Be Sure to Read Instruction Manuals Before Use

Thank you for selecting DAIHEN arc welding robot Almega series.
Almega series are the robots with high performance and various functions developed by making full use of the
latest technology. Since the knowledge of welding peculiar to a welding machine maker is applied to both
hardware and software, we are sure that each user can be fully satisfied
In order to use the superior performance and the abundant functions safely and fully, be sure to read the
following instruction manuals including this manual and other attached documents, and understand the
knowledge of the machines, safety information, and notes thoroughly.

(1) Instruction manuals related to the manipulator EX-M series, and the robot control unit EX-C series are as
follows.

Instruction Manual Type
Instruction
Manual No.
Main Contents
INSTALLATION & MAINTENANCE


(Almega EX-V6 / V6L / V16)
1L8300A
Specifications of a robot, installing &
connecting method, starting up, periodical
inspection, solution at the time of failure,
maintenance parts list, etc.
BASIC OPERATIONS

(EX-C)
1L8300C
Explanation of operation switch of robot, basic
operation method from teaching to automatic
operation, frequently used functions, etc.
TEACHING

(EX-C)
1L8300D
Detailed explanation of each command and
teaching method, etc.
UTILIZING FEATURES and
FUNCTIONS

(EX-C)
1L8300G
Setting of the environment in which a robot is
being used, useful function, explanation of the
function to manage a robot and the operation
method, etc.
INTERFACE WITH JIG

(EX-C)
1L8300E
Interfacing method with robot jigs, usage of
sequence control function, etc.
OPTION

(EX-C)
1L8300F
Optional functions such as multi-task and
general operation method, etc.
EXTERNAL AXES CONTROLLER

(External Axes Controller for EX-C)
1L8600A
Installation and connection method of external
axes controller which are required when using
3 external axes or more in EX-C, maintenance
parts list, etc.

[Notes] 1. Specifications and information contained in these manuals are subject to change at any time
without notice.

2. Optional hardware or software is necessary in order to use the function described as Optional in
the manual.

3. The screen display of a teach pendant shown in the manual are described as examples, which
may be different from the actual ones.

4. Although we cautiously compiled this standard specifications to eliminate as much error as
possible, we do not take any responsibility for damages resulting from neither direct nor indirect
errors.

5. The manual is a part of robot products. When transferring or selling off a robot, be sure to append
the manual.

6. No part of this manual may be reproduced without permission.
- 1 -
- 2 -
(2) Instruction manuals related to the manipulator AX-M series, and the robot control unit AX-C series are as
follows.

Standard Manuals
Instruction Manual Type
Instruction
Manual No.
Main Contents
INSTALLATION


1L8800A
Safety precautions, installing & connecting method,
starting up, periodical inspection, solution at the time
of failure
CONTROLLER MAINTENANCE/
STANDARD CONFIGURATIONS

1L8800B
Specifications of controller, explanation of each parts
and maintenance, parts list, etc.
MANIPULATOR
1L7700A
Specifications or maintenance of manipulator, parts
list, etc.
BASIC OPERATIONS


1L8800C
Explanation of manual operation, teaching, automatic
operation, file utilities, backing-up data, basic
operations of Arc/Spot welding application, etc.
REFERENCE (Built-in Tutorial)


1L8800D
Basic operations, terms, explanations of
Constants/Service menus, Details of function
command, list of short-cut code, parts replacing
procedure, trouble shooting, etc.
This manual is not provided as the paper manual,
but is built in the robot as Help tutorial function.
EXTERNAL INPUT/OUTPUT
1L8800H
Interfacing method with external control device, list of
I/O signals, start/halt the automatic operation, and
usage of software PLC, etc.

Application Manuals
Instruction Manual Type
Instruction
Manual No.
Main Contents
APPLICATION MANUAL
(ARC WELDING)
1L8800F
Basic settings, functions for arc welding, teaching
technic, etc.
APPLICATION MANUAL
(HANDLING)
1L8800G
Basic settings, functions for handling, teaching
technic, etc.
APPLICATION MANUAL
(SPOT WELDING)
1L8800E
Basic settings, functions for spot welding, teaching
technic, etc.

Instruction manuals are available other than the above for each optional function that you have purchased.

[Notes] 1. Specifications and information contained in these manuals are subject to change at any time without notice.
2. Optional hardware or software is necessary in order to use the function described as Optional in the
manual.
3. The screen display of a teach pendant shown in the manual are described as examples, which may be
different from the actual ones.
4. Although we cautiously compiled this standard specifications to eliminate as much error as possible, we do
not take any responsibility for damages resulting from neither direct nor indirect errors.
5. The manual is a part of robot products. When transferring or selling off a robot, be sure to append the
manual.
6. No part of this manual may be reproduced without permission.













- 3 -

(3) Instruction manuals related to the manipulator V/B series, and the robot control unit AX21 are as follows.

Standard Manuals
Instruction Manual Type
Instruction
Manual No.
Main Contents
INSTALLATION


1L20400A
Safety precautions, installing & connecting method,
starting up, periodical inspection, solution at the time
of failure
CONTROLLER MAINTENANCE/
STANDARD CONFIGURATIONS

1L20400B
Specifications of controller, explanation of each parts
and maintenance, parts list, etc.
MANIPULATOR
NB4 / NB4L / NV6 / NV6L / NV20
1L10460A
Specifications or maintenance of manipulator, parts
list, etc.
BASIC OPERATIONS


1L20400C
Explanation of manual operation, teaching, automatic
operation, file utilities, backing-up data, basic
operations of Arc/Spot welding application, etc.
REFERENCE (Built-in Tutorial)


1L20400D
Basic operations, terms, explanations of
Constants/Service menus, Details of function
command, list of short-cut code, parts replacing
procedure, trouble shooting, etc.
This manual is not provided as the paper manual,
but is built in the robot as Help tutorial function.
EXTERNAL INPUT/OUTPUT
1L20400H
Interfacing method with external control device, list of
I/O signals, start/halt the automatic operation, and
usage of software PLC, etc.

