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TRANSPORTATION AND INSTALLATION 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.
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TRANSPORTATION AND INSTALLATION MANUAL Copyright 2010 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.
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TRANSPORTATION AND INSTALLATION MANUAL Preface This manual describes the basic specifications of the industrial robot and controller, and how to unpack and install them. Specifically, it describes how to unpack the shipment containing the equipment, how to install the equipment, how to connect wiring and air piping, and how to attach tools.
TRANSPORTATION AND INSTALLATION MANUAL Precautions on Safety Important information on the robot and controller is noted in the instruction manual to prevent injury to the user and persons nearby, prevent damage to assets and to ensure correct use. Make sure that the following details (indications and symbols) are well understood before reading this manual.
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• Always use the power voltage and power capacity designated Mandatory by Toshiba Machine. Failure to do so could lead to device faults or fires. • Always use the designated power cable. Using a cable other than that designated could lead to fires or faults.
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TRANSPORTATION AND INSTALLATION MANUAL CAUTION • NEVER lift the robot by the arm 2 cover or arm 2. Doing so will apply an excessive force on the robot's mechanism section and could lead to faults. • For the controller, secure the ample space for air vent. Prohibited Heating of controller could lead to malfunction.
TRANSPORTATION AND INSTALLATION MANUAL Table of Contents Page Specifications ......................11 Robot Configuration Diagram ................11 Name of Each Part ..................12 External Dimensions..................13 Specifications Table..................15 Transportation ......................16 Unpacking......................16 Transportation ....................18 2.2.1 Mass and Dimensions ...............18 2.2.2 Transporting the Robot..............19 2.2.3 Transporting the Controller..............22 Storage ......................23 2.3.1 Storage Precautions for the Robot ............23...
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TRANSPORTATION AND INSTALLATION MANUAL attached) ...................38 4.1.3 Connecting the Motor Cable “CN2” ([2]of Fig. 4.1) (Cable attached)39 4.1.4 Connecting the Encoder Cable “ENC” ([3] of Fig. 4.1) (Cable attached) ......................40 4.1.5 Connecting the Robot Control Signal Cable “HAND” ([4] of Fig. 4.1) (Cable attached)................40 4.1.7 Examples of Connector Terminal Arrangement.........43...
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Fig. 1.1 Robot Configuration Diagram ................11 Fig. 1.2 Name of each part....................12 Fig. 1.3 External dimensions of the robot (TH450A) ............13 Fig. 1.4 External dimensions of the robot (TH550A) ............14 Fig. 2.1 Packaging state....................17 Fig. 2.2 Outer dimensions at transport (TH450A)............18 Fig.
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TRANSPORTATION AND INSTALLATION MANUAL Fig. 5.13 Setting of maximum speed and acceleration/deceleration in relation to gravity center offset (Axis 4) (TH550A) .................74 STE 80899 – 10 –...
Robot Configuration Diagram TSPC communication cable (obtained by customer) PC (obtained by customer) Program support software TSPC (option) TCPRGOS (option) TH450A/TH550A robot unit Cable between robot and Operation panel controller Split type (option) Teach pendant (option) TP cable Robot controller Fig.
Fig. 1.2 shows the name of each part of the robot. The name of each part of the robot The name of each part of the robot is common between the TH450A and TH550A. is common between the TH450A and TH550A.
TRANSPORTATION AND INSTALLATION MANUAL External Dimensions Fig. 1.3 refers to the external dimensions of the robot. 4 × ø14 Hand-operated air Joint mounting holes 4 × ø4 tube Hand I/O connector Brake OFF switch About 350 Space for cable Fig. 1.3 External dimensions of the robot (TH450A) STE 80899 –...
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TRANSPORTATION AND INSTALLATION MANUAL 4 × ø14 Hand-operated air Joint 4 × ø4 tube mounting holes Hand I/O connector Brake OFF switch About 350 Space for cable Fig. 1.4 External dimensions of the robot (TH550A) STE 80899 – 14 –...
