Zymark XP Manual

Zymate XP Robot
System V Controller Service Manual

Preface iii
Preface
Copyright
This manual is published by Zymark Corporation, Zymark Center,
Hopkinton, MA 01748 USA. Copyright 2000, Zymark Corporation. All
rights reserved. Reproduction by any means or in any form of this
manual or the products it describes is prohibited.
Trademarks
The System V, Zymate, and the Zymark logo are registered trademarks
of Zymark Corporation. All other trademarks and registered trademarks
are the property of their respective holders.
Contents
This manual was prepared for service technicians of the Zymate XP
Robot, who received formal training in its use as instructed by
representatives of Zymark Corporation. While the manual will serve as
a useful refresher and reference document, it is not a substitute for
formal training.
The information in this manual may contain typographical errors or

technical inaccuracies and is subject to change without notice.
Modifications may also be made to the product described in this manual
at any time.
Statement of Proper Use

The Zymate XP Robot contains a robotic arm with interchangeable
hands for transferring vessels of different size between stations in
cylindrical space during sample preparation. The System V Controller
controls the operation of the Zymate XP Robot and many of the
modules.
It is the customer’s reponsibility to keep the Robot and System V

Controller clean and free from debris.
WARNING
• Use this product only in the manner described in this manual.

When used other than as specified, the safety protections
may be impaired.
• There are no user-serviceable parts inside. Refer service to
qualified service personnel.
• Services that alter the hardware or software on this product,
performed by a vendor other than Zymark Corporation or an
approved Zymark vendor, voids the warranty.
P/N 63004 Rev. 3 XP Robot/System V Controller Service Manual Zymark Corporation

iv Preface
Contact Us
If after reading this manual you have any further questions or need
assistance regarding this product, please contact us at the Zymark
Technical Support Center.
Phone: (508)-435-9761
Fax: (508)-435-0950
Email: techsupport@zymark.com
The Technical Support Center hours of operation are Monday through

Friday from 8:00 a.m. to 8:00 p.m. EST.
Visit our World Wide Web site on the Internet at www.zymark.com. The
Center provides expert services including product troubleshooting,
repair instruction, service and installation scheduling and replacement
part information.
For support in Europe contact Zymark LTD, Runcorn, UK

+44-1928-711448 or fax +44-1928-791228. For more information
contact your local Zymark representative.
FCC
When tested as part of a system, this equipment has been tested and
found to comply with the limits of a Class A digital device, pursuant to
part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment
is operated in a commercial environment. This equipment generates,
uses, and can radiate radio frequency energy and, if not installed and
used in accordance with the instruction manual, may cause harmful
interference to radio communications.
Operation of this equipment in a residential area is likely to cause

harmful radio interference; in which case, the user will be required to
correct the interference at his own expense.
NOTE
Changes or modifications to this equipment not expressly

approved by the party responsible for compliance could void the
user’s authority to operate the equipment.
Safety Notice
Zymark has taken every precaution to ensure that the Zymate XP Robot
will provide reliable and safe performance throughout its life. Collision
detection, rounded corners, and optional robot hold-switch capabilities
are a few of it safety features. However, with every piece of complex
and rapidly operating machinery, care must be taken to operate the
equipment in accordance with its intended use.
Zymark Corporation XP Robot/System V Controller Service Manual P/N 63004 Rev. 3

Preface v
WARNING
The Zymate XP Robot operates at high speeds. Use care when

operating it. Do not interfere with the operation of the robot, lean
into its work path, put your hand or arm in its path, or other such
activity that could result in serious physical injury.
Table of Symbols
Table 1 includes symbols that identify particularly important
information and alert you to the presence of hazards as indicated. Some
of these symbols may not appear in this manual or on the product this
manual describes:
Table 1. Symbols
Symbol Description
DANGER: An imminently hazardous situation, which,
if not avoided, will result in death or serious injury.
WARNING: A potentially hazardous situation, which,

if not avoided, could result in death or serious injury.
NOTE: A cautionary statement; an operating tip or

maintenance suggestion; may result in instrument
damage if not followed.
Hazardous voltage; risk of shock injury.
Risk of body parts, hair, jewelry, or clothing getting

caught in a moving part.
Risk of puncture injury.
Risk of eye injury; wear safety glasses.
Risk of fire.
Risk of poison.
Risk of explosion.
Hazardous fumes.

