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
Instruction Manual Type Main Contents
Manual No.
INSTALLATION & MAINTENANCE Specifications of a robot, installing &
connecting method, starting up, periodical
1L8300A
inspection, solution at the time of failure,
(Almega EX-V6 / V6L / V16) maintenance parts list, etc.
BASIC OPERATIONS Explanation of operation switch of robot, basic
1L8300C operation method from teaching to automatic
(EX-C) operation, frequently used functions, etc.
TEACHING Detailed explanation of each command and
1L8300D teaching method, etc.
(EX-C)
UTILIZING FEATURES and Setting of the environment in which a robot is
FUNCTIONS being used, useful function, explanation of the
1L8300G
function to manage a robot and the operation
(EX-C) method, etc.
INTERFACE WITH JIG Interfacing method with robot jigs, usage of
1L8300E sequence control function, etc.
(EX-C)
OPTION Optional functions such as multi-task and
1L8300F general operation method, etc.
(EX-C)
EXTERNAL AXES CONTROLLER Installation and connection method of external
axes controller which are required when using
1L8600A
(External Axes Controller for EX-C) 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.

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 (2) Instruction manuals related to the manipulator “AX-M series”, and the robot control unit “AX-C series” are as
follows.

■Standard Manuals
Instruction
Instruction Manual Type Main Contents
Manual No.
INSTALLATION Safety precautions, installing & connecting method,
1L8800A starting up, periodical inspection, solution at the time
of failure
CONTROLLER MAINTENANCE/ Specifications of controller, explanation of each parts
STANDARD CONFIGURATIONS 1L8800B and maintenance, parts list, etc.

MANIPULATOR Specifications or maintenance of manipulator, parts

1L7700A
list, etc.
BASIC OPERATIONS Explanation of manual operation, teaching, automatic
1L8800C operation, file utilities, backing-up data, basic
operations of Arc/Spot welding application, etc.
REFERENCE (Built-in Tutorial) Basic operations, terms, explanations of
Constants/Service menus, Details of function
command, list of short-cut code, parts replacing
1L8800D
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 Interfacing method with external control device, list of
1L8800H I/O signals, start/halt the automatic operation, and
usage of software PLC, etc.

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

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

■Standard Manuals
Instruction
Instruction Manual Type Main Contents
Manual No.
INSTALLATION Safety precautions, installing & connecting method,
1L20400A starting up, periodical inspection, solution at the time
of failure
CONTROLLER MAINTENANCE/ Specifications of controller, explanation of each parts
STANDARD CONFIGURATIONS 1L20400B and maintenance, parts list, etc.

MANIPULATOR Specifications or maintenance of manipulator, parts

1L10460A
（NB4 / NB4L / NV6 / NV6L / NV20） list, etc.
BASIC OPERATIONS Explanation of manual operation, teaching, automatic
1L20400C operation, file utilities, backing-up data, basic
operations of Arc/Spot welding application, etc.
REFERENCE (Built-in Tutorial) Basic operations, terms, explanations of
Constants/Service menus, Details of function
command, list of short-cut code, parts replacing
1L20400D
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 Interfacing method with external control device, list of
1L20400H I/O signals, start/halt the automatic operation, and
usage of software PLC, etc.

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

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 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.

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
DANGER 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.efore

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 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.

