the memory card The work points and the working speed may be set by using the simple operation teaching pendant option even by someone who has just purchased ROBOKIDS The power supply and controller are built inside the machine thus making the system transportable to the place where it is needed The machine is equipped with an external switch connec...

Страница 15: ...lly 3 ROBOT Illuminates while the servo is on Illuminates continually after home position is checked Turned off during stop 4 TASK Illuminates while any of the robot task or PLC task or peripheral task is being executed 5 POWER Illuminates in green while power is on Illuminates in red when a battery runs out Work table mounting bracket Y axis X axis Unit or tool mounting bracket X axis stand START...

Страница 16: ...ch Internal external selecting switch for I O Upper OUTSIDE Lower INSIDE INLET power USER INPUT OUTPUT connector External I O connector RS232C connector Used only when the full open programmable specification is used SAFETY connector DC24V INPUT I O power connector Up to maximum 1 5 A OPERATION BOX connector Z and ZR axis connector Fan ...

Страница 17: ...1E 1 2 Outline Drawings ROBOKIDS Standard Type CAST AU4 B2521E 320 35 69 250 Stroke 105 40 105 250 203 300 18 A 2 48 60 6 26 40 4 φ4 4 M4 0 03 0 0 03 0 7 A 52 210 Stroke 4 5 210 360 10 110 150 90 6 78 Detailed view of A ...

Страница 18: ...1 5 1 Outline CAST AU4 B2521E Height Adjustable Type CAST AU4 BT2521E 320 35 69 250 Stroke 105 40 105 250 203 300 18 A A 52 210 Stroke 4 5 210 10 110 90 6 78 440 230 ...

Страница 19: ...1 6 CAST AU4 B2521E 3 Axes Model Z unit 4 Axes Model ZR unit φ12h7 5 280 50 Tool attachment position 63 162 97 45 144 5 5 30 57 45 58 11 5 76 26 97 162 68 10 13 179 202 70 48 14 26 4 M4 ...

Страница 20: ...1 7 1 Outline CAST AU4 B2521E Service Tapped Hole Position 50 50 128 10 50 50 128 10 120 6 M3 10 10 250 Side A 10 20 6 M3 Side A only 1 6 4 φ 22 ...

Страница 21: ...1 8 CAST AU4 B2521E 4 φ 22 Service Tapped Hole Position Tall Model ...

Страница 22: ... 1 5kg 1 8 kg 0 014 mm 0 014 mm 0 003 mm 0 04 About 16 kg 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...

Страница 23: ...rect teaching via teaching pendant option Point program Direct data input Full open Total 176 Kbytes RK card Maximum 20 work programs for one operation program Full open 3072 points for one program RK card 2500 points Full open Described by the machine language LUNA RK card The standard software is supplied option 22 inputs and 22 outputs RS232C One channel general purpose Single phase 100 to 240 ...

Страница 24: ...torque 15 kgfcm 2 Remove the Z unit front cover The cover to which Sony logo mark is attached Four positions 3 Fix the Z unit to the mounting plate Three positions Determine the fixing position using the positioning pin that is supplied with the equipment Hexagon socket head cap screw M4 10 1 piece Hexagon socket head cap screws M4 18 2 pieces Spring washer SW4 3 pieces Flat washer W4 3 pieces Tig...

Страница 25: ... Connect the connectors to the Z ZR unit connectors Be sure to fix the connector by tightening the screws 6 Attach the cable holder supplied to the post Hexagon socket head cap screws M3 6 2 pieces Spring washer SW3 2 pieces Flat washer W3 2 pieces Tightening torque 10 kgfcm Cable holder supplied ...

Страница 26: ...2 3 2 Preparation CAST AU4 B2521E 7 Fix the cable clamp of the cable to the cable holder ...

Страница 27: ... 2 Fix the ZR unit to the mounting plate Four positions Determine the fixing position using the positioning pin that is supplied with the equipment Hexagon socket head cap screw M4 6 4 pieces Spring washer SW4 4 pieces Flat washer W4 4 pieces Tightening torque 15 kgfcm 3 Attach the front cover Six positions Tightening torque 8 kgfcm ...