TRANSPORTATION AND INSTALLATION MANUAL Specifications Table Item Specifications Structure Horizontal multi-joint type SCARA robot Model TH450A TH550A Applicable controller TS2000 Mass of robot body 26 kg 28 kg No. of controlled axes Four (4) Arm length 450 mm 550 mm...
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TRANSPORTATION AND INSTALLATION MANUAL CAUTION Put the Z-axis (axis 3) in the raised position as much as possible, when moving Axes 1, 2, and Moving Axis 1, 2, or 4 when the Z-axis is in low positions can lead to premature damage to the ball screw spline (Z-axis shaft).
TRANSPORTATION AND INSTALLATION MANUAL Transportation Unpacking The robot and controller are shipped separately in corrugated cardboards. Fig. 2.1 shows each packaging state. Open the packages in a location easily accessible, where the equipment is to be installed. Take careful precautions not to damage the robot and controller. After opening the packages, make sure that all the accessories are present and that nothing has been damaged during transport.
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If any parts of the equipment are found damaged or any accessories are missing after the shipment containing the robot and controller have reached your office, DO NOT install and operate them. Otherwise, the equipment will malfunction. Contact Toshiba Machine immediately. • Dispose of the wooden pallet, corrugated cardboards, polyethylene shipping bags and cushion material according to the customer’s in-house regulations.
TRANSPORTATION AND INSTALLATION MANUAL Transportation Move the robot and controller very carefully. Make sure that no excessive impact or vibration is exerted on the equipment. If the equipment is to be subject to vibration over a long period, be sure to tighten all the clamp and base set bolts completely. If the equipment is to be moved to a location some distance from where it was unpacked, reposition the cushions as they were and put the equipment back into the corrugated cardboards.
TRANSPORTATION AND INSTALLATION MANUAL Mass of robot body 28 kg Clamp Fig. 2.3 Outer dimensions at transport (TH550A) 2.2.2 Transporting the Robot In principle, the robot should be transported in the state shown in Fig. 2.2 and Fig. 2.3 above. Fold back and secure the arm with the attached clamp. (The robot is shipped in this posture.
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TRANSPORTATION AND INSTALLATION MANUAL It is possible to lift up and transport the robot. Pass the wire through the attached eyebolt, then lift up the robot carefully, as shown in Fig. 2.4. The figure shows the TH450A. Wire Fig. 2.4 Lifting up the robot CAUTION •...
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TRANSPORTATION AND INSTALLATION MANUAL DO NOT hold the cover. Handling areas (shaded areas) DO NOT hold the duct. DO NOT hold the ball screw spline shaft. The figure shows the TH450A. Fig. 2.5 Robot handling areas After the installation, remove the clamp and eyebolt used for transport. CAUTION •...
TRANSPORTATION AND INSTALLATION MANUAL 2.2.3 Transporting the Controller Disconnect all cables and teach pendant before transporting the controller. DANGER • When placing the controller on the floor, etc., make sure not to have your hands or feet caught. STE 80899 –...
TRANSPORTATION AND INSTALLATION MANUAL Storage Avoid storing the robot and controller for long periods of time after unpacking them. If this is unavoidable, however, strictly observe the following precautions for storage. 2.3.1 Storage Precautions for the Robot CAUTION • Secure the base completely to prevent the robot from falling over. When placed directly on the floor, the robot is unstable and will fall over.
0.98m/s or less Dust No inductive dust should exist. Consult with Toshiba Machine first if you wish to use the robot and controller in a dusty environment. No corrosive or combustible gas should exist. Sunlight The robot and controller should not be exposed to direct sunlight.
TRANSPORTATION AND INSTALLATION MANUAL Robot Installation Before installing the robot, you should plan a layout, fully considering the working envelope (or operating range), coordinate system and space for maintenance. 3.2.1 External Dimensions External view drawing of the robot is shown in Fig. 3.1 and Fig. 3.2. 3.2.2 Working Envelope Fig.
