Sony Robotics B2521E User Manual

Sony Desktop Robot  
OPERATION MANUAL  
GA  
CAST-AU4/B2521E  
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How to Use this Operation Manual  
First Time Users  
Read this manual form chapter 1 through chapter 4 before starting any operation. The manual describes the  
procedures required in setting up ROBOKIDS for users who have little experience with FA (Factory  
Automation) equipment.  
Routine Assembly  
Follow the respective application manuals for routine assembly task operations.  
Replacing the Unit or Memory Card  
Remove the existing unit. Attach the new unit and replace the memory card. References of the memory card  
may be found in this Operation manual or the respective application manuals.  
This manual describes the ROBOKIDS base machine. Details for application unit installations may be  
found in the operation manuals that are attached when purchasing the application units.  
CAST-AU4/B2521E  
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Manual Configuration  
This operation manual describes the procedures required to operate the desktop robot ROBOKIDS Various  
types of applications such as dispensing and soldering may be accomplished by exchanging the memory  
cards (RK card) which stores the programs required to run an application. The semi-programmable  
specification allows the user to modify an operation program and peripheral task program to perform a  
specific work. The full open programmable specification enables the use to freely write any program to  
perform an unique application. This manual contains the common contents between dispensing, soldering,  
semi-programmable and the full open programmable specification. For further details refer to the memory  
card (RK Card) operation manual (or the Full Open Programmable operation manual for the full open  
programmable specifications.)  
Safety Instruction  
Describes the safety precautions for user’s safety.  
Unpacking  
Describes the precautions during unpacking, and lists the supplied accessories.  
1. Outline  
Outlines features, names and functions of controls, and its specifications.  
2. Preparation  
Helps you set up the base machine. Beside the supplied accessories, you also may need to purchase the  
dispensing unit, soldering unit, air compressor, workpiece fixing tool (including fixing screws)  
depending on the configuration.  
3. Maintenance  
Describes daily maintenance.  
4. Troubleshooting  
Describes countermeasure (only the contents which are in common in applications) when an error  
occurs during operation. The Operation Manual of each memory card (RK card) describes  
countermeasures for dispensing errors and soldering errors.  
5. Replacement Parts  
Shows list of main replacement parts of the base machine.  
6. Appendix  
Described input and output specifications of each connector.  
CAST-AU4/B2521E  
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Contents  
Safety Instruction ............................................................................................................... S-1  
Unpacking ........................................................................................................................... U-1  
1. Outline  
1-1 Nomenclature.................................................................................................................... 1-2  
1-2 Outline Drawings.............................................................................................................. 1-4  
1-3 Specifications.................................................................................................................... 1-9  
1-3-1 Machine Specification ........................................................................................ 1-9  
1-3-2 Control Specifications ...................................................................................... 1-10  
2. Preparation  
2-1 Attaching the Units ........................................................................................................... 2-1  
2-1-1 Attaching the Z-unit ........................................................................................... 2-1  
2-1-2 Attaching the ZR-unit ......................................................................................... 2-4  
2-2 Connecting the External Signal ........................................................................................ 2-7  
2-3 Connecting to an Electrical Outlet.................................................................................. 2-12  
2-4 Starting Up the Base Machine ........................................................................................ 2-13  
2-4-1 Full-open Programmable Specification ............................................................ 2-13  
2-4-2 When Using Memory Card “RK card” ............................................................ 2-13  
3. Maintenance  
3-1 Maintaining the Machine .................................................................................................. 3-1  
3-2 Greasing the Machine and Removing Fallen Materials ................................................... 3-1  
3-3 Cleaning and Replacing the Air Filter .............................................................................. 3-4  
3-4 Replacing the Battery ....................................................................................................... 3-6  
4. Troubleshooting  
4-1 Common Items.................................................................................................................. 4-1  
4-1-1 Stepping Out ....................................................................................................... 4-1  
4-1-2 External Noise .................................................................................................... 4-3  
4-1-3 Abnormal Sound from Unit’s Motors ................................................................ 4-3  
4-2 Full-open Programmable Specifications........................................................................... 4-4  
4-3 When Memory Card (RK Card) is Used .......................................................................... 4-7  
Trouble Check Sheet ................................................................................................................. 4-10  
5. Repair Parts Lists  
5-1 ROBOKIDS Body ............................................................................................................ 5-1  
5-2 Z-axis Unit ........................................................................................................................ 5-1  
5-3 ZR-axis Unit ..................................................................................................................... 5-2  
6. Appendix .................................................................................................................................... 6-1  
CAST-AU4/B2521E  
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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 Manual, and  
carefully note the following safety rules.  
Observe all precautions to ensure safety.  
Read the precautions on pages 3 to 6 thoroughly.  
Perform regular inspections.  
Inspect the machine referring to chapter “3. Maintenance”.  
In the event of accidents....  
Consult with the dealer that is indicated on warranty card after filling in the trouble check  
sheet which is attached to the end of the Operation Manual.  
CAST-AU4/B2521E  
S-1  
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Definition of warning symbols  
Pay particular attention to the following symbols and conventions shown on the machine and on the  
Operation Manual. Fully understand the contents of symbols and conventions before reading the Operation  
Manual.  
Machine Symbols》  
Indicates a protective terminal of mechanical parts to which an external protective earth wire  
is connected.  
When the part with this mark is removed, the high voltage appears.  
Check the operation manual before using the part with this mark.  
Be cautious not to pinch your hands or fingers into the units moving parts.  
Before you perform any maintenance and/or check, disconnect the unit from  
the main power supply.  
Operation Manual Symbols》  
Indicates that mis-operations or mis-handling may result in unexpected danger (fire, etc.,)  
and the that operator is at risk (of major injury).  
Warning  
Indicates that mis-handling may result in unexpected danger (electric shock, etc.,) and that  
the operator is at risk of injury or the equipment at risk of damage.  
Caution  
CAST-AU4/B2521E  
S-2  
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Safety Instruction  
I Important Safeguards  
N The tool driving mechanism are subject to unexpected movement. Pay attention to safety  
measures.  
N 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.  
N Mistakes during maintenance and inspections may result in accidents.  
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  
N 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.  
N
Heavy object. Move and transport with two or more persons, and pay attention to safety measures.  
N To maintain safety do not make any modifications to the equipment in order.  
N 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.)  
N Avoid installing in the following locations:  
In places which receive direct sunlight or which experience temperature ranges  
exceeding 0 degrees °C and 40 degrees °C.  
In places which experience relative humidity ranges exceeding 35% and 90%, and  
places in which condensation is generated by rapidly changing humidity.  
In places where corrosive gas or inflammable gas exists.  
In places where the unit will be subject to direct vibrations or impact.  
Close to machinery which emits electrical noise, such as welders, electric dischargers  
or high-frequency generators.  
Caution  
In places where any obstacles are anticipated during maintenance and inspection.  
N 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.  
N 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.  
N Be careful that motor gets very hot.  
CAST-AU4/B2521E  
S-3  
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Precautions on Usage  
Operate on the specified voltage  
Operate the ROBOKIDS only on AC power voltage as specified on the label of the machine. The power  
cord must be directly connected to the electrical output, and grounded. The ROBOKIDS conforms with the  
safety requirements of the target country to which it is shipped.  
When a machine will not be used for extended period of time  
If the machine is not in use for a long period, unplug the power cord from the electrical output. To unplug,  
pull on the plug. Never pull on the cord.  