ＮＫ３６４５Ａ

ＥＸ－１ＰＢ２５０
ＡＸ－１ＰＢ２５０
ＡⅡ－１ＰＢ２５０

ＮＫ３６８１Ａ

ＮＫ３７１７Ａ

ＥＸ－１ＰＢ５００，１０００
ＡＸ－１ＰＢ５００，１０００
ＡⅡ－１ＰＢ５００，１０００

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 Contents
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/AⅡ-1PB250) ..................................................................... 5
1.4.2 Mounting a Load on the Table (EX-1PB500/AX-1PB500/AⅡ-1PB500) ............................................................... 6
1.4.3 Mounting a Load on the Table (EX-1PB1000/AX-1PB1000/AⅡ-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 Joint (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 Basic Specifications
1.1 Basic Specifications
Name Positioner Headstock
EX-1PB250 EX-1PB500 EX-1PB1000
Type AX-1PB250 AX-1PB500 AX-1PB1000
AⅡ-1PB250 AⅡ-1PB500 AⅡ-1PB1000
Max.allowable load 250kg 500kg 1000kg
Max. Eccentricity of 85mm 100mm 110mm
Center of gravity (loading capacity =250kg) (loading capacity =500kg) (loading capacity 1000kg)
Max. Height of 520mm 540mm 600mm
Center of gravity (loading capacity =250kg) (loading capacity =500kg) (loading capacity =1000kg)
Rotation speed 25min-1 2.6rad/sec 20min-1 2.1rad/sec 12min-1 1.3rad/sec
Allowable Rotation moment 206N･m 490N･m 1078N･m
Allowable Moment of inertia *2 4.6kg･m2 12.7kg･m2 37.4kg･m2
±92 rotation ±129 rotation ±69 rotation
(EX-1PB250 standard spec.) *1 (EX-1PB500 standard spec.) *1 (EX-1PB1000standard spec.) *1
Rotation range ±23 rotation ±32 rotation ±17 rotation
(AX/AⅡ-1PB250 standard (AX/AⅡ-1PB500 standard (AX/AⅡ-1PB1000standard
spec.) *1 spec.) *1 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 CO2, 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/AⅡ-1PB250,500,1000)
Ambient temperature / humidity 0~45℃, 20~80% (no condensation)
*1 ･The rotation range is limited to±1 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.

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Table 1.1 Optional Structure and Type
Type Optional Structure
EXPB251-E EXPB501-E EXPB1001-E
AXPB251-E AXPB501-E AXPB1001-E None (standard specification) *3
A2PB251-E A2PB501-E A2PB1001-E
EXPB251-EA EXPB501-EA EXPB1001-EA
AXPB251-EA AXPB501-EA AXPB1001-EA With Air-rotary joint Assy *4
A2PB251-EA A2PB501-EA A2PB1001-EA
EXPB251-EC EXPB501-EC EXPB1001-EC
AXPB251-EC AXPB501-EC AXPB1001-EC With Air-rotary joint Assy + Curl code Assy
A2PB251-EC A2PB501-EC A2PB1001-EC
EXPB251-ES EXPB501-ES EXPB1001-ES
AXPB251-ES AXPB501-ES AXPB1001-ES With Air-rotary joint Assy + Slip ring Assy
A2PB251-ES A2PB501-ES A2PB1001-ES
*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 machine’s motor.
5. The above specifications are subject to change without notice.

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1.2 Outside Dimensions

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

Fig. 1.2 Outer Dimensions of EX-1PB500/AX-1PB500/AⅡ-1PB500 (mm)

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Fig. 1.3 Outer Dimensions of EX-1PB1000/AX-1PB1000/AⅡ-1PB1000 (mm)

Fig. 1.4 Outside Shape

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 1.3 Name of Each Parts
Origin marker Inspection cover
Service hole

Motor / Encoder connection Welding earth terminal

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/AⅡ-1PB250)

Fig. 1.6 Mounting Dimensions on Table Side (mm)

Mounting a Load on the Table Side

・ φ100H7(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.
・ φ71 Penetrating hole on the center of a table can be used. However, the hole might be unusable
if options are mounted. (See Chap5. Option)

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1.4.2 Mounting a Load on the Table (EX-1PB500/AX-1PB500/AⅡ-1PB500)

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

Mounting a Load on the Table Side

・ φ100H7(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.
・ φ71 Penetrating hole on the center of a table can be used. However, the hole might be unusable
if options are mounted. (See Chap5. Option)

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

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

Mounting a Load on the Table Side

・ φ150H7(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.
・ φ116 Penetrating hole on the center of a table can be used. However, the hole might be unusable
if options are mounted. (See Chap5. Option)

