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 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 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, starting
1L20400A
up, periodical inspection, solution at the time of failure
CONTROLLER MAINTENANCE/ Specifications of controller, explanation of each parts and
1L20400B
STANDARD CONFIGURATIONS maintenance, parts list, etc.
MANIPULATOR Specifications or maintenance of manipulator, parts list, etc.
1L10460A
（NB4 / NB4L / NV6 / NV6L / NV20）
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,
1L20400D parts replacing procedure, trouble shooting, etc.
※ This manual is not provided as the paper manual, but is
built in the robot as Help tutorial function.
EXTERNAL INPUT/OUTPUT Interfacing method with external control device, list of I/O
1L20400H 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) technique, etc.
APPLICATION MANUAL Basic settings, functions for arc welding, teaching
1L20400G
(HANDLING) technique, etc.
APPLICATION MANUAL Basic settings, functions for arc welding, teaching
1L20400K
(SEALING) technique, etc.
APPLICATION MANUAL Basic settings, functions for arc welding, teaching
1L21270S
(THERMAL SPRAYING) technique, etc.
■Option Function Manuals
Instruction
Instruction Manual Type Main Contents
Manual No.
OSCILLOSCOPE FUNCTION 1L21270V Instruction Manual for OSCILLOSCOPE FUNCTION
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
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.
-1-
 Notice
About this manual
This instruction manual describes the installation and maintenance of Positioner Headstock(1 axis Positioner).
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

-2-
 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.

Fig. Warning Label Location (AⅡ-1PB250,500,1000)

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 Contents
1 Basic Specifications ...........................................................................................................................................1
1.1 Basic Specifications.................................................................................................................................1
1.2 Outside Dimensions ................................................................................................................................2
1.3 Name of Each Parts ................................................................................................................................4
1.4 Dimensions for Mounting on Table Face .................................................................................................4
1.4.1 Mounting a Load on Table (AⅡ-1PB250)............................................................................................4
1.4.2 Mounting a Load on the Table (AⅡ-1PB500)......................................................................................5
1.4.3 Mounting a Load on the Table (AⅡ-1PB1000)....................................................................................5

2 Allowable Load...................................................................................................................................................6
2.1 Maximum Allowable Load........................................................................................................................6
2.2 Payload Moment Diagram .......................................................................................................................6
2.3 Allowable Rotation Moment.....................................................................................................................7
2.4 Allowable Moment Of Inertia ...................................................................................................................8
2.5 How to check the load Moment ...............................................................................................................9

3 Installation Guidelines......................................................................................................................................14
3.1 Foundation.............................................................................................................................................14
3.2 Environmental Requirements ................................................................................................................14
3.3 Installing a Safety Fence .......................................................................................................................14
3.4 Installation method.................................................................................................................................15

4 Transport Method.............................................................................................................................................17
4.1 Positioner Transport Method .................................................................................................................17

5 Options.............................................................................................................................................................18
5.1 Air Rotary Joint (Option) ........................................................................................................................18
5.2 Equipped Cable (Option) .......................................................................................................................19
5.2.1 Curl Cord (Option) ..........................................................................................................................19
5.2.2 Slip Ring (Option) ...........................................................................................................................22
5.3 Tail Stock (Option) .................................................................................................................................25
5.3.1 Tail stock (L7090B).........................................................................................................................25
5.3.2 1-axis double support positioner ....................................................................................................26

6 Grounding Method ...........................................................................................................................................28

7 Maintenance.....................................................................................................................................................29
7.1 Welding Current allowance....................................................................................................................29
7.2 Maintenance of Collector (current-collecting brush)..............................................................................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 ..................................................................................................................................32

9 Internal Wiring of the Main Unit........................................................................................................................33

9.1 Electric Circuit Diagram .........................................................................................................................33

10 Inspection Items ...............................................................................................................................................34

