Maintenance en

MAINTENANCE FOR 5DA ROBOTS -
5DA
CONFIDENTIAL - 2014 - all rights reserved
MAINTENANCE FOR 5DA ROBOTS
DD0000484701 - 09/04/2014
- Translation of the original manual -
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MAINTENANCE FOR 5DA ROBOTS - TABLE OF CONTENTS
5DA
I - TABLE OF CONTENTS
Our manipulator robots components undergo various tests before being certified. Your robot has
undergone endurance tests in our workshops. We can therefore guarantee optimal performance,
subject to the following advice being followed.
Periodic maintenance operations, page 3

- Schedule of operations, page 3
- Accessing the filter in a compact beam-mounted (CBM) cabinet 3.2, page 4
- Self-locking screws, page 4
- Checking the Nord-Lock fixings, page 4
- Bearing block maintenance, page 5
List of recommended consumables, page 9

Rack and pinion play, page 10
- Principle for 5DA11 robots, page 10
- Principle for 5DA25-35 robots, page 12
Belt tension, page 14

- Requirements, page 14
- 5DA11 robots, page 15
- 5DA25-35 robots, page 17
Calibrating the CNC axes, page 20

- Procedure, page 20
- Calibration points, page 21
You will find the parts lists for your robots drawings in the "BOM and Exploded Drawings" chapter.
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MAINTENANCE FOR 5DA ROBOTS - PERIODIC MAINTENANCE OPERATIONS
5DA
II - PERIODIC MAINTENANCE OPERATIONS

II - 1. Schedule of operations
FREQUENCY
Daily
Weekly
Monthly
OPERATION
Drain the flushing device on the air-conditioning unit.
Check the condition of the dampers (impacts, etc.).
If the robot hits the end of the beam violently, you should get it checked
by one of our technicians.

Check the air pressure.
Check the condition of the pressure gauges.
Check hoses do not leak and are in good condition.
Remove pellets and powder from the top of the beam if necessary.
Check that the cables are in good condition and correctly positioned in the conduits.
Check that the grease level in the rack and pinion cartridges does actually go down.
If the peripheral units have been supplied by us, check their low-sensitivity
differential protecting system.
Check that the protective elements are correctly fixed.
Analyze abnormal noises, vibrations, etc.
Cabinet:
If there are any, check the condition of the operating and fault pilot lamps.
If the cabinet does not have removable filters, remove the dust from the electronic
boards compartment and the transformers compartment.
Quarterly
Yearly
Yearly or every
5000 km
Every 3 years
If the cabinet has a removable filter, clean or replace the fan suction filter. See
Accessing the filter in a compact beam-mounted (CBM) cabinet 3.2, page 4.
Check the protection and emergency stop devices in all modes. See the
Commissioning chapter.
After the 1st quarter following robot commissioning, check that all fixings are
correctly tightened as instructed: page 4.
Transmission belt checks: Check the condition of the teeth and the cables. If they
are worn, replace the belt as per the procedure delivered with the ordered belt.
Contact our After Sales Service if you have any questions.
Check that all fixings are correctly tightened as instructed: page 4.
Replace the grease cartridge.
Tighten any loose connections.
Replace the detachable relays on the interface board.
Replace the bearing blocks' lubrication units and grease the bearing blocks again:
page 5.
Replace the CPU boards battery.
CHECKING IS NOT SUFFICIENT; A FAULT REQUIRES ACTION.

=> Clean, grease, set, replace; any preventive or corrective action taken will extend the working life of
your robot.
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5DA

II - 2. Accessing the filter in a compact beam-mounted (CBM) cabinet 3.2
The filter is fixed on a fixed support located between the end of the beam and the CBM cabinet 3.2.
Extract the filter

after removing
the 2 screws
and removing
the plate 1
II - 3. Self-locking screws
As long as the screw's driving recess is not damaged, the screw can be reused 3 times. If you have a
doubt about the driving recess, you must replace the screw.
II - 4. Checking the Nord-Lock fixings
Check that none of the screws are loose or cracked on the following assembled elements:
- beam / spacer
- spacer / platen
- platen / IMM platen
- leg / beam (if there is a leg)
A screw is considered loose if its head rotates when the recommended tightening torque (see
Installation manual) is applied.
If you cant access a screw, check visually or using a micrometer that the assembled elements
(beam / spacer, spacer / platen, platen / IMM platen, leg / beam (if there is a leg)) dont come apart
under maximum stress.
If a screw isnt correctly tightened:

