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Sony CAST-AU4 - User Manual

Sony CAST-AU4
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OPERATION MANUAL
Sony Desktop Robot
GA
CAST-AU4/B2521E

Questions and Answers

  • M
    Mark MosleySep 12, 2025
    How do I resolve error E118 on Sony Robotics?
    • R
      Robert GoodmanSep 12, 2025
      If error E118 appears on your Sony Robotics system, which indicates an integer value out of range error, correct the integer value.
  • B
    Brooke DuarteAug 25, 2025
    What to do if error E300 appears on Sony Robotics?
    • C
      Cory ButlerAug 25, 2025
      If error E300 appears on your Sony Robotics machine, it indicates that the emergency stop has been triggered. To resolve this, cancel the emergency stop switch.
  • M
    Michael DavisAug 26, 2025
    What does error E114 mean on Sony CAST-AU4 Robotics and how to fix it?
    • K
      Kimberly NortonAug 27, 2025
      If error E114 appears on your Sony Robotics system, it indicates a 'Point data not present error'. To fix this, load the point number. If the problem persists, replace the CPU board.
  • R
    Richard SanfordAug 28, 2025
    How to fix error E031 on Sony CAST-AU4 Robotics?
    • A
      Allison CareyAug 28, 2025
      If error E031 appears on your Sony Robotics system, it means the internal memory is overflowing. To resolve this, delete any unnecessary programs.
  • J
    Julie FrederickAug 29, 2025
    What does error E110 mean on Sony Robotics?
    • W
      William WilsonAug 29, 2025
      If error E110 appears on your Sony Robotics system, which indicates an object code error, replace the battery when the Power lamp lights up in red.
  • M
    Mr. Michael ScottAug 31, 2025
    How to resolve error E100 on Sony CAST-AU4?
    • C
      Crystal BrownAug 31, 2025
      If error E100 appears on your Sony Robotics system, it indicates a 'System task not present error'. To resolve this, install the system task.
  • S
    Samantha WilsonNov 20, 2025
    What to do if my Sony CAST-AU4 machine steps out due to motor overload?
    • J
      Janet JohnsonNov 20, 2025
      If your Sony Robotics machine steps out due to motor overload, several factors could be responsible. First, check if the load exceeds the maximum payload specified in the machine's specifications. Also, watch out for unexpected external forces, especially from stiff wires or pipes. Rapid speed changes can also cause this issue, so reduce the operating speed before such movements. If movements in the same direction are being combined, the application program may need modification. Eccentric loading can also be a factor; if you cannot improve the weight balance, reduce the operating speed. Inspect the mounting screws for any issues before use. If the problem persists, and you suspect a belt tension issue, contact your Sony dealer or Sony Max Corporation FA Service. Lastly, if operating at lo...
  • D
    Debra FigueroaSep 13, 2025
    What to do for error E000-E030 on Sony CAST-AU4 Robotics?
    • L
      Lindsey ParksSep 13, 2025
      If error E000 ~ E030 appears on your Sony Robotics machine, it indicates the CPU board is defective. Replace the Base board to resolve this.
  • J
    Johnny GeorgeSep 10, 2025
    What does error E117 mean on Sony CAST-AU4 Robotics?
    • L
      Lisa GonzalesSep 10, 2025
      If error E117 appears on your Sony Robotics system, which indicates an array number error, correct the array number.
  • P
    Paula WellsSep 6, 2025
    What should I do if error E113 appears on Sony CAST-AU4?
    • J
      Jennifer RossSep 6, 2025
      If error E113 appears on your Sony Robotics system, which indicates an I/O number error, correct the I/O number.

Summary

About this Operation Manual

How to Use this Operation Manual

First Time Users

Guide for new users on initial operation.

Routine Assembly

Instructions for routine assembly tasks.

Replacing Unit or Memory Card

Procedures for replacing components.

Manual Configuration Overview

Key Sections Overview

Overview of manual's main topics: Safety, Outline, Prep, Maint., Trouble, Parts, Appendix.

Safety Instructions and Precautions

Warning Symbols Definition

Explanation of warning symbols used in the manual and on the machine.

Important Safeguards

Crucial safety measures to prevent accidents and injuries.

Usage and Transportation Precautions

Guidelines for safe operation, usage, and machine transport.

Component Handling Precautions

Handling guidelines for memory cards, teaching pendants, and maintenance.

Battery Handling and Replacement

Procedures and safety for handling and replacing the internal battery.

Product Outline and Specifications

1. Outline

Introduction to ROBOKIDS, its purpose, and basic features.

1-1 Nomenclature

Identification of front view components and LED indicators.

1-1 Nomenclature - Rear View and Peripherals

Identification of rear view components and teaching pendants.

1-2 Outline Drawings

Dimensional drawings for standard and height adjustable types.

1-2 Outline Drawings - Axis Units

Dimensional drawings for Z-unit and ZR-unit.

1-3 Specifications

Detailed machine specifications like envelope, speed, payload.

1-3 Specifications - Control Specs

Detailed control specifications like drive method, power, I/O.

Preparation and Setup

2-1 Attaching the Units

Step-by-step guide to attach the Z-unit.

2-1-2 Attaching the ZR-unit

Step-by-step guide to attach the ZR-unit.

2-2 Connecting External Signals

Instructions for connecting external switches and I/O.

2-3 Connecting to Electrical Outlet

Procedure for connecting the machine to a power outlet.

2-4 Starting Up the Base Machine

Procedures for starting up the machine in different modes.

Maintenance Procedures

3-1 Maintaining the Machine

General cleaning and maintenance procedures.

3-2 Greasing and Fallen Materials Removal

Procedure for greasing guide rails and cleaning.

3-3 Cleaning and Replacing Air Filter

Procedure for cleaning or replacing the air filter.

3-4 Replacing the Battery

Procedure for replacing the internal battery.

Troubleshooting Guide

4-1 Common Item Troubleshooting

General troubleshooting for common issues like stepping out.

4-2 Full-open Specification Troubleshooting

Troubleshooting for full-open mode using error history.

Error Code Troubleshooting

Table of error codes, causes, and solutions.

4-3 RK Card Usage Troubleshooting

Troubleshooting flow for RK card usage.

Fault-Finding Charts

Charts for diagnosing common symptoms and finding solutions.

Repair Parts Lists

5-1 ROBOKIDS Body Parts

List of repair parts for the ROBOKIDS main unit.

5-2 Z-axis Unit Parts

List of repair parts for the Z-axis unit.

5-3 Z;R-axis Unit Parts

List of repair parts for the Z/R-axis units.

Appendix

USER I;O Connector Specifications

Pin assignments for USER I/O connector input and output.

Connector Pinouts

Pin definitions for Debug, Operation Box, RS232C, SAFETY, and ZR-axis connectors.

Supply Period of Repair Parts

Sony CAST-AU4 Specifications

General IconGeneral
CategoryRobotics
ManufacturerSony
ModelCAST-AU4
Degrees of Freedom6
Communication InterfaceEthernet

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