No.

1L11120A-E-2

series

INSTRUCTION MANUAL
Positioner Headstock
AII-1PC500/1PC1000

Read and follow these instructions and all safety blocks carefully.
Have only trained and qualified persons install, operate, or service this unit.

Give this manual to the operator.

For help, call your distributor.

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.
Instruction manuals related to the manipulator V/B/H series, and the robot control unit AX21 are as follows.
Standard Manuals
Instruction Manual Type

Instruction
Manual No.

Main Contents

INSTALLATION

Safety precautions, installing & connecting method,

starting up, periodical inspection, solution at the time
of failure
Specifications of controller, explanation of each parts
and maintenance, parts list, etc.

1L20400A
CONTROLLER MAINTENANCE/
STANDARD CONFIGURATIONS
MANIPULATOR
NB4 / NB4L / NV6 / NV6L / NV20 / NH5
MANIPULATOR
(NV50)
MANIPULATOR
(NV133/NV166/NV210)
CONTROLLER INSTALLATION
AND MAINTENANCE
<ADDENDUM>(AX21-*C)
BASIC OPERATIONS

1L20400B

Specifications or maintenance of manipulator, parts

list, etc.
Specifications or maintenance of manipulator, parts
list, etc.
Specifications or maintenance of manipulator, parts
list, etc.
Specifications of controller, explanation of each parts
and maintenance, parts list, etc.

1L10460A
1L10752A
1L10753A
1L20407B

Explanation of manual operation, teaching, automatic

operation, file utilities, backing-up data, basic
operations of Arc/Spot welding application, etc.
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.
Interfacing method with external control device, list of
I/O signals, start/halt the automatic operation, and
usage of software PLC, etc.

1L20400C
REFERENCE (Built-in Tutorial)
1L20400D

EXTERNAL INPUT/OUTPUT
1L20400H

Application Manuals
Instruction Manual Type
APPLICATION MANUAL
(ARC WELDING)
APPLICATION MANUAL
(HANDLING)
APPLICATION MANUAL
(SPOT WELDING)
APPLICATION MANUAL
(SEALING)
APPLICATION MANUAL
(THERMAL SPRAYING)

Instruction
Manual No.

Main Contents
Basic settings, functions for arc welding, teaching
technic, etc.
Basic settings, functions for arc welding, teaching
technic, etc.
Basic settings, functions for arc welding, teaching
technic, etc.
Basic settings, functions for arc welding, teaching
technic, etc.
Basic settings, functions for arc welding, teaching
technic, etc.

1L20400F
1L20400G
1L20400E
1L20400K
1L21270S

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

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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.
7. Prohibited altering or remodeling
- Do not alter or remodel our products.
- You may get injured or have your equipment damaged because of fire, failure or malfunction caused by altering or
remodeling the product.

- The warranty does not cover any altered or remodeled products.

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TRAINING

COURSES

Manipulator, Robot Control Unit, their peripheral devices and the relevant instructions are to be used only by
trained and experienced personnel for safety reasons.
Therefore, DAIHEN Corporation provides various training courses such as the SAFETY, OPERATION,
MAINTENANCE and so on. For more details, contact your distributor or DAIHEN Corporation.

LIMITED WARRANTY
DAIHEN Corporation warrants our products against defects in parts and workmanship, which have occurred
under the appropriate service and maintenance conditions with the periodic inspections described in this
manual, for the shorter period of either 14 months after B/L date of shipment from Japan or 2000 hours of
actual working time from the date of delivery to the original user. This warranty shall be invalidated by any
abuse, misuse, misapplication or improper installation by users. DAIHEN, at its option, will repair or replace
any products during the warranty period, which DAIHEN, upon inspection, shall determine to be defective in
material and/or workmanship. The foregoing shall constitute the sole remedy for any breach of DAIHEN's
warranty.
DAIHEN MAKES NO WARRANTIES, EITHER EXPRESS OR IMPLIED, EXCEPT AS PROVIDED HEREIN,
INCLUDING WITHOUT LIMITATION THEREOF, WARRANTIES AS TO MARKETABILITY,
MERCHANTABILITY, FOR A PARTICULAR PURPOSE OF USE, OR AGAINST INFRINGEMENT OF ANY
PATENT. IN NO EVENT SHALL DAIHEN BE LIABLE FOR ANY DIRECT, INCIDENTAL OR
CONSEQUENTIAL DAMAGES OF ANY NATURE, OR LOSSES OR EXPENSES RESULTING FROM ANY
DEFECTIVE PRODUCT OR THE USE OF ANY PRODUCT.

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Notice
Notes on Safety
Before installation, operation, be sure to read "Chapter 1 Points on Safty" in INSTALLATION manual and other
attached documents thoroughly and acquire all the knowledge of machines, safety information, and precautions.
Furthermore, before maintenance, inspection, and trouble scene, be sure to read CONTROLLER
MAINTENANCE manual and MANIPULATOR 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).

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

WARNING

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.

CAUTION
The following symbol is also used for particularly important checkpoints:

This is a particularly important checkpoint.

IMPORTANT

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.

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Labels on Headstock
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.

WARNING

? ? ?