Check that all the screws shown on the installation drawing are present. If any are missing, note
which ones.
Replace all the screws on the assembled element (beam / spacer, spacer / platen, platen / IMM
platen, leg / beam (if there is a leg)), following the assembly instructions given in the Installation
chapter.
Check once again that the elements don't come apart.
You must always report this problem to our After Sales Service and tell them which screws are
faulty or missing.
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5DA
II - 5. Bearing block maintenance
You must use the recommended grease and pumps for the particular types of guides to
ensure they function correctly and do not wear prematurely.
Greasing the bearing blocks
Greaser
The quantity of grease to inject depends on the bearing block.

Refer to the values given in the manuals supplied with the following grease kits:
DD00002396__ for the NSK bearing blocks
DD00004279__ for the THK bearing blocks
Identifying the bearing blocks, see page 6
To assist you with this operation, a kit for greasing the bearing blocks again is available (page 9).
Y Axis - For very small movements (< 40 mm): In the unloading cycle, you must program the
movement along the longest stroke possible.
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5DA
Identifying the bearing blocks
The robot may have NSK and / or THK brand bearing blocks.
The brand is marked on the bearing block:
NSK
THK
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5DA
Replacing the lubrication units
The bearing blocks are always equipped with a lubrication unit:

Bearing block 2
Bearing block 1
Bearing block 3
Rail
Lubrication units
Bearing block 2 is protected by the lubrication units of bearing blocks 1 and 3, so its lubrication unit does
not need to be replaced.
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5DA
K1 lubrication unit
NSK bearing block
Procedure for replacing the NSK bearing blocks' lubrication units
The procedure for replacing the lubrication units is given in the manual supplied with the grease kit
(DD00002396__).
You must follow this procedure.
QZ lubrication unit
THK bearing block

Spacer
Wiper
Procedure for replacing the THK bearing blocks' lubrication units
The procedure for replacing the lubrication units is given in the manual supplied with the grease kit
(DD00004279__).
You must follow this procedure.
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5DA
MAINTENANCE FOR 5DA ROBOTS - LIST OF RECOMMENDED CONSUMABLES

III - LIST OF RECOMMENDED CONSUMABLES
In order to schedule your preventive maintenance, remember to order your spare parts a few weeks
in advance.
Mechanics
Grease packs
Robot
5DA11
THK S3
Robot
5DA25
Robot
5DA35
R600001429__
R600001422__
R600001845__
R600001848__
Direct arm DI
THK S5
R600001835__
Standard telescopic arm

TE ST
THK S3
R600001430__
R600001423__
THK S5
R600001846__
R600001849__
Compact telescopic arm

TE ER
THK S3
R600001431__
THK S5
R600001847__
Grease kits
Kit
NSK bearing
blocks
THK bearing
blocks
AM00006930__
Made up of
1 Pump
AC00001631__
1 Grease cartridge
AC00001630__
1 Grease pump
nozzle
AC00001633__
1 Pump
AC00001847__
1 Grease cartridge
AC00001846__
AM00007759__
Identifying the bearing blocks, see page 6
Electronics
Interface board relays: Kit no. AE00002038_ _ comprising:
- 1 K8 RELAY
- 1 K9 RELAY
- 1 K10 RELAY
Interface board fuses, part no. AE00002039_ _:
- 4 time-delay FUSES 5x20 6.3A/250v
- 1 FUSE 5x20 1A/250v
CPU board battery, CR1632 3V TYPE part no. AE00003187_ _
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MAINTENANCE FOR 5DA ROBOTS - RACK AND PINION PLAY
5DA
IV - RACK AND PINION PLAY

IV - 1. Principle for 5DA11 robots
Example with the X movement

1. Loosen the 4 screws 1 one turn.
2. Tighten screw 2 until the pinion is tight against the rack. The rack and pinion play is therefore zero.
3. Moderately tighten the 4 screws 1 again.
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5DA
4. Record the residual play J1 on the micrometer 3. This play is the play in the motor and/or in the
geared motor.

6. Loosen screw 2 until you get the following play J:
J min > 0.07mm + J1
J max < 0.25 mm + J1

8. Along the whole of the axis' stroke, check that play J is respected. If it isn't, start from point 5 again.
9. Block the 4 screws 1.
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5DA
IV - 2. Principle for 5DA25-35 robots
Example with the X movement
2. Loosen screw 2 until the pinion is tight against the rack. The rack and pinion play is therefore zero.