Application Manuals
Instruction Manual Type
Instruction
Manual No.
Main Contents
APPLICATION MANUAL
(ARC WELDING)
1L20400F
Basic settings, functions for arc welding, teaching
technic, etc.

Instruction manuals are available other than the above for each optional function that you have purchased.

[Notes] 1. Specifications and information contained in these manuals are subject to change at any time without notice.
2. Optional hardware or software is necessary in order to use the function described as Optional in the
manual.
3. The screen display of a teach pendant shown in the manual are described as examples, which may be
different from the actual ones.
4. Although we cautiously compiled this standard specifications to eliminate as much error as possible, we
do not take any responsibility for damages resulting from neither direct nor indirect errors.
5. The manual is a part of robot products. When transferring or selling off a robot, be sure to append the
manual.
6. No part of this manual may be reproduced without permission.


















Notice

About this manual

This instruction manual describes the installation and maintenance of Positioner headstock.
Read and understand the entire contents of this manual, with special emphasis on the safety devices,
before installing, operating or maintaining Manipulator, Robot Control Unit, and their positioner.
Manipulator, Robot Control Unit, their positioner and the relevant instructions are to be used only
by trained and experienced personnel for safety reasons. Do not allow untrained personnel to
install,operate, or maintain those products.

Notes on Safety

Before installation, operation, maintenance and inspection, be sure to read this manual and other attached
documents thoroughly and acquire all the knowledge of machines, safety information, and precautions.
If operating machines in a wrong way, the accident resulting in various ranks of injury or death, or damage may
occur.
In order to call attention to wrong handling, the following four ranks of safety notes (DANGER, WARNING,
CAUTION, and IMPORTANT) are provided.


DANGER

Cases where a mistake made in handling is likely to cause the user to be exposed to
the danger of death or serious injury and where the degree of the urgency
(imminence) of the warning given for the danger to occur is at the high end of the
scale (including high-level danger).


WARNING

Cases where a mistake made in handling is likely to cause the user to be exposed to
the danger of death or serious injury.


CAUTION

Cases where a mistake made in handling is likely to cause the user to be exposed to
the danger of minor injuries or of property damage only.

The following symbol is also used for particularly important checkpoints:


IMPORTANT
This is a particularly important checkpoint.

Note that even the matters which are described as CAUTION can result in serious accident depending on the conditions.
Be sure to keep the safety notes since they describe very important matters.


The meanings of Serious injury, Minor injury, and Damage described above are as follows.

Serious injury Injury which has the aftereffect by loss of eyesight, an injury, the burn (high/low
temperature), an electric shock, fracture, poisoning, etc. and that which requires
hospitalization and long-term treatment as an outpatient.

Minor injury Injury which does not require either hospitalization or long-term treatment as an outpatient,
a burn (high temperature, low temperature), and an electric shock.

Damage Direct and indirect damage in connection with damage of property and equipment.efore
- 4 -
Labels on Positioner



DAIHEN robot positioner is labeled with alarm signs for safe use.
Do not tear them off, damage them or cover. If it is the case, contact our engineers for
making an order.
For how to order, inquire of our sales engineers in your local area.

The following shows the alarm signs attached to positioner.

- 5 -

C o n t e n t s
1 Basic Specifications............................................................................................................................................................1
1.1 Basic Specifications......................................................................................................................................................1
1.2 Outside Dimensions......................................................................................................................................................3
1.3 Name of Each Parts......................................................................................................................................................5
1.4 Dimensions for Mounting on Table Face.......................................................................................................................5
1.4.1 Mounting a Load on Table (EX-1PB250/AX-1PB250/A-1PB250) .....................................................................5
1.4.2 Mounting a Load on the Table (EX-1PB500/AX-1PB500/A-1PB500) ...............................................................6
1.4.3 Mounting a Load on the Table (EX-1PB1000/AX-1PB1000/A-1PB1000)..........................................................6
2 Allowable Load...................................................................................................................................................................7
2.1 Maximum Allowable Load.............................................................................................................................................7
2.2 Payload Moment Diagram............................................................................................................................................7
2.3 Allowable Rotation Moment ..........................................................................................................................................9
2.4 Allowable Moment Of Inertia.........................................................................................................................................8
3 Installation Guidelines.......................................................................................................................................................11
3.1 Foundation.................................................................................................................................................................. 11
3.2 Environmental Requirements...................................................................................................................................... 11
3.3 Installing a Safety Fence............................................................................................................................................. 11
3.4 Installation method......................................................................................................................................................12
4 Transport Method.............................................................................................................................................................14
4.1 Positioner Transport Method.......................................................................................................................................14
5 Options .............................................................................................................................................................................15
5.1 Air Rotary J oint (Option)..............................................................................................................................................15
5.2 Equipped Cable (Option) ............................................................................................................................................16
5.2.1 Curl Code (Option) ............................................................................................................................................16
5.2.2 Slip Ring (Option)..............................................................................................................................................19
5.3 Tail stock (Option).......................................................................................................................................................25
5.3.1 Tail stock(L7090B).............................................................................................................................................20
5.3.2 1-axis double support positioner........................................................................................................................21
6 Grounding Method............................................................................................................................................................28
7 Maintenance.....................................................................................................................................................................29
7.1 Welding Current allowance........................................................................................................................................29
7.2 Maintenance of Collector (Collector Print Element)...................................................................................................29
7.3 Tension Adjustments of Timing Belts.........................................................................................................................30
8 Parts List for Maintenance................................................................................................................................................31
8.1 Parts List...................................................................................................................................................................31
8.2 Replacement Parts....................................................................................................................................................31
8.3 Lubricant ...................................................................................................................................................................31
8.4 Replacing Battery......................................................................................................................................................27
9 Internal Wiring of the Main Unit.........................................................................................................................................33
9.1 Electric Circuit Diagram.............................................................................................................................................33
10 Inspection Items................................................................................................................................................................35
11 Warranty...........................................................................................................................................................................35
11.1 Warranty Period.....................................................................................................................................................35
11.2 Deadline for Supplying/ Repairing the Robot Maintenance Parts..........................................................................36
-1-
1 Basic Specifications