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-6-

Contents
1

4
5

6
7

9
10
11

Basic Specifications ...........................................................................................................................................1

1.1 Basic Specifications.................................................................................................................................1
1.2 Outside Dimensions ................................................................................................................................2
1.3 Name of Each Parts ................................................................................................................................3
1.4 Dimensions for Mounting on Table Face .................................................................................................4
Allowable Load...................................................................................................................................................7
2.1 Maximum Allowable Load........................................................................................................................7
2.2 Payload Moment Diagram .......................................................................................................................7
2.3 Allowable Rotation Moment.....................................................................................................................8
2.4 Allowable Moment Of Inertia ...................................................................................................................9
2.5 How to check the load Moment .............................................................................................................10
Installation Guidelines......................................................................................................................................15
3.1 Foundation.............................................................................................................................................15
3.2 Environmental Requirements ................................................................................................................15
3.3 Installing a Safety Fence .......................................................................................................................15
3.4 Installation method.................................................................................................................................16
Transport Method.............................................................................................................................................18
4.1 Positioner Transport Method .................................................................................................................18
Options.............................................................................................................................................................19
5.1 Equipped Cable (Option) .......................................................................................................................19
5.1.1 Curl Cord (Option) ..........................................................................................................................19
5.1.2 Rotary Joint (Option) ......................................................................................................................21
5.2 Tail Stock (Option) .................................................................................................................................23
5.2.1 Tail stock (L7090B).........................................................................................................................23
5.3 Other Options ........................................................................................................................................25
5.3.1 Connector Cover (L11120G) ..........................................................................................................25
5.3.2 Point Mark ......................................................................................................................................25
Grounding Method ...........................................................................................................................................26
Periodic Inspection...........................................................................................................................................27
7.1 Periodic Inspection ................................................................................................................................27
7.1.1 Sety Measures for Inspection, Maintenance, Adjustments and Repairs of the Positioner.......................................27
7.1.2 Periodic Inspection Schedule .........................................................................................................29
7.1.3 Notes on Periodic Inspection .........................................................................................................29
7.2 List of Maintenance Items......................................................................................................................30
Maintenance.....................................................................................................................................................31
8.1 Maintenance of Collector (current-collecting brush)..............................................................................33
8.2 Grease Replacement Procedure for Reduction Gears .........................................................................33
8.3 Replacing Battery ..................................................................................................................................35
Parts List for Maintenance ...............................................................................................................................36
9.1 Parts List................................................................................................................................................36
Internal Wiring of the Main Unit........................................................................................................................37
10.1 Electric Circuit Diagram .........................................................................................................................37
Warranty...........................................................................................................................................................38
11.1 Warranty Period.....................................................................................................................................38
11.2 Deadline for Supplying/ Repairing the Robot Maintenance Parts .........................................................38

1 Basic Specifications
1.1 Basic Specifications

Rotation range
Allowable moment
Allowable moment of inertia

Table 1.1.1 Basic Specification

Positioner Headstock
1PC500
1PC1000
500kg
1000kg
100mm
110mm
(loading capacity =500kg)
(loading capacity =1000kg)
300mm *3
600mm *3
(loading capacity =500kg)
(loading capacity =1000kg)
20min-1
12min-1
2.1rad/sec
1.3rad/sec
370*1
490Nm
1078Nm
2
37.4kgm2 *2
12.7kgm *2

Drive system
Rotation axis repeatability
Position feedback

AC servo motor 1.2 kW

0.1mm (position at R300)
Absolute encoder

Name
Max.allowable load
Max. Eccentricity of
Center of gravity
Max. Height of
Center of gravity
Rotation speed

Mass (weight)
Allowable welding current
Installation type
Grounding Method
Color
Ambient temperature / humidity

110kg
193kg
(with rotary joint :114kg)
(with rotary joint :197kg)
500A : Rated duty cycle 60%
Floor installation
Exclusive grounding equivalent to Class D or higher grounding
White
0~45, 20~80% (no condensation)
(1N=0.102kgf)

*1 Endless rotation could be chosen as an option.

Endless rotation couldnt be chosen if using Curl cord Assy equipped type.
*2 The allowable moment of inertia is the allowable value where the load equivalent to the allowable load
moment has been added.
*3 The eccentricity of the center of gravity and the height of center of gravity have the limitation in the
combination. Please refer to Chap 2 Allowable Load for details.
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.

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Table 1.1.2 Optional Structure and Type

Optional Structure
PC501- A
PC1001- A
None (standard specification) *4
PC501- A C
PC1001- A C
With Curl cord Assy
PC501- A S
PC1001- A S
With Rotary joint Assy
*4 Could change to a specification of EC, or ES type with an option.
Type

1.2 Outside Dimensions

Fig. 1.2.1-1 Outer Dimensions of 1PC500-A

(mm)

Fig. 1.2.1-2 Outer Dimensions of 1PC1000-A

(mm)

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Fig. 1.2.2 Outside Shape (1PC500/1PC1000)

1.3 Name of Each Parts

Fig. 1.3.1 Outside View (1PC500/1PC1000)

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1.4 Dimensions for Mounting on Table Face

Fig. 1.4.1-1 Mounting Dimensions on Table Side of 1PC500 (mm)

Mounting a Load on the Table Side of 1PC500

100H7(depth:10)fitting can be used on the center of table.

Holes, 8xM16 depth: 20(P.C.D.220) and 6xM12 depth: 20 (P.C.D.418), are used as jig clamp screw holes.
Mounting bolts are to be prepared by the customer.
55 center hole on the center of a table can be used. However, the hole might be unusable if options are
mounted. (See Chap5. Option)
Use the fixing bolts (M16 and M12, Intensity:12.9) and fix by a tightening torque (M16:255Nm;M12:103 N
m). Adjust the bolts to make it long about (M16:16mm~20mm; M12:12mm~30mm).
When the length of the bolts exceeds the valve mentioned in above, the interference between the bolts and
the reduction gear on the other side will cause the positioner to malfunction.

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Fig. 1.4.1-2 Mounting Dimensions on Table Side of 1PC1000 (mm)

Mounting a Load on the Table Side of 1PC1000

150H7(depth:15)fitting can be used on the center of table.