Do not drop any foreign material into the machine  
Dropping any flammable liquid or metal, object into the machine can cause errors and trouble of the machine.  
Should any of them drop into the machine, unplug the power cord and contact your local Sony dealer.  
Do not place any obstacles in front of the fans.  
Heat dissipation will be insufficient and the accumulated heat can cause malfunctions.  
Precautions on Transportation  
• Avoid excessive shock. Excessive shock such as dropping the machine may cause damage.  
• Do not hit the units or work table during operation. Also be careful so that hands and/or clothes are not  
pinched by the machine. It can cause unexpected physical injury.  
• Be sure to hold the bottom panel when moving the machine.  
CAST-AU4/B2521E  
S-4  
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Safety Instruction  
Precaution on memory cards  
Before inserting or removing a memory card, always turn the power off.  
The data stored in the memory card may be damaged if a memory card is inserted or removed while the  
power is on.  
Precaution on the teaching pendant  
ROBOKIDS uses a teaching pendant for the CAST-PRO or SRX. The CAST-U teaching pendant and  
CAST-PRO teaching pendant are not compatible. Do not use the CAST-U teaching pendant with the  
ROBOKIDS.  
If the CAST-U teaching pendant is used with the ROBOKIDS., the ROBOKIDS cannot exit the  
emergency stop state and can be damaged. Do not use the CAST-U teaching pendant with the  
ROBOKIDS.  
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.  
Caution  
Precaution on maintenance  
Periodic inspection of the following items is recommended once every six months.  
Operation check of the fan attached to the controller  
Be sure to check the operation of the fan attached to the controller before starting operation.  
Equipment can be seriously damaged by heat accumulated in ICs in certain operating environments in  
which equipment is used without sufficient heat dissipation.  
CAST-AU4/B2521E  
S-5  
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On handling batteries  
The following battery is used in the base machine controller.  
Lithium battery (primary battery) of type : CR17335SE-CN21 Manufactured by Sanyo Electric Co.  
Incorrect handling of the battery may result in dangerous situation.  
Do not perform the actions as listed below for safety. Sony Corporation is not responsible for  
the troubles related to the operation of the following precautions.  
(1) Shorting  
Do not short the batteries.  
Shorting the battery may damage the equipment or may result in thermal injury due to  
overheating.  
(2) Disassembling  
Do not disassemble the batteries.  
Gas will be generated irritating the throat. Lithium metal may be generated. The batteries  
can be heated internally resulting in explosion or fire if the batteries are subject to shock.  
(3) Throwing into fire or water  
The battery may explode, generate fire due to liquid leakage or internal shorting if the  
battery is heated. Never throw the battery into fire. The batteries can explode if they are  
Caution  
thrown into fire. Throwing the batteries into water may lose the battery function.  
(4) Soldering  
Do not make any soldering directly to the batteries. The batteries can explode or generate  
fire due to liquid leakage or internal shorting inside the batteries caused by heat.  
(5) Do not connect the batteries with reverse polarities between (+) and (-)  
(6) Using the batteries for other applications  
Do not use the batteries for other applications. The batteries may be damaged or the  
equipment can be damaged due to specification differences.  
(7) Charging  
Do not charge the lithium battery (primary battery). Gas will be generated inside causing  
explosion and fire.  
Life and replacement of batteries  
The nominal life of the lithium battery (primary battery) used in the controller is 3 to 5 years. Replace it  
every 3 years as a guide line. (Refer to section “3-4 Replacing the Battery” for the replacement procedure.)  
Life, however, can be shorter than the nominal life depending upon the ambient environments.  
The front POWER indicator changes from green to red when a battery runs out.  
CAST-AU4/B2521E  
S-6  
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Unpacking  
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.  
Caution  
NOTE  
Be sure to use the packaging material specified by Sony Corporation when transporting the  
machine.  
Accsesorybox  
Removebyholdinghands  
atthebottom asshown  
bythearrows.  
CAST-AU4/B2521E  
U-1  
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When the machine is unpacked, make sure the following items are in the package.  
Base machine  
Power cable  
(For AC 200V to 240 V)  
Operation box  
USER I/O connector  
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.)  
CAST-AU4/B2521E  
U-2  
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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.  
• The programs required for an application are stored in the memory card “RK Card”.  
Operation is started by inserting the specific memory card into the base machine and teaching the work  
points. The machine may be switched to perform a different application be exchanging the memory card.  
• The work points and the working speed may be set by using the simple operation teaching pendant  
(option) even by someone who has just purchased ROBOKIDS.  
• The power supply and controller are built inside the machine thus making the system transportable to the  
place where it is needed.  
• The machine is equipped with an external switch connector and also an USER I/O connector allowing  
synchronous operation with external equipment. Remote operation is also possible.  
The external switch and connector enabling operation of the machine by two operators, must  
be prepared by the user.  
NOTE  
I 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  
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1-1 Nomenclature  
Front View  
X-axis  
Unit or tool mounting bracket  
Work table mounting bracket (Y-axis)  
X-axis stand  
TECH. PEN. connector  
(for teaching pendant of CAST-PRO)  
*EJECT button  
Debug station connector  
*To debug station  
START button  
Operation box  
Memory card slot  
5-gang LED display  
(POWER, TASK, ROBOT,  
ONLINE, ERROR indications  
from the left)  
SRX teaching  
pendant connector  
RS 232C program  
transfer connector  
PROGRAM switch  
STOP button  
* Debug station • • • Option  
Either the SRX teaching pendantor 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.  
CAST-AU4/B2521E  
1-2  
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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  
is used.)  
CAST-PRO Teaching Pendant  
SRX Teaching pendant  
8
8
8
CAST-P06 (option)  
SRX-P005/S (option)  
CAST-AU4/B2521E  
1-3  
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1-2 Outline Drawings  
I ROBOKIDS  
Standard Type (CAST-AU4/B2521E)  
320  
(35)  
250  
(Stroke)  
φ4 + 0.03  
0
4-M4  
2
A
(6)  
48  
(60)  
Detailed view of "A"  
(6)  
105  
40  
105  
(69)  
(250)  
(78)  
A
(52)  
210  
(Stroke)  
210  
CAST-AU4/B2521E  
1-4  
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1. Outline  
Height Adjustable Type (CAST-AU4/BT2521E)  
320  
(35)  
250  
(Stroke)  
A
105  
40  
(250)  
105  
(69)  
(78)  
(6)  
A
(52)  
210  
(Stroke)  
210  
CAST-AU4/B2521E  
1-5  
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I 3-Axes Model  
162  
Z-unit  
70  
97  
45  
58  
68  
11  
4-M4  
48  
I 4-Axes Model  
162  
ZR-unit  
97  
63  
30  
57  
φ12h7  
CAST-AU4/B2521E  
1-6  
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1. Outline  
Service Tapped-Hole Position  
20  
10  
Side A  
6-M3  
6-M3  
(Side A only)  
(1.6)  
10  
10  
(250)  
22  
4-φ  
CAST-AU4/B2521E  
1-7  
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Service Tapped-Hole Position (Tall Model)  
CAST-AU4/B2521E  
1-8  
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1. Outline  
1-3 Specifications  
1-3-1 Machine Specifications  
Three axes specification Four axes specification  
Item  
Two axes specification  
with Z-axis  
250 mm  
210 mm  
70 mm  
300 mm/s (*2)  
300 mm/s  
100 mm/s (*2)  
with ZR-axis  
250 mm  
210 mm  
70 mm  
X-axis  
250 mm  
Work envelope  
Y-axis  
Z-axis  
R-axis  
X-axis  
Y-axis(*4)  
Z-axis  
R-axis  
X-axis  
Y-axis  
Z-axis  
R-axis  
X-axis  
Y-axis  
Z-axis  
R-axis  
X-axis  
Y-axis  
Z-axis  
R-axis  
210 mm  
0° to 360°  
300 mm/s (*3)  
300 mm/s  
70 mm/s (*3)  
550°/s (*3)  
0.05 mm  
0.05 mm  
0.05 mm  
0.1°  
300 mm/s (*1)  
Maximum speeds  
300 mm/s  
0.05 mm  
0.05 mm  
0.05 mm  
0.05 mm  
Pose-repeatability  
0.05 mm  
(positioning accuracy)  
5kg  
Maximum payload  
Resolution (*5)  
5kg  
5kg  
5kg  
2kg  
0.014 mm  
0.014 mm  
1.8 kg  
0.014 mm  
0.014 mm  
0.006 mm  
0.014 mm  
0.014 mm  
0.003 mm  
0.04°  
Robot mass (including units)  
Operating ambient temperature  
About 13 kg  
About 15 kg  
0 to 40 °C  
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 kg or less. Set the speed value lower than the  
maximum value when the payload exceeds 1.5 kg.  