vi Preface
Table 1. Symbols (Continued)

Symbol Description
Hot surface; risk of burns.
Protective ground symbol.
Ground symbol.
CE compliance mark.
Signifies that the unit has passed safety tests for

grounding, high voltage spikes and voltage leakage.
Input.
Output.
Equipment Yellow Caution, risk of danger

labels are Red Stop
color Blue Mandatory action
coded: Green Safe condition or information
Helpful hints, additional information

Table of Contents vii
Table of Contents
Preface............................................................................................................................................ iii
XP Robot Troubleshooting.............................................................................................................1
XP Robot Troubleshooting ....................................................................................................................... 2
Arm and Column Wipers Replacement Procedure .....................................................................5
Procedure Scope ....................................................................................................................................... 5
Parts Required ................................................................................................................................... 5
Tools Required .................................................................................................................................. 5
Remove The Old Wipers .......................................................................................................................... 5
Install The New Wipers ............................................................................................................................ 7
Arm Housing Interconnect Board Replacement Procedure .......................................................9
Procedure Scope ....................................................................................................................................... 9
Parts Required ................................................................................................................................... 9
Tools Required .................................................................................................................................. 9
Remove The Old Board ............................................................................................................................ 9
Install The New Board............................................................................................................................ 10
Arm Housing to Turntable Coil Cord Replacement Procedure...............................................13
Procedure Scope ..................................................................................................................................... 13
Parts Required ................................................................................................................................. 13
Tools Required ................................................................................................................................ 13
Remove The Old Covers ........................................................................................................................ 13
Remove The Old Coil Cord.................................................................................................................... 14
Install The New Coil Cord...................................................................................................................... 15
Reinstall The Covers............................................................................................................................... 15
Arm Housing to Wrist Coil Cord Replacement Procedure ......................................................17
Procedure Scope ..................................................................................................................................... 17
Parts Required ................................................................................................................................. 17
Tools Required ................................................................................................................................ 17
Remove The Covers ............................................................................................................................... 17
Remove The Old Coil Cord.................................................................................................................... 18
Install The New Coil Cord...................................................................................................................... 19
Verify Smooth Reach Operation ............................................................................................................ 20
Reassemble The Robot ........................................................................................................................... 20
Baseboard Replacement Procedure.............................................................................................23
Procedure Scope ..................................................................................................................................... 23
Parts Required ................................................................................................................................. 23
Tools Required ................................................................................................................................ 23
Remove The Old Baseboard................................................................................................................... 24
Install The New Baseboard..................................................................................................................... 24
Check The Reach and Vertical Zero Settings......................................................................................... 25
Set Robot Zeros and Calibrate................................................................................................................ 26
Set Wrist Zero.................................................................................................................................. 26
Calibrate Wrist................................................................................................................................. 27
Set Rotary and Vertical Zero ........................................................................................................... 27
Check Rotary 360° .......................................................................................................................... 28

viii Table of Contents
Calibrate Vertical............................................................................................................................. 28
Set Reach Zero ................................................................................................................................ 29
Calibrate Reach ............................................................................................................................... 29
Alternative Rotary and Vertical Zero Settings ................................................................................ 30
Fan Replacement Procedure ........................................................................................................31
Procedure Scope ..................................................................................................................................... 31
Parts Required ................................................................................................................................. 31
Tools Required ................................................................................................................................ 31
Remove The Old Fan.............................................................................................................................. 32
Install The New Fan................................................................................................................................ 33
Flex Circuit Replacement Procedure ..........................................................................................35
Procedure Scope ..................................................................................................................................... 35
Parts Required ................................................................................................................................. 35
Tools Required ................................................................................................................................ 35
Remove The Old Flex Circuit................................................................................................................. 36
Fold The New FlexCircuit ...................................................................................................................... 37
Install The New Flex Circuit .................................................................................................................. 38
Post Bearing Replacement Procedure.........................................................................................43
Procedure Scope ..................................................................................................................................... 43
Parts Required ................................................................................................................................. 43
Tools Required ................................................................................................................................ 43
Optional ........................................................................................................................................... 43
Disassembly............................................................................................................................................ 43
Remove Covers....................................................................................................................................... 44
Remove Cable Tension and Secure The Cables ..................................................................................... 45
Remove The Column Cap and Arm Housing......................................................................................... 47
Remove The Old Post Bearings.............................................................................................................. 47
Install The New Bearings ....................................................................................................................... 48
Reassembly ............................................................................................................................................. 48
Reassemble The Arm Housing And Column Cap........................................................................... 48
Reattach The Cables ............................................................................................................................... 49
Tension The Cables ................................................................................................................................ 50
Reinstall The Covers ....................................................................................................................... 50
Reach Bearing Adjustment Procedure........................................................................................51
Procedure Scope ..................................................................................................................................... 51
Parts Required ................................................................................................................................. 51
Tools Required ................................................................................................................................ 51
Optional ........................................................................................................................................... 51
Bearing Adjustment ................................................................................................................................ 51
Position The Robot .......................................................................................................................... 51
Adjust The Bearings ............................................................................................................................... 52
Recheck Adjustment............................................................................................................................... 54
Reassemble Robot .................................................................................................................................. 54
Reach Bearing Replacement Procedure......................................................................................57