1.1 Basic Specifications
Name Positioner Headstock
Type
EX-1PB250
AX-1PB250
A-1PB250
EX-1PB500
AX-1PB500
A-1PB500
EX-1PB1000
AX-1PB1000
A-1PB1000
Max.allowable load 250kg 500kg 1000kg
Max. Eccentricity of
Center of gravity
85mm
(loading capacity =250kg)
100mm
(loading capacity =500kg)
110mm
(loading capacity 1000kg)
Max. Height of
Center of gravity
520mm
(loading capacity =250kg)
540mm
(loading capacity =500kg)
600mm
(loading capacity =1000kg)
Rotation speed 25min
-1
2.6rad/sec 20min
-1
2.1rad/sec 12min
-1
1.3rad/sec
Allowable Rotation moment 206Nm 490Nm 1078Nm
Allowable Moment of inertia *2 4.6kgm
2
12.7kgm
2
37.4kgm
2
Rotation range
92 rotation
(EX-1PB250 standard spec.) *1
23 rotation
(AX/A-1PB250 standard
spec.) *1
129 rotation
(EX-1PB500 standard spec.) *1
32 rotation
(AX/A-1PB500 standard
spec.) *1
69 rotation
(EX-1PB1000standard spec.) *1
17 rotation
(AX/A-1PB1000standard
spec.) *1
Rotation axis repeatability 0.1mm (position at R300)
Rotation stopping position Any position
Detection of Rotation
stopping position
Absolute encoder
Rotation control Controlled by Robot control Unit
Mass (weight) 110kg 170kg 220kg
Allowable welding current 500A : Rated duty cycle 60%
Configurable control unit EX-C / AX-C / AX21 External Axes Controller
Applicable welding CO
2
, MAG, MIG
Installation method Installable on the 5 sides of a cabinet
Grounding Method It shall be independent from peripheral equipment and the resistance shall be less than 100 ohms.
Color Sky gray(EX-1PB250,500,1000) White(AX/A-1PB250,500,1000)
Ambient temperature / humidity
0~45, 20~80% (no condensation)
*1 The rotation range is limited to1 rotation if using Curl code Assy equipped type.
Endless rotation could be chosen as an option.
*2 The allowable moment of inertia is the allowable value where the load equivalent to the allowable load
moment has been added.

























Table 1.1 Optional Structure and Type
Type Optional Structure
EXPB251-E
AXPB251-E
A2PB251-E
EXPB501-E
AXPB501-E
A2PB501-E
EXPB1001-E
AXPB1001-E
A2PB1001-E
None (standard specification) *3
EXPB251-EA
AXPB251-EA
A2PB251-EA
EXPB501-EA
AXPB501-EA
A2PB501-EA
EXPB1001-EA
AXPB1001-EA
A2PB1001-EA
With Air-rotary joint Assy *4
EXPB251-EC
AXPB251-EC
A2PB251-EC
EXPB501-EC
AXPB501-EC
A2PB501-EC
EXPB1001-EC
AXPB1001-EC
A2PB1001-EC
With Air-rotary joint Assy +Curl code Assy
EXPB251-ES
AXPB251-ES
A2PB251-ES
EXPB501-ES
AXPB501-ES
A2PB501-ES
EXPB1001-ES
AXPB1001-ES
A2PB1001-ES
With Air-rotary joint Assy +Slip ring Assy
*3 Could change to a specification of EA, EC, or ES type with an option.
*4 Could change to EC or ES type by mounting Curl code Assy or Slip ring Assy afterward.







IMPORTANT

1. The positional repeatability is a measured value obtained when the manipulator operating conditions
are stabilized with the automatic operation of the manipulator repeated sufficiently.
2. The positional data are backed up by the battery in this positioner. The period of battery backup with the primary
power off is approximately 3 years.After this period, it is necessary to replace the battery and adjust the ABSO
position.
3. The battery backup period may be shorter depending on the environmental conditions, the operating
conditions and so on.
4. A holding brake is provided in this machines motor.
5. The above specifications are subject to change without notice.