*4) The maximum value is subject to the payload of 3.0 kg or less. Set the speed value lower than the  
maximum value when the payload exceeds 3.0 kg.  
*5) The resolution does not indicate the absolute position accuracy. It indicates the amount of movement  
(round-off function) per every pulse that is theoretically calculated from the machine structure.  
This value changes especially when direction of movement or speed is changed.  
The resolution value can change depending on the card when the RK card is used.  
CAST-AU4/B2521E  
1-9  
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1-3-2 Control Specifications  
Drive method  
Movement method  
Control axis count  
Interpolation function  
CP control speed  
Pulse motor drive (open loop control)  
PTP, CP  
Up to four axes (all axes simultaneous control)  
3-dimensional linear interpolation and 3-dimensioal circular interpolation  
1 to 100 mm/s  
Direct teaching via teaching pendant (option)  
Point program  
Teaching method  
Program capacity  
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  
Point data storage capacity  
Programming method  
Full open : Described by the machine language LUNA  
RK card : The standard software is supplied (option)  
22 inputs and 22 outputs  
General-purpose I/O  
Serial I/F  
RS232C : One channel (general-purpose)  
Single-phase 100 to 240 V 10% 50/60 Hz  
300 VA  
Power supply voltage  
Power consumption  
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.  
CAST-AU4/B2521E  
1-10  
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2. Preparation  
2. Preparation  
2-1 Attaching the Units  
2-1-1 Attaching the Z-unit  
1. Fix the supplied mounting plate to the  
work table. (Two positions)  
Hexagon socket head cap screws  
M4 × 10, 2 pieces  
Tightening torque 15 kgfcm  
2. 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  
Flat washer  
SW4, 3 pieces  
W4, 3 pieces  
Tightening torque 15 kgfcm  
CAST-AU4/B2521E  
2-1  
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4. Attach the removed front cover. (Four  
positions)  
Tightening torque  
8 kgfcm  
5. Connect the connectors to the Z-/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  
Flat washer  
Tightening torque  
SW3, 2 pieces  
W3, 2 pieces  
10 kgfcm  
Cable holder  
(supplied)  
CAST-AU4/B2521E  
2-2  
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2. Preparation  
7. Fix the cable clamp of the cable to the  
cable holder.  
CAST-AU4/B2521E  
2-3  
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2-1-2 Attaching the ZR-unit  
1. Remove the front cover. (The cover to  
which Sony logo mark is attached.) (Six  
positions)  
2. Fix the ZR-unit to the mounting plate.  
(Four positions)  
Determine the fixing position using the  
positioning pin that is supplied with the  
equipment.  
Hexagon socket head cap screw  
M4 × 6, 4 pieces  
Spring washer  
Flat washer  
Tightening torque  
SW4, 4 pieces  
W4, 4 pieces  
15 kgfcm  
3. Attach the front cover. (Six positions)  
Tightening torque  
8 kgfcm  
CAST-AU4/B2521E  
2-4  
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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 × 6, 2 pieces  
Spring washer  
Flat washer  
Tightening torque  
SW3, 2 pieces  
W3, 2 pieces  
10 kgfcm  
Cable holder  
(supplied)  
CAST-AU4/B2521E  
2-5  
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5. Fix the clamp of the cable on the cable  
holder.  
CAST-AU4/B2521E  
2-6  
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2. Preparation  
2-2 Connecting the External Signal  
The base machine is equipped with the following connectors for external signal communication.  
• SAFETY (for external switch) connector (rear)  
External Stop (same function as the STOP button of the main unit)  
• Door, barrier  
• External return (same operation as the RETURN button in the two operators line mode operation)  
• USER INPUT/OUTPUT (EXTERNAL I/O) connector (rear)  
• Selecting programs (same operation as the PROGRAM switch of the main unit) : (I3 ~ I10)  
• Error reset (There is no switch corresponding to this function.) : (I11)  
• External start (same operation as the START button of the main unit) : (I1)  
1. Connect an external switch to the SAFETY connector by soldering.  
Connect the wires to the corresponding pins of the external switch connector.  
Refer to the connector diagram for external switch, for the signals at the respective pins and type of  
mating connector.  
How to control the stop:  
• Connect pin-10 and pin-11 to the respective switches.  
• Connect pin-14 to pin-15. (or to pin-7)  
How to control the RETURN :  
• Connect pin-9 and pin-7 (or pin-15) to the respective switches.  
Example of external  
Switch box  
stop switch  
Door switch  
Floor mat switch  
CAST-AU4/B2521E  
2-7  
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Connector for external switch (SAFETY)  
Safety box  
Contents  
24 V  
Pin No.  
1
Max 0.1 A  
2
SA RETURN OUT  
SA EMG OUT  
Stop RELAY OUT (C)  
Stop RELAY OUT (NO)  
Stop RELAY OUT (NC)  
0 V  
RETURN indicator  
Stop indicator  
3
These lines can be freely used by users because  
these lines are prepared for independent relay  
to be energized at the time of stop.  
(Pins-4 and -6 are normally closed.  
In a stop, pins-4 and -5 are closed.)  
4
5
6
7
Connect shield  
of the cable  
8
FG  
RETURN button  
Stop button  
9
SA RETURN IN  
SA Stop IN (C)  
SA Stop IN (NC)  
BAR (C)  
10  
11  
12  
13  
14  
15  
Barrier switch, door switch, etc.  
BAR (NC)  
SA Stop ENABLE  
0 V  
Wiring diagram of connector for external switch (SAFETY)  
Applicable plug  
Applicable shell  
Type : DA-15PF-N (pin connector)  
Type : DA-C4-J10  
N An external stop button can be inserted between pins-14 and –15, or between  
pins-14 and –7.  
N Be sure to use a shielded cable. The maximum length of a shielded cable is 1.5 m. The  
external shield must be connected to pin No. 8.  
NOTE  
N The external equipment (switch, indicator, box, etc.,) to be used for external operation  
must be prepared by users.  
CAST-AU4/B2521E  
2-8  
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2. Preparation  
2. Connect the external signals to the USERl I/O connector by soldering.  
Connect the wires to the corresponding pins of the USER I/O connector.  