Holes, 8xM16 depth: 24(P.C.D.310) and 6xM12 depth: 20 (P.C.D.508), are used as jig clamp screw holes.
Mounting bolts are to be prepared by the customer.
75 center hole on the center of a table can be used. However, the hole might be unusable if options are
mounted. (See Chap5. Option)
Use the fixing bolts (M16 and M12, Intensity:12.9) and fix by a tightening torque (M16:255Nm;M12:103 N
m). Adjust the bolts to make it long about (M16:16mm~24mm; M12:12mm~30mm).
When the length of the bolts exceeds the valve mentioned in above, the interference between the bolts and
the reduction gear on the other side will cause the positioner to malfunction.

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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, 1PC500 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:
(Rated current)2

[Allowable availability] =

(Operation current) 2

[Example calculation]
(1) For using welding current 350A
(500)2
[Allowable availability] =
(350) 2

[Rated availability]

0.6

1.2 = 120%

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

(2) For using welding current of (300A + 300A)
(500)2
0.6
[Allowable availability] =
(300 + 300) 2

0.41 = 41%

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.

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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

Table 2.1.1 Max Allowable Load
Type

Max.
allowable load

Allowable
moment

Allowable moment
of inertia

Max. Eccentricity of
center of gravity

Max. height of
center of gravity

1PC500
500kg
100mm
300mm
490Nm
12.7 kgm2
1PC1000
1000kg
110mm
600mm
1078Nm
37.4 kgm2
The eccentricity of the center of gravity and the height of center of gravity have the limitation in the
combination. (See Fig.2.2.2)

2.2 Payload Moment Diagram

Fig. 2.2.1 Eccentricity of center of gravity and height of center of gravity

a) 1PC500

b) 1PC1000
Fig. 2.2.2 Allowable Payload Moment

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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 ]

Eccentricity of the center

of gravity

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

1PC500

Mass of the load = 400kg, The height of the center of Gravity = 300mm,
Eccentricity of the center of gravity = 100mm, no external force

(1) Calculating the allowable rotation moment M

M=

400

Mass (kg)

9.8

Gravitational Acceleration (m/s2)

0.100

Eccentricity of Center of gravity (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 300mm <368mm Allowable Height of Center of Gravity (when 400kg
is boarded, the eccentricity of the center of gravity is 100 mm from Fig.2.2.1)
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. 2.3.1.
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)]

0.3m

500kg
Mass of Max. Load
Max. Height of Center of Gravity

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

External
force
Fig. 2.3.1 Example of Positioner + Grinding Robot
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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.
The warranty doesnt cover when the moment and the moment of inertia exceeds the permissible value shown
in the figure.

Moment of inertia
(kgm^2)
60
59.5

E.g.)
In the case of the moment of 200Nm for 1PC500, the allowable
moment of inertia should be up to 40kgm2.

50
40
30
20
12.7
10

100

200

300

400

500
490

(Nm)
Moment
Fig. 2.4.1-1 1PC500 Moment and moment of inertia

Moment of inertia
(kgm^2)
220

E.g.)
In the case of the moment of 600Nm for 1PC1000, the
allowable moment of inertia should be up to 110kgm2.

209
200
180
160
140
120
100
80
60
40
37.4
20

100

200

300

400

500

600

700

800

900

1000 1100
1078

(Nm)]
Moment

Fig. 2.4.1-2 1PC1000 Moment and moment of inertia

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2.5 How to check the load Moment

It is necessary to check with the oscilloscope function if the load status meets the positioners
specification.
For details of the oscilloscope function, refer to the instruction manual for OSCILLOSCOPE FUNCTION.
If the load conditions have been changed, be sure to reconfirm the latest status.
* Be sure to confirm that all the measurement results in each movement pattern described below meet
the reference value prescribed in (4).
If not, reconsider and modify the jigs or others to meet the conditions. Note that the use of positioner
out of the specifications if problems occur is exempt from the warranty.
(1) Measurement procedures
Measurement procedures are as follows.
Teaching the motion in measurement
Measuring the current
Evaluating the measurement results
(2) Teaching the motion in measurement
If the actual motion posture is not available, take a similar posture instead prescribed in each
pattern.
When the max. motion range in measurement is not available, move the positioner fully at least
within the range.
Measure the following patterns 1, 2, and 3.
(a) Pattern 1Measure the maximum current.
(b) Pattern 2Measure the eccentric load holding current.
(c) Pattern 3Check if not exceeding the overload detection level with the actual motion pattern.
Ambient conditions Shall be at room temperature (around 20).
When the ambient temperature is too low, move the robot several times in advance before
measurement.

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aMovement pattern 1180reciprocating motion

Teach speed
motion
Accuracy levelA8

Start/Stop point shall be at

the horizontal position on the
right side viewed from the
front where the max. eccentric
load applied.

Passing through
overhead

Fig.2.5.1

Turnaround point shall be

at the horizontal position
on the left side viewed
from the front where the
max. eccentric load applied.

Action pattern 1

bMovement patternThe upswing stop action.

Teach speed
motion
Accuracy levelA8

Start/Stop point shall be at the

horizontal position on the right
side viewed from the front
where the max. eccentric load
applied. Then, move the
workpiece 2 upwards and turn
it around.

Again, turn around the

workpiece when it
reaches the horizontal
position on the right
side.

Fig.2.5.2

Hold the workpiece in the

position 2 up from the original
start position.

Action pattern 2

c Movement pattern 3 Actual motion pattern

Repeat the actual motion for a couple of cycles (about 1 min.) with the oscilloscope stand-by. Then, resume
measuring during motion without pause. If 1 cycle takes a long time, resume measuring soon after the motion of
1minute or longer.