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TRANSPORTATION AND INSTALLATION MANUAL 630 (Z-axis stroke at 300 mm) Standard Z-axis stroke (Z-axis stroke at 300 mm) Optional Z-axis stroke 2-axis operation range 2-axis operation range 1-axis operation range 1-axis operation range Fig. 3.1 External view and working envelope (TH450A) STE 80899 –...
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630 (Z-axis stroke at 300 mm) Standard Z-axis stroke (Z-axis stroke at 300 mm) Optional Z-axis stroke 2-axis operation range 2-axis operation range 1-axis operation range 1-axis operation range Fig. 3.2 External view and working envelope (TH550A) STE 80899 – 27 –...
The robot's joint angle origin (0° or 0 mm position) is factory-calibrated according to the base reference planes. Fig. 3.3 shows the base coordinate system and origin of each axis joint angle. The coordinate system is common between the TH450A and TH550A. The figure shows the TH450A.
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TRANSPORTATION AND INSTALLATION MANUAL Reference plane Reference plane Axis 4 Axis 1 Axis 2 Axis 3 Origin of base coordinate system (when Z-axis stroke is 150 Origin of base coordinate system (when Z-axis stroke is 300 Fig. 3.3 Base coordinate system and joint angle origin STE 80899 –...
TRANSPORTATION AND INSTALLATION MANUAL 3.2.4 Installing the Robot The robot is secured, using the mounting holes on the base (four (4) places). Use M12 hexagon socket head cap screws. The robot installation method is shown in Fig. 3.4. Reference planes are provided on the base unit.
TRANSPORTATION AND INSTALLATION MANUAL Installing the Controller 3.3.1 External Dimensions External view of the controller is shown in Fig. 3.5. Top view Left side view TOSHIBA MACHINE EMERGENCY MANU POWER COM1 EXT.SIGNAL EXT.PC HOST MODE TCPRG SERVO SERVO STOP CYCLE...
DO NOT stack the controllers. • DO NOT place any object on top of the controller. INTERNAL EMERGENCY TEACHING POWER EXT.SIGNAL EXT.HOST MODE TOSHIBA MACHINE SERVO SERVO 50 mm or over INTERNAL EMERGENCY 50 mm or over TEACHING POWER COM1 EXT.SIGNAL...
When mounting the robot controller in a rack, mount the side brackets using the screw holes provided on both ends of the front panel, and secure the controller to the rack. The side brackets in Fig. 3.7 are optional. 319.4 4–R3 TOSHIBA MACHINE I NT EMERGENCY MANU POWER CO M1 EXT.
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TRANSPORTATION AND INSTALLATION MANUAL As the cable connectors are connected to the rear side of the controller, provide a space of 110 mm or more on the rear side. For maintenance, the upper cover should be removed. (See Fig. 3.8.) Install the controller for enabling easy access to the controller when conducting maintenance.
TRANSPORTATION AND INSTALLATION MANUAL Fig. 3.9 Clearance of controller front side Precautions for Handling the Teach Pendant Be careful of the following matters when handling the teach pendant. CAUTION • DO NOT drop the teach pendant or hit it against anything. •...
TRANSPORTATION AND INSTALLATION MANUAL Safety Measures When installing the robot, provide sufficient space to carry out the work safely. Clarify the hazard zone, and provide a safety fence so that other persons cannot enter the zone easily. The hazard zone is the zone near the robot's working space where a hazardous state could occur if a person enters.
TRANSPORTATION AND INSTALLATION MANUAL System Connections Cable Wiring This section describes the various types of cables and connectors and explains how these are to be connected. 4.1.1 Connector Arrangement on the Controller The cables connected to the robot controller are shown in Fig. 4.1. Power cable Motor cable (CN2) Encoder cable (CN3)
TRANSPORTATION AND INSTALLATION MANUAL 4.1.2 Connecting the Power Cable “CN1” ([1] of Fig. 4.1; plug connector attached) The power cable is used to supply the main AC power to the controller. Table 4.1 Power supply specifications Item Specifications Power supply Single phase, AC 190 ~ 250 V, 50/60 Hz ±1 Hz Power capacity 2.3 kVA...