Table of Contents ix
Procedure Scope ..................................................................................................................................... 57

Parts Required ................................................................................................................................. 57
Tools Required ................................................................................................................................ 57
Optional ........................................................................................................................................... 57
Bearing Replacement.............................................................................................................................. 57
Remove The Arm Housing Cover................................................................................................... 57
Remove The Upper Bearing Assembly........................................................................................... 58
Replace The Upper Bearings........................................................................................................... 59
Prepare to Replace The Lower Bearings ......................................................................................... 59
Replace The Lower Rear Bearings.................................................................................................. 60
Replace The Lower Front Bearings................................................................................................. 60
Resecure The Bearing Assemblies .................................................................................................. 61
Reach Cables Replacement Procedure........................................................................................63
Procedure Scope ..................................................................................................................................... 63
Parts Required ................................................................................................................................. 63
Tools Required ................................................................................................................................ 63
Remove The Old Cables......................................................................................................................... 63
Check Set Screw Position................................................................................................................ 64
Remove The Old Cables.................................................................................................................. 65
Install The New Cables........................................................................................................................... 66
Wrap The New Cables..................................................................................................................... 66
Reassemble The Arm and Attach The Cables................................................................................. 67
Tension The New Cables................................................................................................................. 67
Reset The Potentiometer......................................................................................................................... 68
Check Zero and Calibration.................................................................................................................... 69
Reach Motor Replacement Procedure ........................................................................................71
Procedure Scope ..................................................................................................................................... 71
Parts Required ................................................................................................................................. 71
Tools Required ................................................................................................................................ 71
Remove The Old Motor.......................................................................................................................... 71
Remove The Motor.......................................................................................................................... 72
Install The New Motor............................................................................................................................ 73
Install The Bracket and Tension Assembly On The Motor............................................................. 73
Install The Motor Assembly............................................................................................................ 74
Reassemble The Robot .................................................................................................................... 74
Reach Potentiometer Replacement Procedure ...........................................................................77
Procedure Scope ..................................................................................................................................... 77
Parts Required ................................................................................................................................. 77
Tools Required ................................................................................................................................ 77
Remove The Old Reach Potentiometer .................................................................................................. 79
Set and Install The New Reach Potentiometer ....................................................................................... 80
Adjust The Potentiometer ....................................................................................................................... 81
Reach Timing Belt Replacement Procedure...............................................................................85
Procedure Scope ..................................................................................................................................... 85

x Table of Contents
Parts Required ................................................................................................................................. 85