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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

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

2.2 Payload Moment Diagram

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

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

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Fig. 2.3 Allowable Payload Moment (EX-1PB1000/AX-1PB1000/AⅡ-1PB1000)

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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 EX-1PB500/AX-1PB500/AⅡ-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

M= 400 × 9.8 × 0.100
Mass (kg) Gravitational Acceleration (m/s2) Eccentricity of Center of gravity (m)
= 392N・m < 490N・m ← 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

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. 2.4 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.
If the value of the moment of inertia exceeds the value shown in the figures, contact us in advance.

慣性モーメント
Moment of inertia
(kg･m^2)
60
59.5

慣性モーメント 50
Moment of inertia
(kg･m^2) 40
20.3
20
30
15
20
10 12.7
10
5
4.6
0 100 200 300 400 500
490
0 50 100 150 200206 250
負荷モーメント (N･m)
負荷モーメント (N･m) Moment
Moment

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

慣性モーメント
Moment of inertia
(kg･m^2) E.g.1)
220 In the case of the moment of 600N･m for 1PB1000, the
209 allowable moment of inertia should be up to 110kg･m2.
200

180 E.g.2)
In the case of the moment of 0N･m for 1PB1000, the allowable
160 moment of inertia should be up to 209kg･m2.
(The turntable rotating in the horizontal plane is equivalent to
140 this condition.)

120

100

80

60

40
37.4
20

0 100 200 300 400 500 600 700 800 900 1000 1100
1078
負荷モーメント (N･m)]
Moment

Fig. 2.7 **-1PB1000

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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 safety fence.

Safety Fence

Manipulator
Base

Robot Control unit

Welding power Supply

Fig. 3.1 Installation Example

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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/AⅡ-1PB250

Bolt: Hex. Socket Head Cap Screw M16 (Strength Grade 12.9)
Clamping torque in mounting: 255 N・m

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

Fig. 3.5 Installation Dimensions of EX-1PB1000/AX-1PB1000/AⅡ-1PB1000

Bolt: Hex. Socket Head Cap Screw M20 (Strength Grade 12.9)
Clamping torque in mounting: 500 N・m
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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/AⅡ-1PB250 = M16,
EX-1PB500/AX-1PB500/AⅡ-1PB500,EX-1PB1000/AX-1PB1000/AⅡ-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/AⅡ-1PB250 : 110kg
EX-1PB500/AX-1PB500/AⅡ-1PB500 : 170kg
EX-1PB1000/AX-1PB1000/AⅡ-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

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5 Options
The 2 kinds of options, Air rotary joint and equipped cable, are provided for EX/AX/AⅡ-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 Joint (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 Joint Assy Specification

EXPB251-EA EXPB501-EA EXPB1001-EA
Type AXPB251-EA AXPB501-EA AXPB1001-EA
A2PB251-EA A2PB501-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 φ40mm

Fig. 5.1 Outside Dimensions of Air Rotary Joint (mm)

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5.2 Equipped Cable (Option)
The equipped cables can be stored in the center of the table for EX-1PB/AX-1PB/AⅡ-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

EXPB251-EC EXPB501-EC EXPB1001-EC
Type AXPB251-EC AXPB501-EC AXPB1001-EC
A2PB251-EC A2PB501-EC A2PB1001-EC
Parts No. L6968J
Number of Conductor 12 (0.5mm2×12)
Fasten side: Receptacle MS3102A28-20P
Connecting Part
Rotation side: 0.5mm2×12 (crimp contact A1. 25-YS4A)
Fasten side for connection Plug MS3106B28-20S
Accessories
Cable clamp MS3057-16A
Hollow hole Diameter None

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

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 Ａ Red Ａ

Ｂ White Ｂ

Ｃ Black Ｃ
Table 5.3 Equipped Cable Specifications
Ｄ Gray Ｄ
Number of Conductor 12