TRANSPORTATION AND INSTALLATION MANUAL DANGER • Be sure to use the designated wire. Failure to do so could lead to fires or faults. • When connecting the connector and wires, make sure not to mistake the terminal arrangement. • After making the connection, use a tester, etc., to confirm the connection. For the terminal arrangement, see Para.
TRANSPORTATION AND INSTALLATION MANUAL [1] Connect to CN2, CN3, CN4 Fig. 4.2 Robot side connector arrangement 4.1.4 Connecting the Encoder Cable “CN3” ([3] of Fig. 4.1) (Cable attached) The encoder cable is a signal line used to transmit a signal from the rotation angle detecting encoder of each robot axis to the controller.
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TRANSPORTATION AND INSTALLATION MANUAL 4.1.6 Connecting and Disconnecting Cables CAUTION • Before connecting or disconnecting any controller cable, be sure to turn off the main power (“POWER”) switch. • When disconnecting a cable, be sure to pull the plug and not the cord. Otherwise, you may damage the cable.
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TRANSPORTATION AND INSTALLATION MANUAL Square connectors: CN3, CN4, CN5, CN6, CN12 Firstly, completely insert the cable side connector into the controller connector. Then tighten the lock screws on both ends of the cable side connector with a screwdriver. A loose screw can cause a contact failure or other accident. To avoid this, make sure that the screws are clamped completely.
TRANSPORTATION AND INSTALLATION MANUAL 4.1.7 Examples of Connector Terminal Arrangement a) Power cable connector CN1 Connects to controller. Type: JL04V–2E18–10PE–B DANGER Manufacturer: • Completely connect the Japan Aviation grounding cable. Electronics Industry Otherwise, an electric shock or fire may be Single phase, AC 190~250 V, caused if a fault or 50/60 Hz...
TRANSPORTATION AND INSTALLATION MANUAL Controller Connector Signals 4.2.1 Connector Signal Connection Diagrams Diagrams showing which signals correspond to which terminals are shown in Section 2 of the Interface Manual. 4.2.2 Jumpers for Safety Related Signals The following system input signals are provided to serve for the safety purpose. System input signals CN5–16 (STOP)
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TRANSPORTATION AND INSTALLATION MANUAL CAUTION • Unless the signals of SVOFF and emergency stop contacts 1, 2 are jumpered, the controller servo power cannot be turned on. • Unless the CYCLE signal is jumpered, the controller enters the cycle operation mode.
TRANSPORTATION AND INSTALLATION MANUAL Separating Control Panel from Controller 4.3.1 Removing Control Panel Remove the control panel in the following manner. Loosen the four (4) screws at the four (4) corners, which secure the control panel. Remove these screws, then carefully draw out the control panel toward your side. Caution: Be careful of the cable connected on the rear side.
TRANSPORTATION AND INSTALLATION MANUAL 4.3.3 Control Panel Mounting Dimensions The dimensions of mounting the control panel are shown in Fig. 4.6. Cross truss head screws (ø3 × 6, ZN3–B) are used. INTERNAL EMERGENCY TEACHING POWER EXT.SIGNAL EXT.HOST MODE SERVO SERVO STOP CYCLE SELECT...
TRANSPORTATION AND INSTALLATION MANUAL 4.3.4 Mounting Dummy Panel on Controller When the control panel has been disengaged from the controller, mount a dummy panel on the place where the control panel was set before, as shown in Fig. 4.7. The dummy panel, mounting parts, etc.
TRANSPORTATION AND INSTALLATION MANUAL 4.3.5 Dimensions when Separating Control Panel Fig. 4.8 shows the connections of the control panel and dummy panel. Provide a clearance of 50 mm or more (with cover, 60 mm or more) on the rear side of the separated control panel.