Tools Required ................................................................................................................................ 85
Remove The Defective Belt.................................................................................................................... 85
Remove The Belt............................................................................................................................. 86
Install The New Belt............................................................................................................................... 87
Install The Belt ................................................................................................................................ 87
Reassemble The Robot .................................................................................................................... 88
Rotary Drive Cable Replacement Procedure .............................................................................89
Procedure Scope ..................................................................................................................................... 89
Parts Required ................................................................................................................................. 89
Tools Required ................................................................................................................................ 89
Optional ........................................................................................................................................... 89
Disassembly............................................................................................................................................ 89
Position The Robot and Remove Covers......................................................................................... 89
Remove The Tensioning Screw Cable ............................................................................................ 90
Remove The Fixed End Cable......................................................................................................... 91
Remove The Rotary Drive Drum .................................................................................................... 91
Installation .............................................................................................................................................. 92
Wrap Fixed End Cable (Longer cable)............................................................................................ 92
Wrap Tensioning Screw Cable (Shorter cable) ............................................................................... 92
Reinstall The Rotary Drive Drum ................................................................................................... 93
Dress The Cables Over The Pulleys................................................................................................ 95
Wrap The Fixed (Long) Cable Around The Turntable ................................................................... 96
Wrap The Tensioning Screw Cable Around The Turntable............................................................ 96
Adjustment and Reassemble................................................................................................................... 97
Cable Adjustment ............................................................................................................................ 97
Position Adjustment ........................................................................................................................ 98
Reassemble The Robot .................................................................................................................. 100
Rotary Motor Replacement Procedure.....................................................................................101
Procedure Scope ................................................................................................................................... 101
Parts Required ............................................................................................................................... 101
Tools Required .............................................................................................................................. 101
Disassembly.......................................................................................................................................... 101
Position The Robot ........................................................................................................................ 101
Relax Cable Tension...................................................................................................................... 102
Disconnect The Motor................................................................................................................... 103
Remove The Motor........................................................................................................................ 103
Installation ............................................................................................................................................ 104
Mount The New Motor.................................................................................................................. 104
Connect The Motor........................................................................................................................ 105
Set Cable Tension and Install Covers............................................................................................ 105
Rotary Potentiometer Replacement Procedure........................................................................107
Procedure Scope ................................................................................................................................... 107
Parts Required ............................................................................................................................... 107
Tools Required .............................................................................................................................. 107
Remove The Covers ............................................................................................................................. 107
Remove The Old Potentiometer ........................................................................................................... 108
Set and Install The New Potentiometer ................................................................................................ 109
Adjust The Potentiometer ..................................................................................................................... 110

Table of Contents xi
Complete The Installation..................................................................................................................... 111

Rotary Servo Cable Replacement Procedure ...........................................................................113
Procedure Scope ................................................................................................................................... 113
Parts Required ............................................................................................................................... 113
Tools Required .............................................................................................................................. 113
Optional ......................................................................................................................................... 113
Disassembly.......................................................................................................................................... 113
Position The Robot and Remove Covers....................................................................................... 113
Remove The Cables....................................................................................................................... 114
Installation ............................................................................................................................................ 116
Replace The Cables ....................................................................................................................... 116
Wrap The Bottom Cable Around The Turntable.................................................................................. 118
Wrap The Top Cable Around The Turntable ....................................................................................... 119
Cable Adjustment ................................................................................................................................. 120
Position Adjustment ............................................................................................................................. 120
Complete The Installation..................................................................................................................... 122
Turntable Interconnect Board Replacement Procedure .........................................................123
Procedure Scope ................................................................................................................................... 123
Parts Required ............................................................................................................................... 123
Tools Required .............................................................................................................................. 123
Remove The Old Board ........................................................................................................................ 123
Install The New Board.......................................................................................................................... 124
Turntable to Wrist Coil Cord Replacement Procedure ..........................................................125
Procedure Scope ................................................................................................................................... 125
Parts Required ............................................................................................................................... 125
Tools Required .............................................................................................................................. 125
Remove The Old Coil Cord.................................................................................................................. 126
Install The New Coil Cord.................................................................................................................... 127
Verify Smooth Reach Operation .......................................................................................................... 128
Reinstall The Covers............................................................................................................................. 128
Vertical Cable Replacement Procedure ....................................................................................131
Procedure Scope ................................................................................................................................... 131
Parts Required ............................................................................................................................... 131
Tools Required .............................................................................................................................. 131
Optional ......................................................................................................................................... 131
Disassembly.......................................................................................................................................... 131
Remove Cable Tension.................................................................................................................. 132
Remove The Drive Drum .............................................................................................................. 134
Installation ............................................................................................................................................ 134
Wrap The New Cables................................................................................................................... 134
Reinstall The Drum ....................................................................................................................... 135
Attach The Short Cable ................................................................................................................. 137
Attach The Long Cable ................................................................................................................. 137
Tension The Cables ....................................................................................................................... 137
Reassemble The Robot ......................................................................................................................... 138
Replace The Covers....................................................................................................................... 138
Verify Operation............................................................................................................................ 138
Set Vertical Zero and Check Calibration....................................................................................... 138

xii Table of Contents
Vertical Motor Replacement Procedure ...................................................................................139