-2-
1.2 Outside Dimensions


























Fig. 1.1 Outer Dimensions of EX-1PB250/AX-1PB250/A-1PB250 (mm)
































Fig. 1.2 Outer Dimensions of EX-1PB500/AX-1PB500/A-1PB500 (mm)
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Fig. 1.3 Outer Dimensions of EX-1PB1000/AX-1PB1000/A-1PB1000 (mm)





























Fig. 1.4 Outside Shape
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1.3 Name of Each Parts






















Inspection cover Origin marker
Service hole
Welding earth terminal Motor / Encoder connection
Fig. 1.5 Outside View


1.4 Dimensions for Mounting on Table Face

1.4.1 Mounting a Load on Table (EX-1PB250/AX-1PB250/A-1PB250)























Fig. 1.6 Mounting Dimensions on Table Side (mm)








100H7(depth:10)fitting can be used if the point mark on the table side is removed.
Holes, 8-M12 depth: 20 (P.C.D.250), are used as jig clamp screw holes.
Mounting bolts are to be prepared by the customer.
71 Penetrating hole on the center of a table can be used. However, the hole might be unusable
if options are mounted. (See Chap5. Option)
Mounting a Load on the Table Side
-5-
1.4.2 Mounting a Load on the Table (EX-1PB500/AX-1PB500/A-1PB500)



















Fig. 1.7 Mounting Dimensions on the Table Side (mm)










100H7(depth:10)fitting can be used if the point mark on the table side is removed.
Holes, 8-M16 depth: 25 (P.C.D.220), are used as jig clamp screw holes.
Mounting bolts are to be prepared by the customer.
71 Penetrating hole on the center of a table can be used. However, the hole might be unusable
if options are mounted. (See Chap5. Option)
Mounting a Load on the Table Side


1.4.3 Mounting a Load on the Table (EX-1PB1000/AX-1PB1000/A-1PB1000)

-6-


















Fig. 1.8 Mounting Dimensions on the Table Side (mm)








150H7(depth:15)fitting can be used if the point mark on the table side is removed.
Holes, 8-M16 depth: 30 (P.C.D.310), are used as jig clamp screw holes.
Mounting bolts are to be prepared by the customer.
116 Penetrating hole on the center of a table can be used. However, the hole might be unusable
if options are mounted. (See Chap5. Option)

Mounting a Load on the Table Side
2 Allowable Load
The mass of the load must be acceptable within both limits of the eccentricity of the center of gravity from the
rotation axis and the height of the center of gravity from the table.

2.1 Maximum Allowable Load

Type
Max.
allowable load
Allowable
rotation moment
Max. Eccentricity of
center of gravity
Max. height of
center of gravity
EX-1PB250
AX-1PB250
A-1PB250
250kg 206Nm 85mm 520mm
EX-1PB500
AX-1PB500
A-1PB500
500kg 490Nm 100mm 540mm
EX-1PB1000
AX-1PB1000
A-1PB1000
1000kg 1078Nm 110mm 600mm

2.2 Payload Moment Diagram



















Fig. 2.1 Allowable Payload Moment (EX-1PB250/AX-1PB250/A-1PB250)



















Fig. 2.2 Allowable Payload Moment (EX-1PB500/AX-1PB500/A-1PB500)


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Fig. 2.3 Allowable Payload Moment (EX-1PB1000/AX-1PB1000/A-1PB1000)
-8-
2.3 Allowable Rotation Moment

For the use of this Positioner, the rotational moment of each axis must be within the limit for the mass of the
maximum load. The rotational moment caused by the mass of the load is given by the following:

[Rotational moment (1)] =[Mass of Load] [Gravitational acceleration ]
-9-

Also, if any external force is applied to the load, the load moment acting on each axis is given from the
following.

[Rotational Moment (2)] =[Mass of Load][Eccentricity to the external force acting point]

A total of the above rotational moment (1) and (2) is the maximum rotational moment.

[Example calculation] analyzing type
Eccentricity of the center
of gravity
EX-1PB500/AX-1PB500/A-1PB500

Mass of the load =400kg, The height of the center of Gravity =150mm,
Eccentricity of the center of gravity =100mm, no external force

(1) Calculating the allowable rotation moment M
400 9.8 0.100
Mass (kg) Gravitational Acceleration (m/s
2
) Eccentricity of Center of gravity (m)
M =

=392Nm <490Nm Allowable Rotation Moment

(2) In addition to the above calculation of allowable rotational moment (1), it is necessary to examine the height of
the height of the center of load gravity from the table center.

Height of the center of gravity of the load 150mm <675mm Allowable Height of Center of Gravity (when 400kg
is boarded)

The determination value of (1) and (2) is under the allowable load.
Therefore, the operation of the work in the example is allowable.


Note) In case that the external forces are added as shown in Fig. 2.4
The determination of the added value of the center of gravity height and the moment by the external forces
is necessary.

[Example]

[Mass of Load] [Height of Center of Gravity (B) ] +[External Force] [Height to the External Forces acting point(C)]
500kg 0.1m
Mass of Max. Load Max. Height of Center of Gravity



External
force
A: Eccentricity of the center of gravity
B: Height of the center of gravity
C: Height to the external force acting point
D: Eccentricity of the external force acting point


















Fig. 2.4 Example of Positioner +Grinding Robot

2.4 Allowable Moment Of Inertia

If the diameter of the workpiece is large for the rotation axis which is centered on, considering the effect of the
moment of inertia is needed.
To decide the acceptable value of the moment of inertia for the moment, refer to the figures below.
If the value of the moment of inertia exceeds the value shown in the figures, contact us in advance.




100 200 300 400 500
10
20
30
40
0
50
60
59.5
12.7
490
(Nm)
Moment

Moment of inertia
(kgm^2)

Moment of inertia
(kgm^2)
(Nm)
Moment
50 100 150 200 250
5
10
15
20
4.6
20.3
206
0

Moment of inertia
(kgm^2)















Fig. 2.5 **-1PB250 Fig. 2.6 **-1PB500



100 200 300 400 500
20
40
60
80
0
100
600 700 800 900 1000
209
1100
1078
37.4
120
140
160
180
200
220
(Nm)]
Moment

Moment of inertia
(kgm^2)

E.g.1)
In the case of the moment of 600Nm for 1PB1000, the
allowable moment of inertia should be up to 110kgm
2
.





E.g.2)
In the case of the moment of 0Nm for 1PB1000, the allowable
moment of inertia should be up to 209kgm
2
.
(The turntable rotating in the horizontal plane is equivalent to
this condition.)