TRANSPORTATION AND INSTALLATION MANUAL Tool Interface Mounting Tool The tool is mounted on the end of the tool shaft. Dimensions of the tool shaft section are shown in Fig. 5.1. As shown in Fig. 5.1, the tool is centered with the ø12H7 mating section. The tool direction is adjusted by means of the 4 ×...
TRANSPORTATION AND INSTALLATION MANUAL Tool Wiring and Piping The robot is provided with wiring and air piping for the tool. These wiring and piping extend to the arm 2 and are used as follows: 5.2.1 Tool Signals (Controller Side) The controller is provided with tool signals (i.e., eight (8) input signals for sensor, etc., eight (8) control signals for solenoid valve, etc., 24 VDC(P24V) and 24 VDC GND (P24G) signals), which can be connected also from the controller side.
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TRANSPORTATION AND INSTALLATION MANUAL a-2) Input signal connector CN4 (Type P) Signal Input circuit and example of Signal name connections Input D-IN0 signal 0 Customer's side TS3000 Input TS2000 D-IN1 signal 1 P24V Input D-IN2 signal 2 Input D-IN3 signal 3 ●...
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TRANSPORTATION AND INSTALLATION MANUAL b-1) Output signal connector CN4 (Type N) Output circuit and example of Signal name Signal No. connections Output D-OUT0 signal 0 Customer's Output D-OUT1 side signal 1 P24V Output DC relay D-OUT2 signal 2 Output D-OUT3 signal 3 24 VDC P24V...
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TRANSPORTATION AND INSTALLATION MANUAL b-2) Output signal connector CN4 (Type P) Output circuit and example of Signal name Signal No. connections Output D-OUT0 signal 0 Customer's Output side D-OUT1 signal 1 P24V Output D-OUT2 signal 2 DC relay Output D-OUT3 signal 3 P24G Diode for preventing...
TRANSPORTATION AND INSTALLATION MANUAL 5.2.2 Tool Wiring Eight (8) input signals are provided for sensors, etc. and eight (8) control signals for solenoid valves, etc. A supply power signal of P24 V is also provided. They are connected to the controller. The wiring arrangement for these cables is shown in Fig. 5.2.
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TRANSPORTATION AND INSTALLATION MANUAL JOFP JOFS JOEP JOES From sequencer etc. Grommet Cable inlet: Inner dia. 17 mm JOES JOFS Disconnect. 11 mm Fig. 5.2 Wiring to sequencer, etc. Input/output signal connector CN0 (Type-N,Type-P) Input/output circuit Signal name Signal No. (Cannon) and example of connections D-IN0...
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TRANSPORTATION AND INSTALLATION MANUAL Input/output circuit Signal name Signal No. (Cannon) and example of connections Plus common (X8HI) D-OUT2 Output signal 2 DC relay drive Customer's side D-OUT3 Output signal 3 P24V Not used Not used DC relay Not used Not used P24V Diode for preventing...
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TRANSPORTATION AND INSTALLATION MANUAL CN0 hand connector 4 × ø4 Quick-operated joint for hand JOFP JOFS JOEP JOES JOEP JOFP Hand JOES JOFS 4 × ø4 air tube 4 × ø4 Quick-operated joint for hand Fig. 5.3 Tool wiring CAUTION •...
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TRANSPORTATION AND INSTALLATION MANUAL Tool connection by using the hollow hole (14 mm-dia.) on Z-axis ball screw shaft. Connect the wiring while being careful about the edge Fig. 5.5 Wiring method STE 80899 – 61 –...
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TRANSPORTATION AND INSTALLATION MANUAL Fixed stay (To be provided by customer.) Tool connection by attaching the fixed stays to the lower side of the arm. Fig. 5.6 Wiring method Note: For the tap holes on the lower side of the arm 2, which are used to attach the fixed stays, it is recommended to machine surfaces A in the figure above.