11 Warranty...........................................................................................................................................................35
11.1 Warranty Period.....................................................................................................................................35
11.2 Deadline for Supplying/ Repairing the Robot Maintenance Parts .........................................................35
1 Basic Specifications
1.1 Basic Specifications
Name Positioner Headstock
Type 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
±23 rotation ±32 rotation ±17 rotation
Rotation range
±1 rotation (A2PB252-EC) *1 ±1 rotation (A2PB502-EC) *1 ±1 rotation (A2PB1002-EC) *1
Initial setting of soft limit ±400°*2 ±400°*2 ±400°*2
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 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 White
Ambient temperature / humidity 0~45℃, 20~80% (no condensation)
*1 ･The rotation range is limited to±1 rotation if using Curl cord assy equipped type.
･Endless rotation could be chosen as an option.
*2. For the standard and the slip ring specification, the endless rotation function is available by adding the
optional “Endless rotation function”, while not for the curl cord specification.
*3 The allowable moment of inertia is the allowable value where the load equivalent to the allowable load
moment has been added.

Table 1.1 Optional Structure and Type

Type Optional Structure
A2PB252-E A2PB502-E A2PB1002-E None (standard specification) *3
A2PB252-EA A2PB502-EA A2PB1002-EA With Air-rotary joint Assy *4
A2PB252-EC A2PB502-EC A2PB1002-EC With Air-rotary joint Assy + Curl cord Assy
A2PB252-ES A2PB502-ES A2PB1002-ES With Air-rotary joint Assy + Slip ring Assy
*3 Could change to a specification of EA, EC, or ES type with an option.
*4 Could change to EC or ES type by mounting Curl cord 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.

-1-
1.2 Outside Dimensions

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

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

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

Fig. 1.4 Outside Shape

-3-
 1.3 Name of Each Parts

Fig. 1.5 Outside View

1.4 Dimensions for Mounting on Table Face

1.4.1 Mounting a Load on Table (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 (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 (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)

-5-
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
AⅡ-1PB250 250kg 206N・m 85mm 520mm
AⅡ-1PB500 500kg 490N・m 100mm 540mm
AⅡ-1PB1000 1000kg 1078N・m 110mm 600mm

2.2 Payload Moment Diagram

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

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

Fig. 2.3 Allowable Payload Moment (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 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

-8-
2.5 How to check the load Moment
It is necessary to check with the oscilloscope function if the load status meets the positioner’s
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.
① Teaching the motion in measurement
② Measuring the current
③ 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 1：Measure the maximum current.
(b) Pattern 2：Measure the eccentric load holding current.
(c) Pattern 3：Check 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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 （a）Movement pattern 1（180°reciprocating motion）
①Teach speed：Ｐ１００％
②ＰＴＰ motion
③Accuracy level：A8

Start/Stop point shall be at Passing through Turnaround point shall be

the horizontal position on the overhead at the horizontal position
right side viewed from the on the left side viewed
front where the max. eccentric from the front where the
load applied. max. eccentric load applied.
Fig.2.8 Action pattern 1

（b）Movement pattern２（The upswing stop action.）

①Teach speed：Ｐ１％
②ＰＴＰ motion
③Accuracy level：A8

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 ﾟ upwards and turn
it around.
Again, turn around the
workpiece when it
reaches the horizontal
position on the right
side.
Hold the workpiece in the
position 2 ﾟ up from the original
start position.

Fig.2.9 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.
-10-
 (3) Measuring the current and speed
Use the oscilloscope function provided in the robot controller to measure the following items with the tilt
axis and rotational axis. In each axis, 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 2.1 CH assignment

CH Type 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.

(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.

- AⅡ-1PB250
(a) Pattern 1： Q phase current of CH2 is between -9.4A and 9.4A.
(b) Pattern 2： Q phase current of CH2 after the motion stop is stabilized between -3.2A and 3.2A.
(c) Pattern 3： Value of the A.P. monitor #1 has not exceeded that of the A.P. monitor #2.