For the signal names and pin numbers of the respective pins, refer to the I/O connector input/output  
specifications, Operation Manual (or Operation Manual of Full Open Programmable in the case of the  
full open programmable specifications) of memory card (RK card).  
Precautions on operating the ROBOKIDS  
When using the RK card, connect the I/O connector supplied to the USER I/O connector SI1  
(SYSRUN) of the machine as shown.  
• USER I/O connector (supplied)  
USER I/O connector  
(supplied)  
Pin No.  
Name  
0 V  
Pin No.1  
Connection  
1
3
SYSRUN  
Pin No.3  
Caution  
• Pin arrangement  
~
~
2
1
4
6
8
7
30 32 34  
29 31 33  
64 66 68  
63 65 67  
Connect a jumper wire with soldering  
(AWG30 or equivalent)  
3
5
9
36 38 40 42  
35 37 39 41  
~
~
* 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)  
PROGRAM switch  
Controlling the program selector  
from external location • • • Set to F”  
Set the first digit of the PROGRAM switch to  
Fwhen controlling the program selector  
from external location.  
If the second digit of the PROGRAM switch is  
set to F, the application program is set to  
external mode.  
CAST-AU4/B2521E  
2-9  
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I Input Circuit  
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.)  
S1  
24V  
0V  
Note1) 24V  
0V  
24V IN  
0V IN  
I/O connector  
PC board side PCR-E68LMDA  
(Honda communication)  
Pin No.  
1
0V  
35  
2
36  
TLP280  
470  
Direction of  
3
3.3k  
3.3kΩ  
3.3kΩ  
current  
SW1  
SI1 operates when  
SW1 is ON.  
680pF  
SI1  
(SYSRUN) Maximum 7mA  
37  
4
SI2  
Reservation  
input  
(
)
SI3  
Reservation  
input  
(
)
SI8  
Reservation  
(
)
input  
I 1  
I 2  
I 3  
I 4  
I 5  
I 21  
I 22  
51  
18  
SW30  
COM1  
Note1) When USER I/O power supply  
source selector slide switch  
is set to 24V.  
52  
19  
53  
Thermistor  
(1A)  
Controller side  
User side  
CAST-AU4/B2521E  
2-10  
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2. Preparation  
I Output Circuit  
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.)  
S1  
24V  
0V  
Note1) 24V  
0V  
24V IN  
0V IN  
I/O connector  
PC board side PCR-E68LMDA  
(Honda communication)  
0V  
TLP127  
Direction of  
current  
X1  
20  
54  
SO1  
(EMC-OUT)  
SO2  
Relay coil voltage  
(DC 24V)  
Maximum  
0.1A  
Diode  
X2  
(ERROR)  
SO3  
21  
(BARRIER)  
SO4  
(DRIVE)  
Reservation  
output  
SO8  
Reservation  
(
)
output  
L 1  
L 2  
68  
18  
52  
19  
53  
X30  
L 22  
Note1) When USER I/O power supply  
source selector slide switch  
is set to 24V.  
COM1  
Thermistor (1A)  
Controller side  
User side  
N Add the diodes as shown when relay coils are connected as the load.  
N Be careful that the thermistor operates to shut down the +24 V power supply when 24 V  
output is used and the current of 1 A or more flows. Modify the external circuit to reduce  
the current capacity to 1 A or less. Thermistor shuts down the +24 V power supply and  
returns when the main power is turned on again.  
NOTE  
(The maximum current capacity of internal power supply is 1 A.)  
N Be careful that current capacity is maximum 0.1 A per one output point.  
N Be sure to use a shielded cable for I/O connection. The maximum length of a shielded  
cable is 1.0 m. Use the core conductor of the shielded cable.  
CAST-AU4/B2521E  
2-11  
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2-3 Connecting to an Electrical Outlet  
Prepare the power cable for AC 200 V to 240 V  
referring to the following connection diagram.  
The user must provide and wire an AC power plug  
to connect to the AC outlet.  
To the three-pin electrical outlet  
Power cable (supplied)  
To the machine INLET  
Connection diagram of the AC power cable for 200 V to 240 V  
Brown  
Blue  
L
N
Green/Yellow  
Earth  
CAST-AU4/B2521E  
2-12  
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2. Preparation  
2-4 Starting Up the Base Machine  
Make sure that the main power is turned off.  
Connect the operation box.  
2-4-1 Full-open Programmable Specification  
Turn on the power switch on the rear panel. Subsequent operating procedure changes depending on the  
application created by user.  
2-4-2 When Using Memory Card “RK card”  
Before operation ensure that an application memory card (RK card) is inserted in the memory card slot.  
When you have purchased another type of optional memory card in order to use the robot in another  
assembly type, re-insert the new card to the memory card slot.  
1. Make sure that the main power is turned  
off. Insert the memory card into the  
memory card slot.  
Do not remove or insert a memory card while  
power is turned on. It may cause trouble.  
2. Connect the USER I/O connector (in  
which SYSRUN is shorted) to the rear  
USER I/O connector  
panel of the ROBOKIDS. (Refer to page  
2-6.)  
Operation box  
Memory card slot  
Memory card  
CAST-AU4/B2521E  
2-13  
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3. Turn the base machine on.  
POWER switch · · · ON  
About five seconds later, the white indicator of  
START button starts flashing in green.  
4. Press the START button.  
The machine starts returning home.  
The green indicator of the START button turns  
on and changes to slow flashing after completing  
home return. (About 30 seconds later)  
5. Press the START button again.  
The green indicator of START button turns on  
and the machine starts assembling work.  
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  
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.  
NOTE  
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.  
CAST-AU4/B2521E  
2-14  
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3. Maintenance  
3. Maintenance  
3-1 Maintaining the Machine  
Clean the surfaces of the machine with a soft dry cloth. If the stain is difficult to remove, use cloth  
moistened with a mild detergent solution, followed by using a dry cloth. Do not use volatile solvents such  
as alcohol, benzene or thinner, as they may mar the finish.  
Consult your local Sony dealer for the consumable parts, jigs and tools which are required for maintenance.  
3-2 Greasing the Machine and Removing the Fallen Materials  
When shipped, the machine is greased along the guide rails of the X- and Y-axes. This ensures smooth  
operation of the work table. To maintain the machine in top condition, grease the rails and remove the fallen  
materials every 6 months. Use the NSK grease No. 1 (Nippon Seiko or Multemp LRL3 equivalent).  
1. Turn off the power of machine, and  
unplug the power cord from an  
electrical outlet.  
When the Z unit is used, move down the Z-axis  
to the bottom and turn off the POWER switch.  
OFF  
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  
3-1  
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3. Move the work table and the work unit  
to the ends by hand, remove the X-axis  
and Y-axis covers by pulling them, then  
remove the fallen materials such as  
screws.  
Remove the front cover of the Z-unit and ZR-  
unit also.  
If the work table and the work unit are not moved to the ends as indicated, they may cause  
damage to the covers.  
NOTE  
4. Wipe of the old grease and apply grease  
at the center of each side of the X-axis  
and Y-axis guide rails.  
Apply about 0.2 g of grease.  
Be careful not to apply grease to the drive belts.  
5. Move the work table and the work unit  
to the left and to the right several times  
to spread the grease over the length of  
each rail.  
Wipe off extra grease at the ends of each rail  
with a cloth. (Extra grease will be solidified  
causing malfunction.)  