Fig. 2.7 **-1PB1000
-10-
3 Installation Guidelines

3.1 Foundation

Installation of the Positioner is the most important factor to maintain the proper Positioner functions. Particularly,
as well as the installation of the Positioner base, the foundation on which the base Is mounted Is Important to
secure the Positioner positioning accuracy and interpolation accuracy. In addition, for fixing the base, the
foundation must have a substantial strength to withstand the reaction force at acceleration / deceleration and the
static load. The ambient atmosphere is another consideration when installing the Positioner as It affects not only
the life of Positioner but also safety.


3.2 Environmental Requirements

Install the Positioner in the place that satisfies these conditions listed below.
(1) Environment which is not exposed to the sun and where the ambient temperature is 0 to 45
throughout the year.
(2) Environment where the humidity is not larger than RH80%.
(3) Environment which is free from dust, dirt, oily smoke, water,etc.
(4) Environment which is free from flammable or corrosive fluid or gas.
(5) Environment where shock or vibration caused by the operation of peripheral equipment Is not
larger than 0.5G at the positioner.
(G: gravitational acceleration, 1G =9.8 m/s
2
)
(6) Environment which has no large electrical noise sources( plasma, high frequency,etc)


3.3 Installing a Safety Fence

Be sure to install a safety fence around the manipulator and the peripheral devices (such as positioner) as
shown in Fig. 3.1 so that no careless or accidental access to the robot is allowed. Furthermore, install the control
unit, the operation box, the teach pendant, the starting box, and other devices outside the safety fence.


























Manipulator
Base
Robot Control unit
Welding power Supply
Safety Fence
Fig. 3.1 Installation Example

-11-
3.4 Installation method

The installation dimensions for the positioner headstock is shown below.
The mounting parts of the headstock have been worked on. Use them as a datum side and close unused
mounting tap hole with attached hole plug as is shown in Fig. 3.2.


















Fig. 3.2 Mounting Hole Plug

































Fig. 3.3 Installation Dimensions of EX-1PB250/AX-1PB250/A-1PB250
Bolt: Hex. Socket Head Cap Screw M16 (Strength Grade 12.9)
Clamping torque in mounting: 255 Nm
-12-



























Fig. 3.4 Installation Dimensions of EX-1PB500/AX-1PB500/A-1PB500
Bolt: Hex. Socket Head Cap Screw M20 (Strength Grade 12.9)
Clamping torque in mounting: 500 Nm






























Fig. 3.5 Installation Dimensions of EX-1PB1000/AX-1PB1000/A-1PB1000
Bolt: Hex. Socket Head Cap Screw M20 (Strength Grade 12.9)
Clamping torque in mounting: 500 Nm
-13-
4 Transport Method

4.1 Positioner Transport Method

Use a crane to transport this machine. In lifting up, use eyebolts and hook a rope using shackles.
The machine must be lifted up in the posture shown in Fig. 4.1.


























Fig. 4.1 Transport Method and Posture


Hook a rope on the eyebolt on the top of positioner headstock (EX-1PB250/AX-1PB250/A-1PB250 =M16,
EX-1PB500/AX-1PB500/A-1PB500,EX-1PB1000/AX-1PB1000/A-1PB1000 =M20) with shackles and
transport them using cranes.
The weight of the main unit of the positioner alone is listed below.

EX-1PB250/AX-1PB250/A-1PB250 : 110kg
EX-1PB500/AX-1PB500/A-1PB500 : 170kg
EX-1PB1000/AX-1PB1000/A-1PB1000 : 220kg

Note) In lifting up, use a rope and shackles with the specifications described below.
R o p e : Durable load more than 500kg, Length more than 1.0m
Shackle : Type SC-12, Durable load 900kg
-14-
5 Options

The 2 kinds of options, Air rotary joint and equipped cable, are provided for EX/AX/A-1PB series.
Also, when using a work by both durability support, Tailstock and a stand are prepared with the option. Use
them according to the use.

5.1 Air Rotary J oint (Option)

The placement of the air rotary joint enables the air drive machine on the table to be always provided with air
even when the table is rotating.
The usable air is: >maximum air pressure usage 1MPa.


Table 5.1 Air Rotary J oint Assy Specification
Type
EXPB251-EA
AXPB251-EA
A2PB251-EA
EXPB501-EA
AXPB501-EA
A2PB501-EA
EXPB1001-EA
AXPB1001-EA
A2PB1001-EA
Parts No. L6968H L7420E L7220E
Number of Port 4
Piping Connect Diameter External Diameter : 8mm (for polyurethane tube)
Adaptable Fluid Air
Max. Air Pressure Usage 1Mpa
Hollow hole Diameter 40mm

































Fig. 5.1 Outside Dimensions of Air Rotary J oint (mm)
-15-
5.2 Equipped Cable (Option)

The equipped cables can be stored in the center of the table for EX-1PB/AX-1PB/A-PB series.
One of the following 2 kinds of the equipment is usable with the air rotary joint as a signal (or as a drive) for the
peripheral devices on board of the table. Choose one according to the use.

5.2.1 Curl Code (Option)
Fig. 5.2 shows how the code is placed. Refer Table 5.3 for the use of equipped cable. Be careful that the
rotation is limited to 1 while placing the curl code.
Air rotary joint must be placed if the curl code is to be placed. Furthermore, make sure that the slip ring (in 5.2.2
5.2.3) cannot be placed if the curl code is placed.