Страница 28: ... 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 6 2 pieces Spring washer SW3 2 pieces Flat washer W3 2 pieces Tightening torque 10 kgfcm Cable holder supplied ...

Страница 29: ...2 6 CAST AU4 B2521E 5 Fix the clamp of the cable on the cable holder ...

Страница 30: ...ain unit I3 I10 Error reset There is no switch corresponding to this function I11 External start same operation as the START button of the main unit I1 1 Connect an external switch to the SAFETY connector by soldering Connect the wires to the corresponding pins of the external switch connector Refer to the connector diagram for external switch for the signals at the respective pins and type of mat...

Страница 31: ...ternal operation must be prepared by users NOTE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 24 V SA RETURN OUT SA EMG OUT Stop RELAY OUT C Stop RELAY OUT NO Stop RELAY OUT NC 0 V FG SA RETURN IN SA Stop IN C SA Stop IN NC BAR C BAR NC SA Stop ENABLE 0 V Barrier switch door switch etc Connector for external switch SAFETY Safety box Pin No Contents Max 0 1 A Connect shield of the cable RETURN indicator S to...

Страница 32: ... Connect a jumper wire to the USER I O connector supplied with soldering attach the connector supplied accessory to the connector 3 Controlling the program selector from external location RK card only Connect the wires to the pins of the USER I O connector corresponding to the external signals by soldering I3 to I10 Set the first digit of the PROGRAM switch to F when controlling the program select...

Страница 33: ...ervation input Reservation input 3 3kΩ TLP280 3 3kΩ 3 3kΩ User side Controller side Note1 24V 0V USER I O power supply source selector slide switch Up position Externally supplied 24V Down position Internal 24V default setting User external power supply connector PC board side MC1 5 2 G 3 81 Phoenix Contact Inc I O connector PC board side PCR E68LMDA Honda communication Thermistor 1A Note1 When US...

Страница 34: ...shielded cable for I O connection The maximum length of a shielded cable is 1 0 m Use the core conductor of the shielded cable NOTE 24V 0V Note1 24V 0V 0V IN 24V IN L 1 L 2 L 22 COM1 0V SO1 EMC OUT SO3 BARRIER SO4 DRIVE SO2 ERROR SO8 Reservation output X1 X2 X30 TLP127 20 54 21 68 18 52 19 53 User side Controller side Thermistor 1A USER I O power supply source selector slide switch Up position Ext...

Страница 35: ...ring to the following connection diagram The user must provide and wire an AC power plug to connect to the AC outlet Brown Blue Green Yellow L N Earth Plug end Power cable end Connection diagram of the AC power cable for 200 V to 240 V To the three pin electrical outlet Power cable supplied To the machine INLET ...

Страница 36: ...application memory card RK card is inserted in the memory card slot When you have purchased another type of optional memory card in order to use the robot in another assembly type re insert the new card to the memory card slot 1 Make sure that the main power is turned off Insert the memory card into the memory card slot Do not remove or insert a memory card while power is turned on It may cause tr...

Страница 37: ...ng work Do not remove or insert a memory card while the power is turned on The machine will not work if the memory card is removed Before turning on the machine always insert the memory card in the memory card slot first The main assembly control program the teaching pendant software only in the semi programmable specification will then be loaded automatically into the unit whenever the machine is...

Страница 38: ...Machine and Removing the Fallen Materials When shipped the machine is greased along the guide rails of the X and Y axes This ensures smooth operation of the work table To maintain the machine in top condition grease the rails and remove the fallen materials every 6 months Use the NSK grease No 1 Nippon Seiko or Multemp LRL3 equivalent 1 Turn off the power of machine and unplug the power cord from ...

Страница 39: ...he ends as indicated they may cause damage to the covers 4 Wipe of the old grease and apply grease at the center of each side of the X axis and Y axis guide rails Apply about 0 2 g of grease Be careful not to apply grease to the drive belts 5 Move the work table and the work unit to the left and to the right several times to spread the grease over the length of each rail Wipe off extra grease at t...