CAST-AU4/B2521E  
3-2  
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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.  
N Be careful not to damage the covers when they are reinstalled.  
N After the covers are attached, move the respective axes using the teaching pendant until  
grease covers all necessary part.  
NOTE  
N Be careful that the motors get very hot immediately after the operation is stopped.  
CAST-AU4/B2521E  
3-3  
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3-3 Cleaning and Replacing the Air Filter  
Air is circulated in the controller of the base  
machine to cool the controller. The cooling air is  
introduced through the air filter on the rear of the  
machine. Dust may be accumulated choking the  
air filter which decreases the cooling power  
causing serious damage such as thermal  
breakdown of ICs if the air filter is not properly  
maintained. Clean the air filter once every six  
months. If the air filter is heavily clogged, replace  
the air filter.  
Front cover  
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  
bottom of the cover to the front, raise the  
catches on the top.  
CAST-AU4/B2521E  
3-4  
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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  
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3-4 Replacing the Battery  
1. Turn off the POWER switch and unplug  
the AC power cord from the AC outlet.  
The battery is located in the recess at the  
bottom on the rear of the Z-axis.  
2. Exchange the battery with the new  
lithium battery.  
lithium battery  
Battery replacement must be completed within eight hours after the main power is turned off.  
If not, internal data can be damaged.  
NOTE  
Replacement lithium battery (primary battery)  
Sony Order No. .........1-528-932-11  
CAST-AU4/B2521E  
3-6  
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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, “Specifications.”  
The payload with which the machine can operate at 100% speed is smaller than the maximum payload, and  
varies for each axis. Check the actual load weight before operating the machine.  
(2) External force  
External forces from cables and pipes are normally larger than anticipated, and can easily exceed the  
retaining torque of the motor. Be careful of unexpected external forces when using stiff wires or pipes that  
cannot be easily bent.  
(3) Rapid speed change  
When a rapid speed change occurs such as an immediate returning movement while an interpolation  
operation is being performed, the load inertia may exceed the retaining torque of the motor, causing the  
motor to step out.  
Before performing such a movement, reduce the operating speed.  
Example : Returning movement of the circular  
interpolation operation  
Example : Returning movement of the Z-axis  
operation  
(Movements are synthesized sometimes.)  
Note 1 : What is “stepping out”?  
When the drive shaft of a motor is overloaded beyond the torque of the motor, the drive shaft spins (revolves  
swiftly without control) regardless of the control that is applied to the motor.  
This is called “stepping out”.  
This term is sometimes used incorrectly for tooth-skipping (between pulley and belt), but stepping out and  
tooth-skipping are actually entirely different phenomena.  
CAST-AU4/B2521E  
4-1  
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(4) Synthesis of movements in the same direction  
In some programs, the machine is operated by synthesizing two movements (the FOS and PFOS with the  
AWAKE instruction of LUNA).  
When the teaching points to be synthesized are aligned on the same line, the machine can step out.  
When such a movement is experienced, the application program must be modified.  
(5) Eccentric loading  
When a load (tool, work, etc.) is very eccentric or far from the mounting surface, stepping out can occur  
even though the load is lower than the maximum payload. If the weight balance cannot be improved,  
reduce the operating speed.  
(6) Mounting screw  
When a mounting screw is so long that the tip of the screw touches the cover or other object, it can cause  
stepping out. You can detect this trouble by listening for a rubbing sound or looking for scars. Check for  
these before use.  
(7) Belt tension  
If the belt tension becomes abnormal, contact your Sony dealer from which you purchased the machine,  
or contact Sony Max Corporation FA Service.  
(8) When the machine is operated at low temperature  
In early morning during winter, the room temperature may fall to 0°C or lower. The temperature inside  
the machine takes time to rise even though the temperature of the room can be increased by using a  
heater.  
In this case, run the machine for half an hour at half the specified speed, or wait until the temperature of  
the machine rises to the temperature of the room.  
CAST-AU4/B2521E  
4-2  
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4. Troubleshooting  
4-1-2 External Noise  
External electrical noise is a difficult problem because it is invisible. Take the following remedial measures.  
If the symptom disappears, electrical noise was probably the cause of the trouble.  
(1) Earthing the power supply  
Always connect the earth of the AC output to ground (Class 3 ground).  
If the earth is not connected, the equipment is susceptible to electrical noise.  
(2) Separation of AC connections  
Connect the AC power of the machine to a separate AC outlet from any equipment that generates  
significant electrical noise.  
(3) Cable length  
The cables connected to the machine can function as antenna and pick up  
electrical wave noise. Make the cable length as short as possible, and use shielded cables where  
possible.  
The teaching pendant is connected by a long cable to the ROBOKIDS, so disconnect the teaching  
pendant when not in use.  
4-1-3 Abnormal Sound from Unit’s Motors  
The Z unit motor and the ZR unit motor are equipped with brakes; these motors may  
occasionally produce abnormal sounds such as scratching or crunching noises. These sounds are caused by  
the structure of the brakes and are not a problem.  
Also, a squeaking or creaking sound may be heard when the emergency stop switch is pressed during AUTO  
operation. These are the stepping out sound that is generated when the Z-axis is forcibly stopped by  
stepping it out in order to prevent the Z-axis from moving down during an emergency stop. These sounds  
cause no problem in terms of reliability.  
CAST-AU4/B2521E  
4-3  
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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     ↑ ↓  
sHOME RETURN  
CONSTANT  
SELECT  
F1 F2 F3 F4  
4 The error history is displayed.  
ERR HISTORY ← → ↑ ↓  
s E110 R1 L1045 199  
E120 R2 L346 199    
Date and time of occurrence  
Display is possible in a 1998/07/01 14:43:19  
format by scrolling right with the key.  
Program line number in which the error  
occurred  
Task name in which the error occurred  
Error number  
A list of errors is displayed starting from the most recent occurrence.  
When an error occurs, it is registered in the top (the topmost line) and the oldest error is deleted.  
CAST-AU4/B2521E  
4-4  
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4. Troubleshooting  
5 Check the error code number E*** on display and find out causes and countermeasures referring to the  
following table.  
When the machine does not operate normally, check the error contents referring to the following table.  
For the contents that are unique to the respective applications, refer to the Operation Manual of the  
memory card (RK card), and take the appropriate measures.  
Error No.  
Causes  
Solutions  
E000 ~ E030 CPU board is defective  
Replace the Base board  
E031  
E100  
Internal memory overflows  
Delete the unnecessary programs  
Install the system task  
System task not present error (full open)  
When the Power lamp lights up in red, replace the battery.  
If it does not corresponds to any of the above contents,  
contact Sony sales or service office.  