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(3) Measuring the current and speed

Use the oscilloscope function provided in the robot controller to measure the following items. Assign the
speed to CH1, Q phase current to CH2, A.P. monitor #1 to CH3, and A.P. monitor #2 to CH4.
To measure the current for detecting the overload, set the A.P. monitor #1 at 965(real number) and the
A.P. monitor #2 at 966(real number).
Also, set the sampling frequency for all the patterns 1, 2, and 3 at 100Hz (approx. 10 seconds).
For details of the operation, refer to Instruction Manual for OSCILLOSCOPE FUNCTION No. 1L21270V.
Table 2.5.1 CH assignment
Data
Sampling
Action
frequency
1
Servo
Speed
100Hz
Pattern1, 2 and 3
2
Servo
Q phase
100Hz
Pattern1, 2 and 3
3
Servo
A.P. monitor #1
100Hz
Pattern1, 2 and 3
4
Servo
A.P. monitor #2
100Hz
Pattern1, 2 and 3
* For the Movement pattern 3, you are recommended to measure within the range of 100Hz although it is
possible to modify the sampling frequency and expand the measurement period of time.
CH

Type

(4) Evaluating the measurement results

Confirm that all the measurement results as instructed for each pattern meet the reference values as
below.
If not, reconsider and modify the jigs and others to meet the conditions. Note that use of the positioner
out of the specifications if problems occur is exempt from the warranty.
[1PC500]
(a) Pattern 1 Q phase current of CH2 is between -18A and 18A.
(b) Pattern 2 Q phase current of CH2 after the motion stop is stabilized between -9.7A and 9.7A.
(c) Pattern 3 Value of the A.P. monitor #1 has not exceeded that of the A.P. monitor #2.
[1PC1000]
(a) Pattern 1 Q phase current of CH2 is between -18A and 18A.
(b) Pattern 2 Q phase current of CH2 after the motion stop is stabilized between -12.2A and12.2A.
(c) Pattern 3 Value of the A.P. monitor #1 has not exceeded that of the A.P. monitor #2.

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* Measurement result <Sample 1> (Pattern 1)

CH2 is set to the Q phase current

of J1 axis, therefore stays between
-16.77A and 16.86A. This meets
the specified range: -18A ~ 18A.
(1PC500)

* Measurement result <Sample 2> (Pattern 2)

CH2 is set to the Q phase current

of J1 axis of which current value
after the motion stop is stabilized
at -8.78A. This meets the specified
range: -9.7A ~ 9.7A.
(1PC500)

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* Measurement result <Sample 3> (Pattern 3)

The display position and scale for

each CH can be arbitrarily set.
Read the value of CH3 and CH4,
and make sure that satisfies CH4
> CH3.
(1PC500)

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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/s2)
(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 guarding fence.

Guarding Fence

Base

Manipulator

Robot Control unit

Welding power Supply
Guarding fence

ISO 13852 (EN294): Safety of machinery

- Safety distances to prevent danger zone being reached by the upper limbs.

Fig. 3.3.1 Installation Example

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3.4 Installation method

The installation dimensions for the positioner headstock are shown below.
Reference planes (worked surface) are prepared in the mounting parts of the headstock. Please use it in
installing the positioner.

View A
A

Fig. 3.4.1-1 Installation Dimensions of 1PC500

View A
A

Fig. 3.4.1-2 Installation Dimensions of 1PC1000

-16-

Movements of the positioner cause a large force of inertia, requiring the installation floor to be strong and rigid.
Therefore, when the positioner and jigs are to be mounted together on the same common frame base, the frame
base must be at least 20 mm in thickness and the positioner must be firmly fixed using four pieces (six pieces) of
hexagon socket head cap screws, spring washer and washer with a tightening torque of 215 N*m. For the
mounting method of the positioner on the base, see Fig 3.4.2.

Fig. 3.4.2 Installing the Positioner Directly on Common Frame Base

-17-

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. In the
carrying task, take enough care not to damage the cover with shackles and wire rope.
The machine must be lifted up in the posture shown in Fig. 4.1.1.

Fig. 4.1.1 Transport Method and Posture

Hook a rope on the eyebolt on the top of positioner headstock (1PC500 = M12/1PC1000 = M16) with shackles
and transport them using cranes.
The weight of the main unit of the positioner alone is listed below.
1PC500: 110kg
1PC1000: 193kg
Note) The position of the center of gravity is as shown in Fig 4.1.1. (The center of gravity of 1PC500 and
1PC1000 are almost at the same position.)
Exceeding tilting angle can possibly cause flip-over. Be caution when installation.
Please take the fall prevention when temporarily put the positioner.

-18-

5 Options
The 2 kinds of equipped cable option are provided for 1PC 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.

DANGER

Do not alter or remodel our products.

You may get injured or have your equipment damaged because of fire,
failure or malfunction caused by altering or remodeling the product.
The warranty does not cover any altered or remodeled products.

5.1 Equipped Cable (Option)

The equipped cables can be stored in the center of the table for 1PC 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.

5.1.1 Curl Cord (Option)

Fig. 5.1.1 shows how the cord is placed. Refer Table 5.1.1.2 for the use of equipped cable.
Furthermore, make sure that the rotary joint (in 5.1.2) cannot be placed if the curl cord is placed.
Table 5.1.1.1 Curl Cord Assy Specification
PC501-AC
PC1001-AC
L11120J00
L11135G00
12 (0.5mm212)
Stationary side: Receptacle MS3102A28-20P
Connecting Part
Rotation side: 0.5mm212 (crimp contact A1. 25-YS4A)
Stationary side for connection Plug MS3106B28-20S
Accessories
Cable clamp MS3057-16A
Center hole Diameter
None

Type
Parts No.
Number of Conductor

Fig. 5.1.1.1 Outside Dimensions of Curl Cord (mm)