ＭＳ３１０２Ａ－２８－２０Ｐ
Cross section 0.5mm2 Ｅ Orange Ｅ
Power capacity 1A
Ｆ Blue Ｆ

Ｇ Brown Ｇ

Ｈ Yellow Ｈ

Ｊ Green Ｊ

Ｋ Brown/White mark Ｋ

Ｌ Red/White mark Ｌ

Ｍ Purple Ｍ

Fig. 5.3 Wiring for Curl Code Specification

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

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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)

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 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

EXPB251-ES EXPB501-ES EXPB1001-ES
Type
AXPB251-ES AXPB501-ES AXPB1001-ES
Parts No. L6968K
Number of Conductor 32 (0.3mm2×16P)
Fasten side: Receptacle MS3102A28-21P
Connecting Part
Rotation side: 0.3mm2×16 (no terminal processing)
Fasten side for connection Plug MS3106B28-21S
Accessories
Cable clamp MS3057-16A
Hollow hole Diameter None

Fig. 5.7 Outside Dimensions of Slip Ring (mm)

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Table 5.5 Equipped Cable Specifications
Number of wire core 32 cores
Cross section 0.3mm2
0.5A (within 1 minute)
Power Capacity
0.3A (Continuously)

Fig. 5.8 Wiring for Positioner and Slip Ring

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

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

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

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 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 (0.3mm2×18P)
Fasten side: Receptacle MS3102A28-21P
Connecting Part
Rotation side: 0.3mm2×18P (no terminal processing)
Fasten side for connection Plug MS3106B28-21S
Accessories
Cable clamp MS3057-16A
Hollow hole Diameter None

Fig. 5.12 Outside Dimensions of Slip Ring (mm)

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Table 5.7 Equipped Cable Specifications
Number of wire core 36 cores
Cross section 0.3mm2
Power Capacity 0.5A

Fig. 5.13 Wiring for Positioner and Slip Ring

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

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

Fig. 5.16 Outside Dimensions of A2PB1001-ES (mm)

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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)

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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 L7090D (Stand A) L7090D (Stand A)
AⅡ-1PB250
EX-1PB500
AX-1PB500 L7090B L7090E (Stand B) L7090D (Stand A)
AⅡ-1PB500
EX-1PB1000
AX-1PB1000 L7090E (Stand B) L7090F (Stand C)
AⅡ-1PB1000

Tailstock
Headstock
EX-1PB250
AX-1PB250
AⅡ-1PB250

StandA StandA
Baseplate
（Option）

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

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 Headstock Tailstock
EX-1PB500
AX-1PB500
AⅡ-1PB500

StandB Baseplate StandA

（Option）

Fig. 5.20 Outside Dimensions of EX-1PB500/AX-1PB500/AⅡ-1PB500 and Tailstock (mm)

Headstock
EX-1PB1000 Tailstock
AX-1PB1000
AⅡ-1PB1000

StandB Baseplate StandC

（Option）

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

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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 3.5mm2 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 ①,②,③, and ④, 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

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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/AⅡ-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:
2
(Rated current)
[Allowable availability] = × [Rated availability]
(Operation current) 2

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

(500)2
[Allowable availability] = × 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 Guide bars

Datum Level
V-channel

Carbon Chip

Fig. 7.1 Replacing Current Collecting Brush

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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 28.4N・m, 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 6.9N 2mm
AⅡ-1PB250
EX-1PB500
AX-1PB500
AⅡ-1PB500
15N 2.5mm
EX-1PB1000
AX-1PB1000
AⅡ-1PB1000