Correct the program  
E110  
Object code error  
E111  
E112  
E113  
E114  
E115  
E116  
E117  
E118  
System task command error (full open)  
Robot command error  
Correct the program of system task or peripheral task  
Correct the I/O number  
I/O number error  
Point data not present error  
Error of point number specified  
Parameter error  
Load the point number. Replace the CPU board  
Correct the point number  
Correct the variables specified  
Correct the array number  
Array number error  
Integer value out of range error  
Correct the integer value  
E119 ~ E124 Syntax error  
X-axis (tool axis) out of operation range  
Correct syntax  
E130  
E131  
E132  
E133  
Correct the target point to which the tool moves  
Correct the target point to which the tool moves  
Correct the target point to which the tool moves  
Correct the target point to which the tool moves  
error  
Y-axis (work axis) out of operation range  
error  
Z-axis (tool axis) out of operation range  
error  
R-axis (tool axis) out of operation range  
error  
E134  
E135  
E136  
E137  
E138  
E139  
E140  
E141  
X-axis system limit error  
Y-axis system limit error  
Z-axis system limit error  
R-axis system limit error  
X-axis point limit error  
Correct the speed so as not to exceed the range  
Correct the speed so as not to exceed the range  
Correct the speed so as not to exceed the range  
Correct the speed so as not to exceed the range  
Correct the speed so as not to exceed the range  
Correct the speed so as not to exceed the range  
Correct the speed so as not to exceed the range  
Correct the speed so as not to exceed the range  
Y-axis point limit error  
Z-axis point limit error  
R-axis point limit error  
Speed is too fast for the distance between  
the two points during interpolation  
operation  
Increase the distance between the two points, or decrease  
the speed  
E154  
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  
Correct the position of the circular auxiliary point, or  
divide the movement into smaller segments of less then  
360 degrees  
E155  
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  
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Error No.  
E301  
Causes  
Solutions  
Correct the speed so as not to exceed the range.  
Replace the sensor  
X-axis limit sensor error  
Correct the speed so as not to exceed the range.  
Replace the sensor  
E302  
E303  
E304  
E314  
E315  
E316  
E317  
Y-axis limit sensor error  
Correct the speed so as not to exceed the range.  
Replace the sensor  
Z-axis limit sensor error  
Correct the speed so as not to exceed the range.  
Replace the sensor  
R-axis limit sensor error  
Correct the speed so as not to exceed the range.  
Correct the target point  
X-axis command position error  
Y-axis command position error  
Z-axis command position error  
R-axis command position error  
Correct the speed so as not to exceed the range.  
Correct the target point  
Correct the speed so as not to exceed the range.  
Correct the target point  
Correct the speed so as not to exceed the range.  
Correct the target point  
CAST-AU4/B2521E  
4-6  
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4. Troubleshooting  
4-3 When Memory Card (RK Card) is Used  
The operational flow starting from turning on the main power of the machine until the programmed  
operation or teaching is started, is shown as follows. Causes and countermeasures when trouble occurs in  
the respective state from 1) to 9) are shown on the next page. Use these tables for troubleshooting.  
There may be a case when an error number is displayed on the teaching pendant. When EEEand error  
numberappear 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  
3)  
START button is pressed  
4)  
Performed Homing  
5)  
START indicator flashes slowly  
Application program switches are set  
Work program switches are set  
Application program  
"0"  
Application program  
"1" ~ "E"  
6)  
8)  
HOME key of  
START button is pressed  
9)  
teaching pendant is pressed  
7)  
To teaching mode  
To running mode  
CAST-AU4/B2521E  
4-7  
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Fault-Finding Chart of 1)  
Symptoms  
Causes  
Solutions  
Connect the SYSRUN  
The simple operation  
OFF LINE is selected  
Set the machine system to ONLINEfrom the  
TP of the SRX  
teaching pendant keeps  
displaying 666”  
Internal PC board is defective  
Card is not inserted  
Exchange the internal PC board  
E01appears on the  
Insert the memory card securely  
simplified TP.  
The card has no program  
Insert a memory card in which program is stored  
E02appears on the  
The CAST specification setting is set to Set the CAST specification setting to YESfrom  
simplified TP.  
NO  
the TP of the SRX  
The main power cannot  
be turned on.  
The main AC power is not turned on  
Connect the AC main power  
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)  
Release the external emergency stops  
Alternatively, short pin-1 and pin-2 of the  
external switch connector  
The external stop signal is being  
connected  
Fault-Finding Chart of 2)  
Symptoms  
Causes  
Solutions  
Replace the START indicator  
Replace the START button  
START indicator does not illuminate START indicator is defective  
START button has the short circuit  
START indicator keeps flashing  
External START switch has the short circuit Replace the external START button  
Fault-Finding Chart of 3)  
Symptoms  
Causes  
Solutions  
Replace the START button  
START button does not function START button is defective  
Fault-Finding Chart of 4)  
Symptoms  
Causes  
Solutions  
E07appears 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  
Controller data is abnormal  
Correct the controller data from TP of the SRX  
reverse direction.)  
CAST-AU4/B2521E  
4-8  
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4. Troubleshooting  
Fault-Finding Chart of 5)  
Symptoms  
Causes  
Solutions  
Turn on the main power of the machine system  
and start operation from the very beginning  
Turn on the main power of the machine system  
and start operation from the very beginning  
E08appears on display TYPESET failed  
E09appears on display START failed  
Fault-Finding Chart of 6) or 7) or 8)  
Symptoms  
Causes  
Solutions  
START indicator keeps flashing Application program switch is defective Replace the application program switch  
HOMEkey does not function Teaching pendant is defective  
Replace the teaching pendant  
E10appears on display A point outside the work envelope is  
Specify the point inside the area and try again  
during teaching  
E11appears on display The target coordinate of copy has exceeded Perform COPY so as not to exceed the work  
during teaching the work envelope during COPY. envelope  
E12appears on display Number of point storage capacity of the target Perform COPY within the storage capacity of  
specified by INSERT/DELETE  
during teaching  
point of copy is insufficient during COPY  
Step-out of the X-axis in the opposite  
point  
Check weight of the tool and check also if there is  
E30appears on display  
direction to home position has occurred any interfering obstacles around the point  
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  
E31appears on display  
E32appears on display  
E33appears on display  
E34appears on display  
E35appears on display  
E36appears on display  
E37appears on display  
Step-out of the Y-axis in the opposite  
Check weight of the work and check also if there  
direction to home position has occurred is any interfering obstacles around the point  
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  
Check weight of the tool and check also if there is  
Step-out of the Z-axis in the opposite  
direction to home position has occurred any interfering obstacles around the point  
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  
Step-out of the R-axis in the opposite  
Check weight of the tool and check also if there is  
direction to home position has occurred any interfering obstacles around the point  
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  
Perform teaching again.  
Teaching has not been done correctly  
Machine is loaded with excessive weight Refer to section 1-3-1 Machine specifications.  
Cover is contacting with moving object Correct the cover position  
The machine does not  
operate normally  
Dropped parts such as screws are choking. Remove anything dropped  
External unit is defective  
External noise is affecting  
Repair or replace the external unit  
Remove the source of noise  
The belt tension adjustment  
Consult your Sony dealer from which you purchased the machine or the nearest Sony FA offices for the  
actual adjustment of the belt tension.  
CAST-AU4/B2521E  
4-9  
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Trouble Check Sheet  
If a trouble occurs, check the following items before contacting your Sony dealer or the nearest Sony FA offices.  
1) Name of dealer from which you purchased the ROBOKIDS  
Company name :  
2) What is the serial number of your ROBOKIDS? (It is marked on the sticker of the rear cover.)  
M No. R No.  
3) What type of memory card are you using ? (It is marked on the memory card.)  
Person in charge :  
Tel:  
TYPE  
NAME  
4) When did the trouble occur?  
1. Has the trouble occurred since you purchased the ROBOKIDS?  
2. The ROBOKIDS ran normally, but then troubles suddenly occurred.  
3. The machine has gradually become worse.  
4. Others  
In case of 1, what was the condition of the ROBOKIDS?  