-19-

Table 5.1.1.2 Equipped Cable Specifications

Number of Conductor
12
Cross section
0.5mm2
Power capacity
1A

Fig. 5.1.1.2 Wiring for Curl Cord Specification

-20-

5.1.2 Rotary Joint (Option)

Fig. 5.1.2.1 shows how the rotary joint is placed. See Table 5.1.2.2 for the specification of the equipped cable.
Note that the rotation is changed to the endless rotation while placing the rotary joint.
Furthermore, make sure that the curl cord (in 5.1.1) cannot be placed if the rotary joint is placed.
Table 5.1.2.1 Rotary Joint Assy Specification
Type
Parts No.
Number of Conductor
Connecting Part
Accessories
Voltage
(Max)
Current
(Max)
Piping Connect Diameter
Number of Port
Allowable Fluid
Rated Working Pressure
Max. Allowable Working Pressure

Center hole Diameter

PC501-AS
PC1001-AS
L11120H00
L11135F00
2
6 (0.75mm 6C)
Stationary: Receptacle MS3102A28-20P
Rotation side: 0.75mm26C (no terminal processing)
Stationary side for connection Plug MS3106B28-20S
Cable clamp MS3057-16A
100V DC/AC
2.0A(continuously)
External Diameter : 8mm (for polyurethane tube)
2
Air (Water is unusable)
0.49 Mpa
0.98Mpa (Max.1 hour without stopping)
None

Fig. 5.1.2.1 Outside Dimensions of Rotary Joint (mm)

-21-

Table 5.1.2.2 Equipped Cable Specifications

Number of wire core
6 cores
Cross section
0.75mm2
Power Capacity
2.0A

Fig. 5.1.2.2 Wiring for Positioner and Slip Ring

-22-

5.2 Tail Stock (Option)

5.2.1

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. 5.2.1.1 Outside Dimensions of Tailstock(L7090B)

(mm)

Fig. 5..2.1.2 Outside Dimensions of collector(L7090C)

(mm)

-23-

PC

The stands are prepared by the customer.

Fig. 5.2.1.3-1

Installation Example of 1PC500 (mm)

PC

Fig. 5.2.1.3-2

Installation Example of 1PC1000 (mm)

-24-

5.3 Other Options

5.3.1

Connector Cover (L11120G)

The connector cover is used for preventing the spatter deposition to the cable connections.

Fig. 5.3.1.1 Outside Dimensions of Connector Cover (mm)

5.3.2

Point Mark
For 1PC500: L11120N
For 1PC1000: L11135H

-25-

6 Grounding Method
For safety, install such an earth system as shown in Fig. 6.1.
(1)
(2)
(3)
(4)
(5)

Be sure to connect the welding cable to the Work-side earth terminal of the positioner.
For the manipulator and the robot control unit, install each individual earth cable of 3.5mm2 or larger.
For details, refer to the Instruction Manual, Control Unit.
Ensure that the earth resistance Is not larger than 100 ohms.
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.
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

-26-

7 Periodic Inspection
7.1 Periodic Inspection
7.1.1

Sety Measures for Inspection, Maintenance, Adjustments and Repairs of the Positioner

To perform inspection, maintenance, adjustments, repairs or other similar work on the positioner, access to
the robot (including a positioner) working range may be required, or work with the primary-side power or the
servo power turned on may be necessary. In any case, be sure to observe the following precautions for
inspection, maintenance, adjustments and repairs.

DANGER

WARNING

WARNING

WARNING

Do not alter or remodel our products.

You may get injured or have your equipment damaged because of fire,
failure or malfunction caused by altering or remodeling the product.
The warranty does not cover any altered or remodeled products.

Whenever the power is ON, never enter the robot working range.
Approaching the operating robot may result in a fatal injury.

Never touch any charged parts.

Touching any charged part may result in a fatal electric shock hazard or burn.

Never put your hand, finger, hair, clothes or the like close to any rotating section.
Putting your hand, finger, hair or clothes close to the wire feed roll of the wire feed
unit may cause you to get caught, resulting in a serious injury.
Similarly, putting your hand, finger, hair or clothes close to the rotating section of a
cooling fan may cause you to get caught and hurt.

(1) Prior to carrying out robot inspection, maintenance, adjustments, repairs, etc., be sure to wear a helmet,
safety shoes, gloves and other protective means that may be deemed necessary, as specified by law.
To be more specific, wear clothes that are suited to each specific work.
(2) Prior to initiating work, press the EMERGENCY Stop button or the Stop button to check if the robot system
stops instantly. Furthermore, if a safety plug, a dead man switch or other protective devices are added to
the robot system, they must be checked for proper operation. Should any fault be detected, stop the
inspection work, turn off the primary power immediately, check for causes and take necessary
countermeasures accordingly.
(3) Ensure that personnel who are not operating the robot must not approach the guarding fence.
(4) Prior to starting work, put up a sign Under Inspection
at a visible place to let people around the robot system
know that inspection is now being carried out.

Under Inspection

(5) Do not use any equipment that may generate electromagnetic noises, in and around the place where
inspection is being performed.
(6) At least two workers should be involved in the inspection or maintenance work, one performing actual work
and the other serving as a watcher.
(7) Personnel to be involved in robot inspection, maintenance, adjustment and/or repairs should receive instructions and
training on robot functions, operation and maintenance. In addition, if special equipment or facilities are provided in the
robot system, then their entire mechanism must also be fully understood.