TRANSPORTATION AND INSTALLATION MANUAL CAUTION • Be sure to use a highly flexible robot cable, which should be secured below the arm with a cable clamp, etc. Unless a robot cable is used, the wire may be broken. • When performing tool wiring and piping, take all necessary measures against breakage due to rub, etc.
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TRANSPORTATION AND INSTALLATION MANUAL The air tube is identified by the number and color. At piping, make sure that each tube is connected properly, referring to the below-mentioned. 1 : Red 2 : White 3 : Blue 4 : Yellow Panel air joint pitch dimensions Fig.
TRANSPORTATION AND INSTALLATION MANUAL Permissible Load Conditions and Program Setting This paragraph describes the permissible load conditions of the robot and how to set up the program according to the load. 5.3.1 Permissible Load Conditions The robot load conditions are defined by the tool mass, moment of inertia and offset value of tool gravity center from the center of the tool shaft, as shown in Fig.
TRANSPORTATION AND INSTALLATION MANUAL Tool gravity center Robot arm Moment of inertia Tool Offset value of gravity center Fig. 5.8 Robot tool 5.3.2 Load Conditions and Program Setting This robot can automatically change the maximum speed, acceleration/deceleration and servo gain by using the PAYLOAD command in the program according to the load conditions.
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TRANSPORTATION AND INSTALLATION MANUAL • The servo gain of each robot axis is automatically changed according to the set load conditions. Program examples Basic program examples using the PAYLOAD command are shown below. For further information, see the Robot Language Manual. (Program example 1) The robot is moved under the load conditions of 5 kg mass and 100 mm gravity center offset.
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TRANSPORTATION AND INSTALLATION MANUAL PAYLOAD={1,30} MOVE P2+POINT(0,0,100) GOTO LOOP FIN: MOVE P0 DOUT(1) STOP Setting of PAYLOAD command In the default state, or when the PAYLOAD command is not used, the maximum speed and acceleration/deceleration are set to 100% and the servo gain is set to the value under the minimum load.
The maximum speed and acceleration/deceleration change with the load mass, as shown in Fig. 5.9. The settings of the maximum speed and acceleration/deceleration are common between the TH450A and TH550A. STE 80899 – 69 –...
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TRANSPORTATION AND INSTALLATION MANUAL Acceleration/ Acceleration/ Deceleration Deceleration Maximum speed Maximum speed Load (kg) Load (kg) Setting of maximum speed and Setting of maximum speed and acceleration/deceleration in relation to acceleration/deceleration in relation to load mass (Axis 1) load mass (Axis 2) Acceleration/ Acceleration/ Deceleration...
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Fig. 5.10, Fig. 5.11, Fig. 5.12 and Fig. 5.13. For the axis 3, however, no restriction is imposed on the offset. The settings are different between the TH450A and TH550A. Load mass ≤ 3 (kg) Load mass ≤...
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TRANSPORTATION AND INSTALLATION MANUAL Load mass ≤ 3 (kg) Load mass ≤ 3 (kg) 3 (kg) < Load mass ≤ 5 (kg) 3 (kg) < Load mass ≤ 5 (kg) Load mass > 5 (kg) Load mass > 5 (kg) Offset (mm) Offset (mm) Setting of acceleration/deceleration in...
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Setting of acceleration/deceleration in Setting of maximum speed in relation to relation to offset (Axis 2) offset (Axis 2) Fig. 5.12 Setting of maximum speed and acceleration/deceleration in relation to gravity center offset (Axes 1 and 2) (TH550A) STE 80899 – 73 –...
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Setting of maximum speed in relation to relation to offset (Axis 4) offset (Axis 4) Fig. 5.13 Setting of maximum speed and acceleration/deceleration in relation to gravity center offset (Axis 4) (TH550A) APPROVED BY: CHECKED BY: PREPARED BY: STE 80899...
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