Table 5.2 Curl Code Assy Specification
Type
EXPB251-EC
AXPB251-EC
A2PB251-EC
EXPB501-EC
AXPB501-EC
A2PB501-EC
EXPB1001-EC
AXPB1001-EC
A2PB1001-EC
Parts No. L6968J
Number of Conductor 12 (0.5mm
2
12)
Connecting Part
Fasten side: Receptacle MS3102A28-20P
Rotation side: 0.5mm
2
12 (crimp contact A1. 25-YS4A)
Accessories
Fasten side for connection Plug MS3106B28-20S
Cable clamp MS3057-16A
Hollow hole Diameter None

































Fig. 5.2 Outside Dimensions of Positioner / Curl Code (mm)
-16-

Red

White

Black

Gray

Orange

Blue

Brown

Yellow

Green

Brown/White mark

Red/White mark

Purple

Table 5.3 Equipped Cable Specifications
Number of Conductor 12
Cross section 0.5mm
2
Power capacity 1A
















Fig. 5.3 Wiring for Curl Code Specification

































Fig. 5.4 Outside Dimensions of EXPB251-EC/AXPB251-EC/A2PB251-EC (mm)
-17-




























Fig. 5.5 Outside Dimensions of EXPB501-EC/AXPB501-EC/A2PB501-EC (mm)































Fig. 5.6 Outside Dimensions of EXPB1001-EC/AXPB1001-EC/A2PB1001-EC (mm)
-18-
5.2.2 Slip Ring (Option 32-cores type)
Fig. 5.7 shows how the ring is placed. See Table 5.5 for the specification of the equipped cable. Note that the
rotation is changed to the endless rotation while placing the slip ring.
Air rotary joint must be placed if the slip ring is to be placed. Furthermore, make sure that the curl code (in
5.2.1) cannot be placed if the slip ring is placed.

Table 5.4 Slip Ring Assy Specification
Type
EXPB251-ES
AXPB251-ES
EXPB501-ES
AXPB501-ES
EXPB1001-ES
AXPB1001-ES
Parts No. L6968K
Number of Conductor 32 (0.3mm
2
16P)
Connecting Part
Fasten side: Receptacle MS3102A28-21P
Rotation side: 0.3mm
2
16 (no terminal processing)
Accessories
Fasten side for connection Plug MS3106B28-21S
Cable clamp MS3057-16A
Hollow hole Diameter None







































Fig. 5.7 Outside Dimensions of Slip Ring (mm)
-19-




Table 5.5 Equipped Cable Specifications
Number of wire core 32 cores
Cross section 0.3mm
2
Power Capacity
0.5A (within 1 minute)
0.3A (Continuously)
























Fig. 5.8 Wiring for Positioner and Slip Ring




























Fig. 5.9 Outside Dimensions of EXPB251-ES/AXPB251-ES (mm)
-20-






























Fig. 5.10 Outside Dimensions of EXPB501-ES/AXPB501-ES (mm)































Fig. 5.11 Outside Dimensions of EXPB1001-ES/AXPB1001-ES (mm)

-21-
5.2.3 Slip Ring (Option 36-cores type)

Fig. 5.12 shows how the ring is placed. See Table 5.7 for the specification of the equipped cable. Note that
the rotation is changed to the endless rotation while placing the slip ring.
Air rotary joint must be placed if the slip ring is to be placed. Furthermore, make sure that the curl code (in
5.2.1) cannot be placed if the slip ring is placed.


Table 5.6 Slip Ring Assy Specification
Type A2PB251-ES A2PB501-ES A2PB1001-ES
Parts No. L10545E
Number of Conductor 36 (0.3mm
2
18P)
Connecting Part
Fasten side: Receptacle MS3102A28-21P
Rotation side: 0.3mm
2
18P (no terminal processing)
Accessories
Fasten side for connection Plug MS3106B28-21S
Cable clamp MS3057-16A
Hollow hole Diameter None






































Fig. 5.12 Outside Dimensions of Slip Ring (mm)






-22-
Table 5.7 Equipped Cable Specifications
Number of wire core 36 cores
Cross section 0.3mm
2
Power Capacity 0.5A


-23-


























Fig. 5.13 Wiring for Positioner and Slip Ring




























Fig. 5.14 Outside Dimensions of A2PB251-ES (mm)































Fig. 5.15 Outside Dimensions of A2PB501-ES (mm)































Fig. 5.16 Outside Dimensions of A2PB1001-ES (mm)
-24-
5.3 Tail Stock (Option)
5.3.1 Tail stock (L7090B)

The tailstock to support the end of a long workpiece is available as an option.
The collector (L7090C) can be mounted as an option to the tailstock before shipment from the factory.
The collector capacity is 500A and the usage rate is 60 %.

































Fig. 5.17 Outside Dimensions of Tailstock(L7090B) (mm)






















Fig. 5.18 Outside Dimensions of collector(L7090C) (mm)
-25-
5.3.2 1-axis double support positioner

Tailstock provides support of stock when using the one axis head stock positioner. See Table5.8 for the
composition of 1-axis double support positioner.



Table 5.8 The composition of 1-Axis Double Support Positioner
Stand
Positioner Headstock Tailstock
Headstock side Tailstock side
EX-1PB250
AX-1PB250
A-1PB250
L7090D (Stand A) L7090D (Stand A)
EX-1PB500
AX-1PB500
A-1PB500
L7090E (Stand B) L7090D (Stand A)
EX-1PB1000
AX-1PB1000
A-1PB1000
L7090B
L7090E (Stand B) L7090F (Stand C)











Option
StandA
Baseplate
StandA
Tailstock
Headstock
EX-1PB250
AX-1PB250
A-1PB250



























Fig. 5.19 Outside Dimensions of EX-1PB250/AX-1PB250/A-1PB250 and Tailstock (mm)
-26-


























StandA
Option
Baseplate StandB
Tailstock
Headstock
EX-1PB500
AX-1PB500
A-1PB500
Fig. 5.20 Outside Dimensions of EX-1PB500/AX-1PB500/A-1PB500 and Tailstock (mm)

































Headstock
Tailstock
StandB
StandC
Option
Baseplate
AX-1PB1000
A-1PB1000
EX-1PB1000

Fig. 5.21 Outside Dimensions of EX-1PB1000/AX-1PB1000/A-1PB1000 and Tailstock (mm)

-27-
6 Grounding Method


For safety, install such an earth system as shown in Fig. 6.1.