-27-

(8) Robot inspection, maintenance, adjustment and repairs must be performed by only those who are qualified
by receiving special training. Furthermore, even if they have received such special training, they are not
allowed to perform inspection, maintenance, adjustment or repairs of other machinery that they are not fully
familiar with.
(9) Any sign that may be given to workers, watchmen and/or operators of related machines must be in
conformity with the Customers safety management standards.
(10) The watcher must observe the following. He shall:
(A) Stand at a place that commands a view of the entire robot working range, and devote himself to the
duty of watching the work.
(B) Always hold the EMERGENCY Stop button, and press it immediately whenever any abnormality
occurs.
(C) Make sure that people other than those who are involved in inspection, etc. do not come close to the
robot working range.
(11) The workers to be involved in inspection or other work must observe the following.
(A) If work can be carried out outside the robot working range, specify the work details prior to starting the
work. In any case, be sure that work is done outside the robot working range.
(B) In principle, perform inspection, etc., with the robot stopped. However, if such inspection or other work
is inevitably required during robot operation, then be sure to report this to the responsible safety
manager, and with permission obtained, perform the work outside the robot working range.
(C) If the robot is required to be in an operable condition when performing inspection work or the like,
specify the work procedure details beforehand so that safe work can be efficiently proceeded with.
Furthermore, if work is not particularly required to be performed in the robot operable condition, carry
out the work with the robot controller, the welding power supply and/or other input-side power supplies
all turned off. If no special safety procedure is required, be sure to turn off such input-side power
supplies for jigs and peripheral equipment or to make them inactive.
(D) When working in the robot working range, be sure you are always in a ready-to-act posture so that you
can immediately press the EMERGENCY Stop button just in case of robot malfunction.
(E) Carefully check your footing before starting work. Be sure to avoid an unstable scaffold or a scaffold
provided at an elevated position (more than 2 meters high).
(F) When you are in the robot working range, do not perform work with your back facing the positioner.
(G) To replace PCBs provided in the robot controller or the teach pendant, take anti-static electricity
countermeasures including anti static electricity sheets.
(12) If any abnormal condition has occurred during work, carefully perform the following procedure.
(A) If any malfunction is observed on the robot system, immediately press the EMERGENCY Stop button.
(B) Immediately report this to the watcher, turn off the control power
of the robot controller, then put up a sign Do not switch on.

Do not Switch ON

(C)Be sure to check that all the related machines are stopped.
(D) When necessity arises to go inside the guarding fence, be sure that the person who is going to enter
pulls out the safety plug himself, carries it with him and proceeds with the work concerned.
(E) Even when the robot has automatically stopped due to a fault in supply voltage to the robot system,
hydraulic pressure or air pressure of related equipment, make sure that it is at a complete stop, then
investigate causes to take necessary countermeasures.
(F) If the EMERGENCY Stop switch or other safety devices should have failed to operate, immediately
turn off the primary power, investigate causes and take necessary countermeasures.
(G) To restart the robot after stopping it by pressing the EMERGENCY Stop button, investigate causes,
take necessary countermeasures, replace the safety plug, then restart it from outside the guarding
fence.
(13) To end the work, carefully check that the necessary connectors, covers, panels, etc. have been all
correctly mounted and wired.
-28-

7.1.2

Periodic Inspection Schedule

The periodic inspection is indispensable in order to continue operating 1PC500 Positioner in a safe and an
efficient manner. Perform the periodic inspection in accordance with the following schedule.
Be sure to overhaul in either a period of whole 6 years or 30,000 cumulative operating hours after delivery,
whichever is shorter.
The inspection and maintenance period is estimated, supposing the positioner only for Arc welding use. For
more frequent use such as handling operation, that period may be shorter. Contact to our engineers for details.

1yr
Inspection
3mths
Inspection

3mths
Inspection

3mths
Inspection

3mths
Inspection

3yrs
Maintenance
1yr
Inspection

1yr
Inspection
3mths
Inspection

3mths
Inspection

3mths
Inspection

3mths
Inspection

3mths
Inspection

3mths
Inspection

3mths
Inspection

3mths
Inspection

27mths

30mths

33mths

3yrs

Daily Inspection
0

3mths

7.1.3

6mths

9mths

1yr

15mths

18mths

21mths

2yrs

Notes on Periodic Inspection

(1) Periodic inspection must be performed by those who have received the special training program by the
Government or DAIHEN Corporation and maintenance instructions offered by DAIHEN Corporation, or at
their presence (Under the Regulations on Industrial Robots: Article 19 and Paragraph 32 of Article 36).
(2) Prior to performing inspection or maintenance, be sure to turn off the external breaker.
Note that, with turning off only the non-fuse breaker of the robot controller, the primary side of the non-fuse
breaker is still being applied with voltage.
In order to show that inspection or maintenance is underway, hang a noticeable sign on the switch of the
external breaker.

Never touch the charged parts.

WARNING

WARNING
ELECTRIC SHOCK
can kill.
Do not touch live electrical
parts.

Disconnect all power

before installing or servicing.

Multiple sources of voltage

may exist inside this
enclosure.
NK3637

-29-

7.2 List of Maintenance Items

Table7.2.1 List of maintenance items(1PC500/1PC1000 in common)
No.

Inspection
3
1
Daily
months

year

Maintenance
3
6
years

Location

Mounting bolt
Cannon plug

Attached spatter, dust of

other foreign matter.
Peeling, fracture
Scratches, soiling, loose
connectors
Loose bolts
Loose bolts

Entire outer appearance

Matchmark panel

External cable

4
5

Description

Corrective Action

Years

Visual check and cleaning

Visual check
Visual check
Retightening
Retightening
Check visually and replace if
necessary.
Remove and clean the
oil-mist, fume , and abrasion.

Carbon brush
(Current-collecting
brush)

Scratches, soiling and

loose connectors.
Abrasion Check.

Current-collecting ring

Abnormality in the
Current-collecting ring

Visual check and clean

Visual check, inspection
and retightening.
Continuity test
Replacing if the internal wiring
is abnormal.

Internal wiring

Tester check

Reduction gear

Grease replenishment.
Abnormality check.