- AⅡ-1PB500
(a) Pattern 1： Q phase current of CH2 is between -17.9A and 17.9A.
(b) Pattern 2： Q phase current of CH2 after the motion stop is stabilized between -7.4A and 7.4A.
(c) Pattern 3： Value of the A.P. monitor #1 has not exceeded that of the A.P. monitor #2.

- AⅡ-1PB1000
(a) Pattern 1： Q phase current of CH2 is between -20.8A and 20.8A.
(b) Pattern 2： Q phase current of CH2 after the motion stop is stabilized between -12A and 12A.
(c) Pattern 3： Value of the A.P. monitor #1 has not exceeded that of the A.P. monitor #2.

-11-
 * Measurement result <Sample 1> (AⅡ-1PB250: Pattern 1)

CH2 is set to the Q phase current

of J1 axis, therefore stays between
-8.68A and 8.68A. This meets the
specified range; -9.4A ~ 9.4A.

* Measurement result <Sample 2> (AⅡ-1PB250: Pattern 2)

CH2 is set to the Q phase current

of J1 axis of which current value
after the motion stop is stabilized
at 3.19A. This meets the specified
range; -3.2A ~ 3.2A.

-12-
* Measurement result <Sample 3> (AⅡ-1PB250: 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.

-13-
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

Manipulator
Base

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. 3.1 Installation Example

-14-
3.4 Installation method
The installation dimensions for the positioner headstock are 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 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 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 AⅡ-1PB1000

Bolt: Hex. Socket Head Cap Screw M20 (Strength Grade 12.9)
Clamping torque in mounting: 500 N・m
-16-
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.

Be careful not to damage

connector box

Fig. 4.1 Transport Method and Posture

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

AⅡ-1PB250: 110kg
AⅡ-1PB500: 170kg
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 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
Type A2PB252-EA A2PB502-EA A2PB1002-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
(Note) 1. The air rotary joint is designed to allow a small amount of air leakage.
To prevent a change in the stop position of the end effector or a drop in pressure, do not use it for
retention purpose of residual pressure.
2. Basically, this air rotary joint is designed based on one kind of air pressure.
If high and low pressures are applied next to each other, there is a possibility that high pressure leaks to
low pressure port. If absolutely necessary, open unused port between high and low to the atmosphere.

(Good example Port1:700kPa Port2: open to the atmosphere Port3:500kPa)

(Bad example Port1:700kPa Port2:500kPa)

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 AⅡ-1PB 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 Cord (Option)

Fig. 5.2 shows how the cord 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 cord.
Air rotary joint must be placed if the curl cord is to be placed. Furthermore, make sure that the slip ring (in 5.2.2)
cannot be placed if the curl cord is placed.

Table 5.2 Curl Cord Assy Specification

Type A2PB252-EC A2PB502-EC A2PB1002-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 Cord (mm)

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 Ａ Red Ａ

Ｂ White Ｂ

Ｃ Black Ｃ
Table 5.3 Equipped Cable Specifications
Ｄ Gray Ｄ

ＭＳ３１０２Ａ－２８－２０Ｐ
Number of Conductor 12
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 Cord Specification

Fig. 5.4 Outside Dimensions of A2PB252-EC (mm)

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Fig. 5.5 Outside Dimensions of A2PB502-EC (mm)

Fig. 5.6 Outside Dimensions of A2PB1002-EC (mm)

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 5.2.2 Slip Ring (Option)
Fig. 5.7 shows how the ring is placed. See Table 5.4 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 cord (in
5.2.1) cannot be placed if the slip ring is placed.

Table 5.4 Slip Ring Assy Specification

Type A2PB252-ES A2PB502-ES A2PB1002-ES
Parts No. L10545E
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 A2PB252-ES (mm)

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Fig. 5.10 Outside Dimensions of A2PB502-ES (mm)

Fig. 5.11 Outside Dimensions of A2PB1002-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. 5.12 Outside Dimensions of Tailstock(L7090B) (mm)

Fig. 5.13 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 Table 5.6 for the
composition of 1-axis double support positioner.