(1) Be sure to connect the welding cable to the Work-side earth terminal provided beneath the c
onnection box of positioner.
(2) For the manipulator and the robot control unit, install each individual earth cable of 3.5mm
2
or larger.
For details, refer to the Instruction Manual, Control Unit.
(3) Ensure that the earth resistance Is not larger than 100 ohms.
(4) As shown in Fig.6.1, be sure to separate each of ,,, and , and never share It as an earth
cable or electrode for other power lines.
(5) For wiring of earth cables using metallic conduits, ducts and cable racks, follow the Electrical
Technical Standards in your country.
































Fig. 6.1 Grounding Method






-28-
7 Maintenance
7.1 Welding Current allowance

For welding a load on the positioner, the availability is determined by the collector capacitance of the collector
print element mounted at the positioner collector end and of the earth cable.
In this section, EX-1PB500/AX-1PB500/A-1PB500 is analyzed.
The conditions for welding a load on the positioner Include; collector capacitance of 500A and the rates
availability of 60%:

[Actual welding time (min.)]
<

0.6 ( 60% )

[Reference welding time: 10min.]

If the operation current is below the rating (500A), the allowable availability is given by the following:

[Allowable availability] =
(Rated current)
2

[Rated availability]


(Operation current)
2

[Example calculation]
(1) For using welding current 350A
[Allowable availability]

=
(500)
2

0.6 1.2 =120%
(350)
2

As the availability is over 100%, continuous welding is possible.

(2) For using welding current of (300A +300A)
[Allowable availability]

=
(500)
2

0.6 0.41 =41%
(300 +300)
2

Reference welding time: 10min. 0.41 =4.1min., Pause: 10min. 4.1min. =5.9min.
According to the availability of 41%, a 5.1min. pause is necessary following 4.1min. welding.
Welding exceeding the allowable availability may cause burnout of the collector print element, abnormal
heating of the table face, unstable arc, etc.


7.2 Maintenance of Collector (current-collecting brush)

Check periodically the amount of abrasion of a carbon chip mounted at the tip of the current collecting parts in
the collector. Make sure if V-channel at the rear end of current collecting shaft is above the datum level, and if
V-channel is hidden, replace with the new carbon chip.


















Current Collecting Device
Datum Level
Guide bars
V-channel
Carbon Chip
-29-
Fig. 7.1 Replacing Current Collecting Brush
7.3 Tension Adjustments of Timing Belts

Timing belts are used between the motor unit and the reduction gear in this positioner. Attaining smooth
transmission by the timing belts requires appropriate belt tension. For the adjusting method of the timing belts,
see the following instructions.

(1) Removing reverse side covers and belt covers will reveal the timing belts as shown in Fig. 7.2.
(2) To make their tension adjustments, loosen the four motor fixing bolts and the lock nut and adjust
the belt tension using the tension adjusting bolt.
(3) When the specified deflection value is obtained, lock the adjusting bolts with the lock nut, retighten
the motor fixing bolts with a clamping torque of 28.4Nm, and apply LOCKTITE to these bolts in
order to prevent them from loosening.

Table 7.1 Belt Deflection Values for Timing Belt tension Adjustments
Pressing Force Deflection
EX-1PB250
AX-1PB250
A-1PB250
6.9N 2mm
EX-1PB500
AX-1PB500
A-1PB500
EX-1PB1000
AX-1PB1000
A-1PB1000
15N 2.5mm






























Fig. 7.2 Tension Adjustments of Timing Belts
-30-
8 Parts List for Maintenance

8.1 Parts List

Major parts and components are shown in the table below.
Type Item Name DWG. No. & Model Parts No. Qty Remarks
W-L01503 5096-496 1
EX-1PB250
AX-1PB250 AC servo motor
W-L02150 -- 1 A-1PB250
Cyclo reduction
gear
W-L01409 5096-462 1
Timing belt W-L01414 5096-463 1
Grease Multemp FZ No.00 2670-051 -
Grease Shell, Albania EP-2 -
EX-1PB250
AX-1PB250
A-1PB250
Battery W-L01399 5096-434 1
W-L01504 5096-497 1
EX-1PB500
AX-1PB500 AC servo motor
W-L02150 -- 1 A-1PB500
Cyclo reduction
gear
W-L01410 5096-465 1
Timing belt W-L01415 5096-466 1
Grease Multemp FZ No.00 2670-051 -
Grease Shell, Albania EP-2 -
EX-1PB500
AX-1PB500
A-1PB500
Battery W-L01399 5096-434 1
W-L01504 5096-497 1
EX-1PB1000
AX-1PB1000
AC servo motor
W-L02150 -- 1 A-1PB1000
Cyclo reduction
gear
W-L01191B 5096-467 1
Timing belt W-L01416 5096-468 1
Grease Multemp FZ No.00 2670-051 -
Grease Shell, Albania EP-2 -
EX-1PB1000
AX-1PB1000
A-1PB1000
Battery W-L01399 5096-434 1