Voltage confirmation

10

11

Battery

Rotary joint (Option)

12

Inspection

Replacement

Replacement

-30-

Scratches, soiling and

loose connectors
Cable check
Overhaul

Grease replenishment.
Replacing if the gear is
abnormal.
Replacement if the voltage
decreases
Replacement
(See Chapter 8.4)
Check visually, inspection.
Replacing if the slip ring
is abnormal.

8 Maintenance
This chapter provides the instructions on the maintenance of robots including a positioner.
To perform inspection, maintenance, adjustment, repairs or other similar works on the robot system, access to
the robot working range may be required, or work with the primary-side power or the servo power turned on may
be necessary. In any case, be sure to observe the following precautions for inspection, maintenance, adjustments
and repairs.

DANGER

WARNING

WARNING

WARNING

Do not alter or remodel our products.

You may get injured or have your equipment damaged because of fire,
failure or malfunction caused by altering or remodeling the product.
The warranty does not cover any altered or remodeled products.

Whenever the power is ON, never enter the robot working range.
Approaching the operating robot may result in a fatal injury.

Never touch any live electrical parts.

Touching any live electrical parts may result in a fatal electric shock hazard or a
burn.

Never put your hand, finger, hair, clothes or the like close to any rotating section.
Bringing hands, fingers, hair or clothes close to the wire feed roll of the wire feed
unit may cause an injury by being caught by it.
Bringing hands, fingers, hair or clothes close to the rotating section of a cooling
fan may cause an injury by being caught by it.

(1) Before carrying out robot inspection, maintenance, adjustments, repairs, etc., be sure to wear a helmet,
safety shoes, gloves and other protective means that may be deemed necessary, as specified by law.
To be more specific, wear clothes that are suited to each specific work.
(2) Before initiating work, press the EMERGENCY Stop button or the Stop button to check if the robot system
stops instantly. Furthermore, if a safety plug, a Deadman switch and/or other protective devices are added
to the robot system, they must be checked for their proper operation. Should any fault be detected, stop
the inspection work, turn off the primary power immediately, check for causes and take necessary
measures accordingly.
(3) Ensure that personnel who are not operating the robot must not approach the guarding fence.
(4) Before starting work, put up a sign Under Inspection
at a visible place to notify people around the robot system
that the inspection is now underway.

Under Inspection

(5) Do not use any devices that may generate electromagnetic noises in and around the place where the
inspection is being conducted.
(6) At least two workers should be involved in the inspection or maintenance work, one performing the actual
work and the other serving as a watchman.
(7) Personnel who are going to conduct the robot inspection, maintenance, adjustment and/or repairs should
receive instructions and training on robot functions, operation and maintenance. In addition, if special
devices or facilities are provided in the robot system, their entire mechanism must also be fully understood.
(8) Robot inspection, maintenance, adjustment and repairs must be performed only by qualified personnel
who have received special training. Furthermore, even if they have received such special training, they are
not allowed to perform inspection, maintenance, adjustment or repairs of machinery other than those they
are fully familiar with.
-31-

(9) Any sign that may be given to workers, watchmen and/or operators of related machines must be in

conformity with the Customers safety management standards.

(10) The watchman has to observe the following.
(A) Stand at a place that commands a view of the entire robot work envelope and concentrate on the duty of
watching the work.
(B) Always hold the EMERGENCY STOP button and press it immediately whenever any abnormality occurs.
(C) Keep personnel except the teaching operator away from the robot work envelope.
(11) The workers to be involved in the inspection or other works must observe the following.
(A) If work can be carried out outside the robot working range, specify the work details before starting the work
and make sure to carry out the work outside the robot working range.
(B) In principle, perform inspection, etc., with the robot stopped. However, if the inspection or other work is
inevitably required while the robot is operating, be sure to report this to the responsible safety manager,
and, with permission obtained, perform the work outside the robot working range.
(C) If the robot is required to be in an operable condition when the inspection work or the like is carried out,
specify the work procedure in detail beforehand so that work can be carried out safely and efficiently.
Furthermore, if work is not particularly required to be performed in the robot operable condition, carry out
the work while the robot controller, the welding power supply and/or other input-side power supplies are all
turned off.
If no special safety procedure is required, be sure to turn off such input-side power supplies for jigs and
peripheral equipment or make them inactive.
(D) When working in the robot working range, be sure that you are always in a ready-to-act posture to be
promptly able to press the EMERGENCY Stop button in case of robot malfunction.
(E) Check your footing carefully before initiating work. Be sure to avoid an unstable scaffold or a scaffold
provided at an elevated position (more than 2 meters high).
(F) When you are in the robot working range, do not perform work with your back facing the manipulator.
(G) When replacing PCBs provided in the robot controller or the teach pendant, take countermeasures against
static electricity, for instance by using anti-static electricity sheets.
(12) If any abnormal condition occurs during the work, follow the procedure below carefully.
(A) If any malfunction is observed in the robot system, press the EMERGENCY Stop button immediately.
(B) Report this immediately to the watchman, turn off the control
power of the robot controller, and then put up a sign
Do Not Switch On.

Do Not Switch ON

(C) Make sure that all the related machines are stopped.
(D) When necessity arises to go inside the guarding fence, be sure that the person who is going to enter pulls
out the safety plug himself, carries it with him while proceeding with the work concerned.
(E) Even when the robot has automatically stopped due to a fault in supply voltage to the robot system,
hydraulic pressure or air pressure of related equipment, make sure that the robot is at a complete stop.
Then, investigate causes and take necessary countermeasures.
(F) If the EMERGENCY Stop switch or other safety devices should have failed to operate, turn off the primary
power immediately, investigate causes and take necessary countermeasures.
(G) In order to restart the robot after stopping it by pressing the EMERGENCY Stop button, investigate causes,
take necessary countermeasures, replace the safety plug, and then restart it from outside the guarding
fence.
(13) To end the work, check carefully that the necessary connectors, covers, panels, etc. have been all
correctly mounted and wired.