Table 5.6 The composition of 1-Axis Double Support Positioner

Stand
Positioner Headstock Tailstock
Headstock side Tailstock side
AⅡ-1PB250 L7090D (Stand A) L7090D (Stand A)
AⅡ-1PB500 L7090B L7090E (Stand B) L7090D (Stand A)
AⅡ-1PB1000 L7090E (Stand B) L7090F (Stand C)

Tailstock
Headstock

StandA StandA
Baseplate
（Option）

Fig. 5.14 Outside Dimensions of AⅡ-1PB250 and Tailstock (mm)

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 Headstock
Tailstock

StandB Baseplate StandA

（Option）

Fig. 5.15 Outside Dimensions of AⅡ-1PB500 and Tailstock (mm)

Headstock
AⅡ-1PB1000 Tailstock

StandB Baseplate StandC

（Option）

Fig. 5.16 Outside Dimensions of AⅡ-1PB1000 and Tailstock (mm)

-27-
6 Grounding Method
For safety, install such an earth system as shown in Fig. 6.1.

(1) Be sure to connect the welding cable to the Work-side earth terminal provided beneath the c
onnection box of positioner.
(2) For the manipulator and the robot control unit, install each individual earth cable of 3.5mm2 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, 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 “LOCKTITETM” to these bolts in
order to prevent them from loosening.

Table 7.1 Belt Deflection Values for Timing Belt tension Adjustments
Pressing Force Deflection
AⅡ-1PB250 6.9N 2mm
AⅡ-1PB500
15N 2.5mm
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
AC servo motor W-L02150 W-L02150 1
Cyclo reduction gear W-L01409 5096-462 1
Timing belt W-L01414 5096-463 1
AⅡ-1PB250
Grease Multemp FZ No.00 2670-051 -
Grease Shell, Albania EP-2 ――― -
Battery W-L01399 5096-434 1 See note
AC servo motor W-L02150 W-L02150 1
Cyclo reduction gear W-L01410 5096-465 1
Timing belt W-L01415 5096-466 1
AⅡ-1PB500
Grease Multemp FZ No.00 2670-051 -
Grease Shell, Albania EP-2 ――― -
Battery W-L01399 5096-434 1 See note
AC servo motor W-L02150 W-L02150 1
Cyclo reduction gear W-L01191B 5096-467 1
Timing belt W-L01416 5096-468 1
AⅡ-1PB1000
Grease Multemp FZ No.00 2670-051 -
Grease Shell, Albania EP-2 ――― -
Battery W-L01399 5096-434 1 See note
(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.

8.2 Replacement Parts

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

8.3 Lubricant
Ref. No. Lubrication location Lubricant
1 Pinion gear section Shell, Albania EP-2
2 Cyclo reduction gear Multemp FZ No.00
Note. Grease: Minimum quantity for a single order of Albania EP-2
is about 200 ml in a can.

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 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-4.2 Configuration” in the instruction manual “MANIPULATOR” . Also, see the
aforementioned section to reset the encoder if the encoder data have been lost.

Remove upper cover

Connector box

Replace old battery by new one

as shown.

Battery
Connector

Battery

Battery
Holder
Connector box inner layout

Keep connecting control cables

during this operation.

Keep power-on Controller

during this operation.
Headstock

Fig. 8.2 Replacing Battery

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9 Internal Wiring of the Main Unit
9.1 Electric Circuit Diagram

Fig. 9.1 Electrical Connection Diagram of AⅡ-1PB250, AⅡ-1PB500 , AⅡ-1PB1000

-33-
10 Inspection Items
The periodic inspection is indispensable in order to continue operating AⅡ-1PB Positioner in a safe and an
efficient manner. Perform the periodic inspection in accordance with the following schedule.

Inspection Maintenance
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

34
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.

35
Positioner Headstock Instruction Manual
No. 1L10833A-E-1 MARCH 16, 2009 THE 1st EDITION
No. 1L10833A-E-2 JUNE 10, 2010 THE 2nd EDITION