4. Record the residual play J1 on the micrometer 3. This play is the play in the motor and/or in the
geared motor.

6. Tighten screw 2 until you get the following play J:
J min > 0.1mm + J1
J max < 0.4 mm + J1

8. Along the whole of the axis' stroke, check that play J is respected. If it isn't, start from point 5 again.
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5DA
Example with the Z movement (TE ER arm)
1
2
2. Loosen screw 2 until the pinion is tight against the rack. The rack and
pinion play is therefore zero.
4. Record the residual play J1 on the micrometer 3. This play is the play in
the motor and/or in the geared motor.
6. Tighten screw 2 until you get the following play J:
J min > 0.1mm + J1
J max < 0.4 mm + J1

8. Along the whole of the axis' stroke, check that play J is respected. If it
isn't, start from point 5 again.
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MAINTENANCE FOR 5DA ROBOTS - BELT TENSION
5DA
V - BELT TENSION
Always check the belt tension after intervening on the motorization.
V - 1. Requirements
To make sure that the belt tension is optimum, use a frequency meter for this operation. Contact our After
Sales Service for the correct tension value.
To obtain a correct tension measurement, the belt must by centered on the 3 pulleys. If this is not the
case, slacken the belt (following the tension procedure operations in reverse order) and center it again.
Using the frequency meter:

Place the frequency meter's probe as shown in the photos below, several millimeters above the
belt.
Vibrate the belt with your finger
Take the measurement
If several measuring points are given, use the largest value.
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5DA

V - 2. 5DA11 robots
V - 2. 1. Z axis
Measuring point
Direct arm on a
5DA11 robot
Measuring point 1
Measuring point 2
Tension procedure
1. Remove cover 1 by removing the 2 screws 2 (only for the Z2 arm).
2. Position the arm at its lowest possible point.

3. Force the overtravel to crush the stop.
4. Release the brake by applying a 24V DC voltage to its power supply (refer to the electrical drawing).
Do not release the brake until the arm is on the bottom stop.

6. Adjust nut 4 to get a frequency of ... Hz at the measuring point shown (See Requirements, page
14).
7. Tighten the 4 screws 3 again.
8. Block the brake again.
9. Program a specific cycle to carry out several back and forward movements at maximum speed.
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5DA

10.Check the tension again. If it is not correct, carry out the tension procedure again.
Z2 arm on a 5DA11 robot
1
2
Direct arm on a 5DA11 robot
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5DA

V - 3. 5DA25-35 robots
V - 3. 1. Y axis
Measuring point
Measuring
point
=
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5DA
Tension procedure
1. Remove cover 1 by removing screws 2

2. Move the 2 carriages back, so that measurement A = 5mm.
3. Loosen the 4 screws 3 one turn
4. Adjust screw 4 to get a frequency of ... Hz at the measuring point shown (See Requirements, page
14)
5. Tighten the 4 screws 3 again
6. Program a specific cycle to carry out several back and forward movements at maximum speed
7. Check the tension again. If it is not correct, carry out the tension procedure again.
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5DA

V - 3. 2. Z axis
Measuring point
Measuring point 1
Measuring point 2
Tension procedure
1. Remove cover 1 by removing screws 2
2. Position the arm at its lowest possible

point
3. Force the overtravel to crush the stop
4. Release the brake by applying a 24V DC
voltage to its power supply (refer to the
electrical drawing)
3
4
Do not release the brake until the
arm is on the bottom stop.

5. Loosen the 4 screws 3 one turn
6. Adjust nut 4 to get a frequency of ... Hz
at the measuring point shown (See
Requirements, page 14)
7. Tighten the 4 screws 3 again
8. Block the brake again
9. Program a specific cycle to carry out
several back and forward movements at
maximum speed
10.Check the tension again. If it is not
correct, carry out the tension procedure
again.
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MAINTENANCE FOR 5DA ROBOTS - CALIBRATING THE CNC AXES
5DA
VI - CALIBRATING THE CNC AXES
To INITIALIZE is to teach the axis a known position whose value is in the memory. See the Operating
Manual.
To CALIBRATE is to precisely measure the axis position compared to a mechanical ZERO.
VI - 1. Procedure
1. Select the manual mode.
2. Power up again.
3. Initialize the axes. See the Operating Manual.
4. Position the robot so that you can measure the distance asked for.
See Calibration points, page 21
5. Hit an emergency stop.
6. Measure then calculate the value to enter using the table. Write down this value.
7. Release the emergency stop and power up again.
8. Make sure that the continuous movement mode is selected.