1. How was the condition during initial operation after purchase?  
2. The main power has not been turned on for a long time  
3. The main power has not been turned on for a short time  
4. What was the condition when the main power was turned on?  
5) Describe the details of the trouble (such as error code, etc.).  
(for days).  
(for days).  
6) Compared with normal operation, at what timing does the error occur?  
7) If you have two or more ROBOKIDS, compare them. What are the results of the comparison?  
8) What happens if you replace parts (such as the memory card)?  
9) Is there any noise source near the ROBOKIDS? Yes / No  
10) What is the condition of the ROBOKIDS at present?  
The ROBOKIDS is not being used.  
The ROBOKIDS is still being used.  
11) Customer  
Company name :  
Department :  
Person in charge :  
Tel :  
Fax :  
Fill in the above items, and send this form to your Sony dealer or the nearest Sony FA offices by fax.  
CAST-AU4/B2521E  
4-10  
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5. Repair Parts Lists  
5. Repair Parts Lists  
5-1 ROBOKIDS Body  
Descriptions  
TASK board  
Part No.  
Remarks  
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  
Built-in board “Small”  
Built-in board “Large”  
BASE board  
Battery  
DC switching power supply ZWS30-5/J  
DC switching power supply ZWS150PF-24/J  
Circuit protector  
For DC 5 V  
For DC 24 V  
POWER switch  
Inside the ROBOKIDS  
Operation box  
Operation box  
Operation box  
Fan harness  
Self-illuminating stop switch  
Self-illuminating stop switch  
Digital switch  
X-axis motor  
Y-axis motor  
X-axis home position sensor harness  
Y-axis home position sensor harness  
X-axis liner guide  
Y-axis liner guide  
X-axis timing belt  
Y-axis timing belt  
Media  
Air filter  
Cable harness  
Electrical fitting assembly  
Control block assembly  
Y-axis assembly  
X-axis assembly  
5-2 Z-axis Unit  
Descriptions  
Z-axis motor  
Part No.  
Remarks  
1-763-187-11  
1-959-096-11  
4-760-643-01  
4-760-641-01  
1-790-017-11  
4-760-642-01  
4-760-650-01  
A-8336-325-A  
Z-axis home position sensor harness  
Z-axis linear guide  
Z-axis timing belt  
Long  
Short  
Z-axis relay cable harness  
Z-axis timing belt  
Bearing  
Mechanism block assembly  
CAST-AU4/B2521E  
5-1  
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5-3 Z/R-axis Unit  
Descriptions  
Part No.  
Remarks  
Z-axis motor  
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  
R-axis motor  
Z-axis home position sensor harness  
R-axis home position sensor harness  
Spline ball screw  
Z-axis timing belt  
R-axis timing belt  
Z/R-axis relay cable harness  
Bearing  
Mechanism block assembly  
CAST-AU4/B2521E  
5-2  
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6. Appendix  
6. Appendix  
I User Input/Output Specifications of USER I/O Connector  
Input  
Contents  
I/O names in terms  
of software  
Connector pin No.  
RK card specification  
Full-open programmable  
specification  
(including semi-programmable specification)  
SYSRUN  
3
SI1  
SI2  
SI3  
SI4  
SI5  
SI6  
SI7  
SI8  
I1  
37  
4
Reserved by system (User cannot use it.)  
Reserved by system (User cannot use it.)  
Reserved by system (User cannot use it.)  
Reserved by system (User cannot use it.)  
Reserved by system (User cannot use it.)  
Reserved by system (User cannot use it.)  
Reserved by system (User cannot use it.)  
38  
5
39  
6
40  
7
START  
User input  
41  
8
I2  
RETRUN  
User input  
User input  
User input  
User input  
User input  
User input  
User input  
User input  
User input  
User input  
User input  
User input  
User input  
User input  
User input  
User input  
User input  
User input  
User input  
User input  
User input  
I3  
Work program No. 1  
42  
9
I4  
Work program No. 2  
I5  
Work program No. 4  
43  
10  
44  
11  
45  
12  
46  
13  
47  
14  
48  
15  
49  
16  
50  
17  
51  
I6  
Work program No. 8  
I7  
Application program No. 1  
I8  
Application program No. 2  
I9  
Application program No. 4  
I10  
I11  
I12  
I13  
I14  
I15  
I16  
117  
I18  
I19  
I20  
I21  
I22  
Application program No. 8  
Error reset  
*
*
*
*
*
*
*
*
*
*
*
* The allocation at I12 to I22 differs depending upon applications. Refer to the Operation Manual of  
memory card (RK card) for more details.  
The switch SI1 (SYSRUN) must always be connected. The ROBOKIDS cannot be operated  
NOTE unless the SI1 is turned on.  
Turn on or off SI1 as required. (Refer to page 2-6.)  
CAST-AU4/B2521E  
6-1  
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Output  
Contents  
I/O names in terms  
of software  
Connector pin No.  
RK card specification  
(including semi-programmable specification)  
Full-open programmable  
specification  
20  
54  
21  
55  
22  
56  
23  
57  
24  
58  
25  
59  
26  
60  
27  
61  
28  
62  
29  
63  
30  
64  
31  
65  
32  
66  
33  
67  
34  
68  
SO1  
SO2  
SO3  
SO4  
SO5  
SO6  
SO7  
SO8  
L1  
EMG-OUT, stop switch, stop status output  
ERROR, robot error signal  
Reserved by system (User cannot use it.)  
Drive servo ON signal  
ONLINE signal  
Reserved by system (User cannot use it.)  
Reserved by system (User cannot use it.)  
Reserved by system (User cannot use it.)  
End of cycle output  
User output  
L2  
Standby output  
User output  
User output  
User output  
User output  
User output  
User output  
User output  
User output  
User output  
User output  
User output  
User output  
User output  
User output  
User output  
User output  
User output  
User output  
User output  
User output  
User output  
L3  
Error output  
L4  
During operation output  
L5  
Unloading position output (during line mode)  
L6  
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
L7  
L8  
L9  
L10  
L11  
L12  
L13  
L14  
L15  
L16  
L17  
L18  
L19  
L20  
L21  
L22  
* The allocation at L6 to L22 differs depending upon applications. Refer to the Operation Manual of  
memory card (RK card) for more details.  
I Pin assignment  
~
~
2
1
4
6
8
7
30 32 34  
29 31 33  
64 66 68  
63 65 67  
3
5
9
36 38 40 42  
35 37 39 41  
~
~
CAST-AU4/B2521E  
6-2  
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6. Appendix  
I 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  
Contents  
of software  
I23  
I24  
I25  
I26  
I27  
I28  
I29  
I30  
I31  
I32  
START button (White button of operation box)  
RETURN button (To be connected from the rear SAFETY connector by user)  
Work program No. 1 (First digit of the PROGRAM switch of the operation box (1))  
Work program No. 2 (First digit of the PROGRAM switch of the operation box (2))  
Work program No. 4 (First digit of the PROGRAM switch of the operation box (4))  
Work program No. 8 (First digit of the PROGRAM switch of the operation box (8))  
Application program No. 1 (Second digit of the PROGRAM switch of the operation box (1))  
Application program No. 2 (Second digit of the PROGRAM switch of the operation box (2))  
Application program No. 4 (Second digit of the PROGRAM switch of the operation box (4))  
Application program No. 8 (Second digit of the PROGRAM switch of the operation box (8))  
Output  
I/O names in terms  
Contents  
of software  
L23  
START LED (White indicator)  
L24  
Stop LED (Red indicator)  
L25  
RETURN indicator (To be connected from the rear SAFETY connector by user)  
Stop indicator (To be connected from the rear SAFETY connector by user)  
The barrier signal from the rear SAFETY connector becomes valid when the barrier is enabled.  