Fig. 7.2 Tension Adjustments of Timing Belts

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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. Q’ty Remarks
EX-1PB250
W-L01503 5096-496 1
AC servo motor AX-1PB250
W-L02150 -- 1 AⅡ-1PB250
EX-1PB250 Cyclo reduction
AX-1PB250 W-L01409 5096-462 1
gear
AⅡ-1PB250 Timing belt W-L01414 5096-463 1
Grease Multemp FZ No.00 2670-051 -
Grease Shell, Albania EP-2 ――― -
Battery W-L01399 5096-434 1
EX-1PB500
W-L01504 5096-497 1
AC servo motor AX-1PB500
W-L02150 -- 1 AⅡ-1PB500
EX-1PB500 Cyclo reduction
W-L01410 5096-465 1
AX-1PB500 gear
AⅡ-1PB500 Timing belt W-L01415 5096-466 1
Grease Multemp FZ No.00 2670-051 -
Grease Shell, Albania EP-2 ――― -
Battery W-L01399 5096-434 1
EX-1PB1000
W-L01504 5096-497 1
AC servo motor AX-1PB1000
W-L02150 -- 1 AⅡ-1PB1000
EX-1PB1000 Cyclo reduction
AX-1PB1000 W-L01191B 5096-467 1
gear
AⅡ-1PB1000 Timing belt W-L01416 5096-468 1
Grease Multemp FZ No.00 2670-051 -
Grease Shell, Albania EP-2 ――― -
Battery W-L01399 5096-434 1

8.2 Replacement Parts

Location Parts Name DWG. No. & Model Parts No. Q’ty
L6968D07 See Chap. 6.3
(EX/AX /AⅡ-1PB250) L6968D07 Current Collecting
Current collecting Carbon chip (EX/AX /AⅡ-1PB500) 2 Device (Current
Unit (Current collecting brush)
L6970D02 L6970D02 Collecting Brush)
(EX/AX /AⅡ-1PB1000) Maintenance
Actual uptime of
500
Cyclo reduction gear Grease Multemp FZ No.00 2670-051 6000 hours or 3
g 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
①

Fig. 8.1 Lubrication of Gear

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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) Joint 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

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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

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

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10 Inspection Items
Inspection Maintenace
No. 3 1 3 6 Location Description Corrective Action
Daily
months year years years
Attached spatter, dust of
1 ○ Entire outer appearance Visual check and cleaning
other foreign matter.
2 ○ Matchmark panel Peeling, fracture Visual check
Scratches, soiling, loose
3 ○ External cable Visual check
connectors
4 ○ Mounting bolt Loose bolts Retightening
5 ○ Cannon plug Loose bolts Retightening
･Scratches, soiling and ･Check visually and replace if
6 ○ Carbon blush loose connectors. necessary.
･Abrasion Check. ･Remove abrasion and clean.
Abnormality in the
7 ○ Collector ring Visual check
Current-collecting ring
･Visual check, inspection
○ ○ Tester check and retightening.
8 Internal wiring
･Continuity test
● Replacement Replacement
･Check for abnormality
Tension check ･Tension adjustment
○
9 Timing belt ･Replacing timing belt
･Tension adjustment
● Replacement Replacement
･Grease replenishment.
･Grease replenishment.
10 ○ ● ● Gear ･Replacing if the gear is
･Abnormality check.
abnormal.
･Grease replenishment.
･Grease replenishment.
11 ● ● Reduction gear ･Replacing if the gear is
･Abnormality check.
abnormal.
Replacement
12 ● ● Battery Replacement
(See Chapter 8.4)
･Scratches, soiling and ･Check visually, inspection.
loose connectors ･Replacing if the rotary joint
13 ○ ○ ○ Rotary Joint(Option)
･A lowering of air is abnormal.
pressure
･Scratches, soiling and ･Check visually, inspection.
14 ○ ○ ○ Slip Ring(Option) loose connectors ･Replacing if the slip ring
･Cable check 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
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 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. 1L7410A-E-1 SEPTEMBER 1, 2001 THE 1st EDITION
No. 1L7410A-E-2 JULY 3 , 2003 THE 2nd EDITION
No. 1L7410A-E-3 OCTOBER 3 , 2007 THE 3rd EDITION
No. 1L7410A-E-4 MARCH 1 , 2009 THE 4th EDITION

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