9. Select the Maintenance environment.
10.Select the "Robot information" icon.
11.Select the "Information on the maintenance of the electric axes" icon.

12.Select the axis to calibrate.
13.Select the "Calibration of the electric axes" icon.
14.Enter the value previously noted. Repeat the procedure from point 4 to calibrate the
other axes.
15. Power the cabinet down, wait 30 sec then power up again.
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5DA

VI - 2. Calibration points
5DA11 robots
Axis
X
Y
Z
Direct arm DI
Z2
Sprue-picker telescopic arm
Value in mm
A + 76
Y Stroke + 133 - B
C + 87
D + 77
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5DA

5DA25-35 robots
Axis
X
Y (5DA25)
Y (5DA35)
Z
Direct arm
Z
Telescopic arm
Value in mm
A + 76
Y Stroke + 177 - B
Y Stroke + 181 - B
C + 96
(2x C) + 92
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5DA
Value in mm
G - 98
Axis
Z2
Sprue-picker telescopic arm
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MAINTENANCE FOR 5DA ROBOTS -

CONFIDENTIAL - 2014 - all rights reserved

MAINTENANCE FOR 5DA ROBOTS

- Translation of the original manual -

MAINTENANCE FOR 5DA ROBOTS - TABLE OF CONTENTS

Periodic maintenance operations, page 3

List of recommended consumables, page 9

Belt tension, page 14

Calibrating the CNC axes, page 20

CONFIDENTIAL - 2014 - all rights reserved

- Translation of the original manual -

MAINTENANCE FOR 5DA ROBOTS - PERIODIC MAINTENANCE OPERATIONS

II - PERIODIC MAINTENANCE OPERATIONS

by one of our technicians.

CONFIDENTIAL - 2014 - all rights reserved

CHECKING IS NOT SUFFICIENT; A FAULT REQUIRES ACTION.

- Translation of the original manual -

MAINTENANCE FOR 5DA ROBOTS - PERIODIC MAINTENANCE OPERATIONS

Extract the filter

II - 4. Checking the Nord-Lock fixings

CONFIDENTIAL - 2014 - all rights reserved

If a screw isnt correctly tightened:

- Translation of the original manual -

MAINTENANCE FOR 5DA ROBOTS - PERIODIC MAINTENANCE OPERATIONS

II - 5. Bearing block maintenance

Greasing the bearing blocks

The quantity of grease to inject depends on the bearing block.

Identifying the bearing blocks, see page 6

CONFIDENTIAL - 2014 - all rights reserved

- Translation of the original manual -

MAINTENANCE FOR 5DA ROBOTS - PERIODIC MAINTENANCE OPERATIONS

Identifying the bearing blocks

CONFIDENTIAL - 2014 - all rights reserved

- Translation of the original manual -

MAINTENANCE FOR 5DA ROBOTS - PERIODIC MAINTENANCE OPERATIONS

Replacing the lubrication units

The bearing blocks are always equipped with a lubrication unit:

CONFIDENTIAL - 2014 - all rights reserved

- Translation of the original manual -

MAINTENANCE FOR 5DA ROBOTS - PERIODIC MAINTENANCE OPERATIONS

NSK bearing block

Procedure for replacing the NSK bearing blocks' lubrication units

You must follow this procedure.

CONFIDENTIAL - 2014 - all rights reserved

THK bearing block

Procedure for replacing the THK bearing blocks' lubrication units

You must follow this procedure.

- Translation of the original manual -

MAINTENANCE FOR 5DA ROBOTS - LIST OF RECOMMENDED CONSUMABLES

Standard telescopic arm

Compact telescopic arm

CONFIDENTIAL - 2014 - all rights reserved

Identifying the bearing blocks, see page 6

- Translation of the original manual -

MAINTENANCE FOR 5DA ROBOTS - RACK AND PINION PLAY

IV - RACK AND PINION PLAY

Example with the X movement

CONFIDENTIAL - 2014 - all rights reserved

3. Moderately tighten the 4 screws 1 again.

- Translation of the original manual -

MAINTENANCE FOR 5DA ROBOTS - RACK AND PINION PLAY

5. Loosen the 4 screws 1 one turn.

J max < 0.25 mm + J1