Страница 40: ...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 grease covers all necessary part Be careful that the motors get very hot immediately after the operation is stopped NOTE 4 axes specification model 3 axes specification model ...

Страница 41: ...es the cooling power causing serious damage such as thermal breakdown of ICs if the air filter is not properly maintained Clean the air filter once every six months If the air filter is heavily clogged replace the air filter 1 Turn off the POWER switch and unplug the power cord from an electrical outlet 2 Remove the front cover Remove the bottom screws While pulling the bottom of the cover to the ...

Страница 42: ...3 5 3 Maintenance CAST AU4 B2521E 3 Replace the media filter 4 Reinstall the front cover as before Replacement media Sony Order No 4 761 607 01 ...

Страница 43: ...tery is located in the recess at the bottom on the rear of the Z axis 2 Exchange the battery with the new 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 lithium battery ...

Страница 44: ... cables and pipes are normally larger than anticipated and can easily exceed the retaining torque of the motor Be careful of unexpected external forces when using stiff wires or pipes that cannot be easily bent 3 Rapid speed change When a rapid speed change occurs such as an immediate returning movement while an interpolation operation is being performed the load inertia may exceed the retaining t...

Страница 45: ...Mounting screw When a mounting screw is so long that the tip of the screw touches the cover or other object it can cause stepping out You can detect this trouble by listening for a rubbing sound or looking for scars Check for these before use 7 Belt tension If the belt tension becomes abnormal contact your Sony dealer from which you purchased the machine or contact Sony Max Corporation FA Service ...

Страница 46: ...a 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...

Страница 47: ...he cursor using the key 4 The error history is displayed 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 F1 F2 F3 F4 MANAGE sHOME RETURN CONSTANT SELECT ERR HISTORY s E110 R1 L1045 199 E120 R2 L346 199 Date and time of occurrence Display is possible in a 1998 07 01 14 43 19 form...

Страница 48: ...rpolation operation The circular auxiliary point ENTER B and start point end point are aligned on a straight line during circular interpolation operation Circle is taught in 360 degrees PLC program error full open Emergency stop is triggered Solutions Replace the Base board Delete the unnecessary programs Install the system task When the Power lamp lights up in red replace the battery If it does n...

Страница 49: ...not to exceed the range Replace the sensor Correct the speed so as not to exceed the range Replace the sensor Correct the speed so as not to exceed the range Replace the sensor Correct the speed so as not to exceed the range Replace the sensor Correct the speed so as not to exceed the range Correct the target point Correct the speed so as not to exceed the range Correct the target point Correct th...

Страница 50: ...When EEE and error number appear alternately it indicates that the trouble is the robot error The robot errors which can occur in the ROBOKIDS are shown as follows When any error number other than those listed below appears consult your Sony dealer for more details Main power of ROBOKIDS is turned on System task number appears START indicator flashes START button is pressed Performed Homing START ...

Страница 51: ...inate START indicator keeps flashing Symptoms The simple operation teaching pendant keeps displaying 666 E01 appears on the simplified TP E02 appears on the simplified TP The main power cannot be turned on The stop indicator keeps turning on Causes OFF LINE is selected Internal PC board is defective Card is not inserted The card has no program The CAST specification setting is set to NO The main A...

Страница 52: ...ernal unit Remove the source of noise Symptoms START indicator keeps flashing HOME key does not function E10 appears on display during teaching E11 appears on display during teaching E12 appears on display during teaching E30 appears on display E31 appears on display E32 appears on display E33 appears on display E34 appears on display E35 appears on display E36 appears on display E37 appears on di...

Страница 53: ... the condition during initial operation after purchase 2 The main power has not been turned on for a long time for days 3 The main power has not been turned on for a short time for days 4 What was the condition when the main power was turned on 5 Describe the details of the trouble such as error code etc 6 Compared with normal operation at what timing does the error occur 7 If you have two or more...