User cannot use it.  
L26  
L27  
L28  
L29  
User cannot use it.  
I User external power supply connector  
Power connector for I/O  
Pin No.  
Name  
24 V  
1
2
GND  
1
2
CAST-AU4/B2521E  
6-3  
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I Connector for Debug Station  
Pin No.  
1
Signal  
FG  
Contents  
Frame ground  
2
TP-RXD  
TP-TXD  
TP-CTS  
TP-RTS  
TP-DTR  
C GND  
SIO-DSR  
SIO-RXD  
C GND  
NC  
Connector for SRX teaching pendant (Receive data)  
Connector for SRX teaching pendant (Transmit data)  
Connector for SRX teaching pendant (Clear to send)  
Connector for SRX teaching pendant (Request to send)  
Connector for SRX teaching pendant (Data terminal ready)  
Signal ground  
3
4
5
6
7
8
Connector for program transfer (Data set ready)  
Connector for program transfer (Receive data)  
Signal ground  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
C GND  
SIO-CTS  
NC  
Signal ground  
Connector for program transfer (Clear to send)  
SIO-RTS  
EXS5  
Connector for program transfer (Request to send)  
Connector for SRX teaching pendant (Emergency stop)  
Connector for SRX teaching pendant (Emergency stop)  
SRX teaching pendant is connected or not  
EXS2  
/TP CN1  
NC  
TP-DSR  
SIO-TXD  
PC05V  
SIO-DTR  
C GND  
PC05V  
Connector for SRX teaching pendant (Data set ready)  
Connector for program transfer (Transfer data)  
+5V for SRX teaching pendant  
Connector for program transfer (Data terminal ready)  
Signal ground  
+5V for SRX teaching pendant  
Type  
: DBLC-J25SAF-10L9  
Manufacturer : JAE  
Manufacturer : JAE  
Manufacturer : JAE  
Applicable plug : DBSP-JB25PF  
Applicable shell : DB-C8-J10-F4-1  
CAST-AU4/B2521E  
6-4  
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6. Appendix  
I Connector for Operation Box  
I/O names in terms  
Pin No.  
Contents  
of software  
1
2
I25  
L23  
L24  
Work program No. 1 (First digit of the PROGRAM switch (1))  
START LED  
3
Stop LED  
0 V  
4
5
I32  
I23  
Application program No. 8 (Second digit of the PROGRAM switch (8))  
START button  
6
7
Stop button  
8
Stop button  
9
24 V  
10  
11  
12  
13  
14  
15  
I31  
I26  
I27  
I28  
I29  
I30  
Application program No. 4 (Second digit of the PROGRAM switch (4))  
Work program No. 2 (First digit of the PROGRAM switch (2))  
Work program No. 4 (First digit of the PROGRAM switch (4))  
Work program No. 8 (First digit of the PROGRAM switch (8))  
Application program No. 1 (Second digit of the PROGRAM switch (1))  
Application program No. 2 (Second digit of the PROGRAM switch (2))  
Type  
: 17HE-13150-73  
Manufacturer : DDK  
Manufacturer : DDK  
Manufacturer : DDK  
Applicable plug : 17HE-23150-CD8A  
Applicable shell : 17H-7PCR-102  
I RS232C connector (Rear Panel)  
Pin No.  
Signal  
NC  
Contents  
1
2
3
4
5
6
7
8
9
TXD  
RXD  
DSR  
SG  
Transmit data  
Receive data  
Data set ready  
Signal ground  
Data terminal ready  
Clear to send  
Request to send  
1
2
3
4
6
7
8
DTR  
CTS  
RTS  
NC  
Type  
: CDS-3109-0122  
Manufacturer : SMK  
Manufacturer : DDK  
Manufacturer : DDK  
Applicable plug : 17JE-23090-02  
Applicable shell : 17JE-09H-1A  
CAST-AU4/B2521E  
6-5  
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I SAFETY Connector  
Pin No.  
1
Signal  
24V  
Contents  
+24 V  
2
3
SA START OUT  
SA STOP OUT  
STOP RELAY OUT (C)  
STOP RELAY OUT (NO)  
STOP RELAY OUT (NC)  
0V  
RETURN indicator  
Stop indicator  
4
Stop output common  
Stop output (NO)  
Stop output (NC)  
5
6
7
8
FG  
FG (Shielded wire, etc.)  
RETURN switch  
Stop switch  
9
SA RETURN IN  
SA Stop IN (C)  
SA Stop IN (NC)  
BAR (C)  
10  
11  
12  
13  
14  
15  
Stop switch  
Barrier (safety door, etc.)  
Barrier (safety door, etc.)  
External stop switch and barrier are enabled  
BAR (NC)  
Stop BAR RELEASE  
0V  
Type  
: DA-J15PF1L9  
Manufacturer : JAE  
Manufacturer : JAE  
Manufacturer : JAE  
Applicable plug : DA-15PF-N  
Applicable shell : DA-C4-J10  
CAST-AU4/B2521E  
6-6  
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6. Appendix  
I Connector for ZR-axis Cable  
Pin No.  
1
Signal  
FG  
Contents  
Frame ground  
2
ZR_COM  
Z_DET  
ZR_DET  
Z_24V  
Z_LIM  
Z_GND  
Z_A  
Unit signal common (GND)  
Z-unit signal  
3
4
ZR-unit signal  
5
DC 24 V for Z sensor  
Z-sensor signal  
6
7
Ground for Z-sensor  
Z-axis phase A signal  
Z-axis -phase B common (DC 24 V)  
Z-axis phase/B  
8
9
Z_B_C  
Z_/B  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
R_A  
R-axis phase A  
R_B_C  
R_/B  
Z-axis -phase B common (DC 24 V)  
R-axis phase/B  
BRK+  
BRK–  
R24V  
R_LIM  
R_GND  
FG  
Brake (+, DC 24 V)  
Brake (-, ground)  
DC 24 V for R sensor  
R sensor signal  
Ground for R sensor  
Frame ground  
Z_A_C  
Z_/A  
Z-axis phase A common (DC 24 V)  
Z-axis phase /A  
Z_B  
Z-axis phase B  
R_A_C  
R_/A  
R-axis phase A common (DC 24 V)  
R-axis phase/A  
R_B  
R-axis phase B  
Model  
: DBLC-J25SAF-10L9 Manufacturer : JAE  
Applicable plug : DB-25PF-IN  
Applicable shell : DB-C4-J11  
Manufacturer : JAE  
Manufacturer : JAE  
CAST-AU4/B2521E  
6-7  
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Supply Period of Repair Parts  
The functional repair parts (parts needed to maintain product performance) of this  
machine will be supplied for up to seven years in principle after production is  
discontinued.  
Because it may be possible to repair the machines depending upon the location of  
the problem even after this period, consult the service or sales representative from  
where you purchased the machine.  
Singapore〕  
Sony Electroncs (Singapore) Pte. Ltd  
TEL : 8615858  
Europe〕  
Sony Wega Produktions GmbH  
FAX : 8621521  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
1st Edition November, 1998  
3rd Edition October, 2001  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Sony Manufacturing Systems Corporation  
Printed in Japan © 2001.10  
3-864-811-13  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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