8.2 Replacement Parts
Location Parts Name DWG. No. & Model Parts No. Qty
Current collecting
Unit
Carbon chip
(Current collecting brush)
L6968D07
(EX/AX /A-1PB250)
(EX/AX /A-1PB500)
L6970D02
(EX/AX /A-1PB1000)
L6968D07


L6970D02
2
See Chap. 6.3
Current Collecting
Device (Current
Collecting Brush)
Maintenance
Cyclo reduction gear Grease Multemp FZ No.00 2670-051
500
g
Actual uptime of
6000 hours or 3
years




8.3 Lubricant
Ref. No. Lubrication location Lubricant
1 Pinion gear section Shell, Albania EP-2
2 Cyclo reduction gear Multemp FZ No.00








-31-
Fig. 8.1 Lubrication of Gear
8.4 Replacing Battery

This section describes the replacement procedures for battery as follows. (See Fig. 8.2)

(1) Perform check go/back operation in accordance with the basic posture check program <such as P9999>
and make sure that the reference position is in alignment with the matchmark <>. If that is not the case,
mark that position.
(2) Then, take out the connector plate of positioner.
(3) Remove the battery connector with the control power ON.
(4) Replace the battery with a new one. Replace with only DAIHEN Part No.5096-434.
(5) J oint a battery connector.
(6) Mount a connector plate.
(7) Perform check go/back operation in accordance with the basic posture check program <P9999>, and
make sure that the reference position will not change from that obtained in (1)above.
(8) Perform encoder reset operation at the basic posture check program <P9999>. Refer to the instruction
manual INSTALLATION-4.2 Configuration in the instruction manual MANIPULATOR (Rev 8 and after).
Also, see the aforementioned section to reset the encoder if the encoder data have been lost.





































Fig. 8.2 Replacing Battery
-32-
9 Internal Wiring of the Main Unit

9.1 Electric Circuit Diagram


























Motor(750W)
W-L01503
Fig. 9.1 Electrical Connection Diagram of EX-1PB250/AX-1PB250



Motor(1500W)
W-L01504
























Fig. 9.2 Electrical Connection Diagram of EX-1PB500/AX-1PB500 , EX-1PB1000/AX-1PB1000




-33-






























Fig. 9.3 Electrical Connection Diagram of A-1PB250/ A-1PB500/ A-1PB1000


-34-
-35-
10 Inspection Items

Inspection Maintenace
No.
Daily
3
months
1
year
3
years
6
years
Location Description Corrective Action
1 Entire outer appearance
Attached spatter, dust of
other foreign matter.
Visual check and cleaning
2 Matchmark panel Peeling, fracture Visual check
3 External cable
Scratches, soiling, loose
connectors
Visual check
4 Mounting bolt Loose bolts Retightening
5 Cannon plug Loose bolts Retightening
6 Carbon blush
Scratches, soiling and
loose connectors.
Abrasion Check.
Check visually and replace if
necessary.
Remove abrasion and clean.
7 Collector ring
Abnormality in the
Current-collecting ring
Visual check
Tester check
Visual check, inspection
and retightening.
Continuity test
8

Internal wiring
Replacement Replacement

Tension check

Check for abnormality
Tension adjustment
Replacing timing belt
Tension adjustment
9

Timing belt
Replacement Replacement
10 Gear
Grease replenishment.
Abnormality check.
Grease replenishment.
Replacing if the gear is
abnormal.
11 Reduction gear
Grease replenishment.
Abnormality check.
Grease replenishment.
Replacing if the gear is
abnormal.
12 Battery Replacement
Replacement
(See Chapter 8.4)
13 Rotary J oint(Option)
Scratches, soiling and
loose connectors
A lowering of air
pressure
Check visually, inspection.
Replacing if the rotary joint
is abnormal.

14 Slip Ring(Option)
Scratches, soiling and
loose connectors
Cable check
Check visually, inspection.
Replacing if the slip ring
is abnormal.
15 Overhaul
Inspection Replacement


















11 Warranty

11.1 Warranty Period

(1) We guarantee the robot system and provide the repair free of charge if the failures occurred within the shorter
-36-
period of the followings under the condition that the robot system has been properly operated and periodically
inspected as described in the instruction manual, and that the failures are due to the manufacturing defects.

The warranty period shall be:
14 months based on B/L date of its shipment of the products.
12 months in case of delivery to domestic customer that afterwards export our products outside of J apan.
Practical cumulative operating time of 2000 hours.

(2) However, the warrantee policy shall not apply to the following cases even when in the guarantee period.
Therefore, repairs will be charged.

(a) Failure due to misuse or operational error.
(b) Failure due to unauthorized repair or modification made by other than DAIHEN.
(c) Damage or failure due to natural disasters such as earthquake, fire and flood.
(d) Failure due to improper transfer or storage after delivery.
(e) Others similar to those above.
(f) Consumable and maintenance parts


11.2 Deadline for Supplying/ Repairing the Robot Maintenance Parts

DAIHEN will supply robot (including a positioner) maintenance parts for seven years and repair parts for ten
years from the discontinuation date of the product.

Repair of the parts is provided for the above-mentioned period in principle. However, DAIHEN will repair as
long as the stock is available.
DAIHEN will make our every effort to secure the parts. However, please note that it may become unavailable
due to the external factors such as the market situation even during the period of time. Your understanding
and cooperation in this regard is very much appreciated.







-37-
























































Positioner Headstock Instruction Manual

No. 1L7410A-E-1 SEPTEMBER 1, 2001 THE 1
st


EDITION
No. 1L7410A-E-2 J ULY 3 , 2003 THE 2
nd


EDITION
No. 1L7410A-E-3 OCTOBER 3 , 2007 THE 3
rd


EDITION
No. 1L7410A-E-4 MARCH 1 , 2009 THE 4
th


EDITION