Страница 54: ...mbly Part No A 8338 047 A A 8338 048 A 1 528 932 11 1 468 348 11 1 468 349 11 1 576 271 11 1 959 099 11 1 572 977 11 1 771 539 11 1 771 538 11 1 763 186 11 1 763 186 11 1 959 094 11 1 959 095 11 4 760 637 01 4 760 638 01 4 760 635 02 4 760 636 02 4 761 607 01 1 959 100 11 A 8338 050 A A 8338 046 A A 8336 316 A A 8336 315 A Remarks Built in board Small Built in board Large For DC 5 V For DC 24 V PO...

Страница 55: ...harness R axis home position sensor harness Spline ball screw Z axis timing belt R axis timing belt Z R axis relay cable harness Bearing Mechanism block assembly Part No 1 763 187 11 1 763 187 11 1 959 101 11 1 959 097 12 4 760 605 01 4 760 645 01 4 760 644 01 1 959 098 12 4 760 650 01 A 8336 314 A Remarks ...

Страница 56: ...tem User cannot use it Reserved by system User cannot use it START RETRUN Work program No 1 Work program No 2 Work program No 4 Work program No 8 Application program No 1 Application program No 2 Application program No 4 Application program No 8 Error reset Full open programmable specification User input User input User input User input User input User input User input User input User input User i...

Страница 57: ... it Reserved by system User cannot use it Reserved by system User cannot use it End of cycle output Standby output Error output During operation output Unloading position output during line mode Full open programmable specification User output User output User output User output User output User output User output User output User output User output User output User output User output User output ...

Страница 58: ...ication program No 1 Second digit of the PROGRAM switch of the operation box 1 Application program No 2 Second digit of the PROGRAM switch of the operation box 2 Application program No 4 Second digit of the PROGRAM switch of the operation box 4 Application program No 8 Second digit of the PROGRAM switch of the operation box 8 I O names in terms of software I23 I24 I25 I26 I27 I28 I29 I30 I31 I32 C...

Страница 59: ... Connector for SRX teaching pendant Clear to send Connector for SRX teaching pendant Request to send Connector for SRX teaching pendant Data terminal ready Signal ground Connector for program transfer Data set ready Connector for program transfer Receive data Signal ground Signal ground Connector for program transfer Clear to send Connector for program transfer Request to send Connector for SRX te...

Страница 60: ... No 2 First digit of the PROGRAM switch 2 Work program No 4 First digit of the PROGRAM switch 4 Work program No 8 First digit of the PROGRAM switch 8 Application program No 1 Second digit of the PROGRAM switch 1 Application program No 2 Second digit of the PROGRAM switch 2 I O names in terms of software I25 L23 L24 I32 I23 I31 I26 I27 I28 I29 I30 Pin No 1 2 3 4 5 6 7 8 9 Signal NC TXD RXD DSR SG D...

Страница 61: ...T C STOP RELAY OUT NO STOP RELAY OUT NC 0V FG SA RETURN IN SA Stop IN C SA Stop IN NC BAR C BAR NC Stop BAR RELEASE 0V Pin No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Contents 24 V RETURN indicator Stop indicator Stop output common Stop output NO Stop output NC FG Shielded wire etc RETURN switch Stop switch Stop switch Barrier safety door etc Barrier safety door etc External stop switch and barrier are...

Страница 62: ...3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Contents Frame ground Unit signal common GND Z unit signal ZR unit signal DC 24 V for Z sensor Z sensor signal Ground for Z sensor Z axis phase A signal Z axis phase B common DC 24 V Z axis phase B R axis phase A Z axis phase B common DC 24 V R axis phase B Brake DC 24 V Brake ground DC 24 V for R sensor R sensor signal Ground for R sen...

Страница 63: ...the machines depending upon the location of the problem even after this period consult the service or sales representative from where you purchased the machine Singapore Sony Electroncs Singapore Pte Ltd TEL 8615858 FAX 8621521 Europe Sony Wega Produktions GmbH Production Technology Division Europe TEL 49 0 711 5858 420 FAX 49 0 711 574153 Japan Sony Manufacturing Systems Corporation FA service De...

Страница 64: ...1st Edition November 1998 3rd Edition October 2001 ...

Страница 65: ...Printed in Japan 2001 10 3 864 811 13 Sony Manufacturing Systems Corporation ...

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