-32-

8.1 Maintenance of Collector (current-collecting brush)

Check periodically the amount of abrasion of a carbon brush 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 brush. Please clean the carbon brush and current-collecting
ring, if there are sedimentation and deposition such as the spatter, fume, and oil-mist on them. Moreover, please
wipe off the oil-mist lightly with a lint-free cloth.To keep the current-collecting ability, please clean as often as
possible.

Fig. 8.1.1 Replacing Current Collecting Brush

WARNING

WARNING

CAUTION

Never touch the charged parts

while the power is ON.
Prior to starting work, make sure
the welding power is OFF.

WARNING
ELECTRIC SHOCK
can kill.
Do not touch live electrical
parts.

Disconnect all power

before installing or servicing.

Multiple sources of voltage

may exist inside this
enclosure.
NK3637

Do not enter the robot work area while the power is ON.
Also, do not work while the robot is operating.

Unstable voltage and current caused by the sedimentation and deposition on

the current-collecting parts lead to poor weld, e.g. bead appearance defect
and lack of penetration. Please clean as often as possible.

8.2 Grease Replacement Procedure for Reduction Gears

Carry out periodical replacement and replenishment of grease for the reduction-gear every three years or every
15,000 operating hours, whichever is shorter.
You request us for replacement or replenishment work, you will be charged for the work.
For the location of grease filler/drain port, see Fig.8.2.1
(1)

Be sure to shut off the primary power before operation.

(2)

Remove the set screw(M16) and the plug in the grease filler port 2 .
-33-

(3)

Instead of the plug in the grease filler port 2, install the long nipple which is attached inside the
connector plate.

(4)

Remove the grease nipple in the drain port and install it to the long nipple in the grease filler port 2.

(5)

Apply grease with a grease gun. The grease brand to be used is Moly White Grease RE No.00.
For the amount of filling is 400 ml.(Newly filled grease starts discharging after old one completely
finished discharging from the grease drain port)

(6)

Remove the long nipple and reattach the plug. (Apply thread seal tape the screw threads.)

(7)

Refix the set screw (M16) in the grease filler port 2.

(8)

Remove the plug from the grease filler port 1 and install the grease nipple which is removed from
the long nipple.

(9)

Apply the other 600ml grease. Grease is considered to have been completely replaced when newly
filled grease starts discharging after old one completely finished discharging from the grease drain
port. (Whether the grease is new or old is distinguished from its color.)

(10) On completion of the replacement, wipe off grease adherent to the body and restore the grease

nipple and plug. When fitting them, apply thread seal tape around the screw threads. The locations
are shown in Fig. 8.2.1.
There may be a slight leakage of the grease after filling, which is not an abnormal condition, as
some grease remained adherent to the drain port.
The tightening torque for the grease nipple (Rc 1/8) and plug is 8Nm

WARNING

Be sure to take out a plug and grease nipple in the drain port, otherwise
grease may flow into the motor inside to result in damage of the motor.

Fig. 8.2.1 Location of grease filler/drain port

WARNING

Do not enter the robot work area while the power is ON.
Also, never apply grease while the robot is operating.

-34-

8.3 Replacing Battery

This section describes the replacement procedures for battery as follows. (See Fig. 8.3.1)
(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 upper cover of connector box.
(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) Joint a battery connector.
(6) Mount a upper cover.
(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-4.3 Configuration in the instruction manual MANIPULATOR . Also, see the
aforementioned section to reset the encoder if the encoder data have been lost.

Replace old battery by new one

as shown.
Battery
Connector

Battery

Battery
Holder

Connector plate inner layout

Keep connecting control cables

during this operation.
Keep power-on
during this operation.

Remove the connector plate

Fig. 8.3.1 Replacing Battery

-35-

Controller

9 Parts List for Maintenance

9.1 Parts List
Major parts and components are shown in the table below.

Item Name

DWG. No. &Model

Parts No.

AC servo motor

W-L02150
W-L02059
W-L02060

W-L02150
W-L02059
W-L02060

Moly White No.00

2670-013

W-L01399

5096-434

L11120D01

L11120D01

RV reduction gear
RV reduction gear

Grease
Battery
Carbon brush
(Current collecting
brush)

Qty
1PC 1PC
500 1000
1
1
1
1
1000 2600
ml
ml
1
1
1

Remarks

A single order of 2670-013 is

575ml.
See note
See Chap. 8.1 Maintenance of
Collector (Current- Collecting
Brush)

(Note) On January 1, 2009, for revision of the UN Recommendations on the Transport of

Dangerous Goods, Model Regulations-15th edition, Transportation regulation of Lithium battery is
partially revised. When you transport the Lithium battery by air, transport it according to providing
items of the newest ICAO-TI and IMDG Code of IMO.
IMPORTAN
1. Grease: Minimum quantity for a single order of Moly White RE No.00 is about 575 ml in a 500-g can.
Please arrange the number of cans as necessary quantity.
2. mark is recommendatory spare parts.

DANGER

Do not alter or remodel our products.

You may get injured or have your equipment damaged because of fire,
failure or malfunction caused by altering or remodeling the product.
The warranty does not cover any altered or remodeled products.

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10 Internal Wiring of the Main Unit

10.1 Electric Circuit Diagram

Fig. 10.1.1 Electrical Connection Diagram

DANGER

Do not alter or remodel our products.

You may get injured or have your equipment damaged because of fire,
failure or malfunction caused by altering or remodeling the product.
The warranty does not cover any altered or remodeled products.

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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
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 Japan.
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.

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Positioner Headstock Instruction Manual

No. 1L11120A-E-1
No. 1L11120A-E-2

Nov 26, 2010

Mar 10, 2011

THE 1st EDITION

THE 2nd EDITION