Procedure Scope ................................................................................................................................... 139
Parts Required ............................................................................................................................... 139
Tools Required .............................................................................................................................. 139
Optional ......................................................................................................................................... 139
Disassembly.......................................................................................................................................... 139
Position The Robot ........................................................................................................................ 139
Relax Cable Tension...................................................................................................................... 141
Disconnect The Motor................................................................................................................... 142
Remove The Motor........................................................................................................................ 142
Installation ............................................................................................................................................ 142
Mount The New Motor.................................................................................................................. 142
Connect The Motor........................................................................................................................ 143
Set Cable Tension and Install Covers............................................................................................ 143
Vertical Potentiometer Replacement Procedure......................................................................145
Procedure Scope ................................................................................................................................... 145
Parts Required ............................................................................................................................... 145
Tools Required .............................................................................................................................. 145
Remove The Old Potentiometer ........................................................................................................... 146
Set and Install The New Potentiometer ................................................................................................ 149
Adjust The Potentiometer ..................................................................................................................... 149
Reassemble The Robot ......................................................................................................................... 150
Vertical Spring Cable Replacement Procedure .......................................................................153
Procedure Scope ................................................................................................................................... 153
Parts Required ............................................................................................................................... 153
Tools Required .............................................................................................................................. 153
Disassembly.......................................................................................................................................... 153
Remove Covers..................................................................................................................................... 153
Remove The Old Cable ........................................................................................................................ 154
Installation ............................................................................................................................................ 157
Install The New Cable .......................................................................................................................... 157
Re-tension and Complete The Cable Installation ................................................................................. 158
Reinstall The Covers............................................................................................................................. 158
Wrist Cable and Flex Coupling Replacement Procedure .......................................................159
Procedure Scope ................................................................................................................................... 159
Parts Required ............................................................................................................................... 159
Tools Required .............................................................................................................................. 159
Disassembly.......................................................................................................................................... 159
Remove The Wrist Cover .............................................................................................................. 159
Remove The Wrist Interconnect Board and Coil Cords................................................................ 160
Remove The Wrist Coupling......................................................................................................... 160
Disassemble The Wrist Coupling (Old Style) ............................................................................... 161
Disassemble The Wrist Coupling (New Style) ............................................................................. 161
Installation ............................................................................................................................................ 162
Fold and Attach The New Cable ................................................................................................... 162
Reassemble The Wrist Pin Holder Assembly (Old Style)............................................................. 162
Reassemble The Wrist Pin Holder Assembly (New Style) ........................................................... 163
Complete The Installation ............................................................................................................. 163
Zero The Wrist...................................................................................................................................... 164

Table of Contents xiii
Calibrate The Wrist............................................................................................................................... 165

Wrist Coupling Pin Replacement Procedure ...........................................................................167
Procedure Scope ................................................................................................................................... 167
Parts Required ............................................................................................................................... 167
Tools Required .............................................................................................................................. 167
Remove The Old Pins........................................................................................................................... 167
Install The New Pins............................................................................................................................. 168
Wrist Interconnect Board Replacement Procedure.................................................................169
Procedure Scope ................................................................................................................................... 169
Parts Required ............................................................................................................................... 169
Tools Required .............................................................................................................................. 169
Remove The Old Board ........................................................................................................................ 169
Install The New Board and Verify Operation....................................................................................... 170
Wrist Motor Replacement Procedure .......................................................................................171
Procedure Scope ................................................................................................................................... 171
Parts Required ............................................................................................................................... 171
Tools Required .............................................................................................................................. 171
Disassembly.......................................................................................................................................... 171
Remove The Wrist Interconnect Board and Coil Cords................................................................ 173
Remove The Wrist Coupling......................................................................................................... 173
Remove The Wrist Stop and Anti-Backlash Gear......................................................................... 173
Remove The Motor........................................................................................................................ 174
Installation ............................................................................................................................................ 174
Install The New Motor .................................................................................................................. 174
Install The Anti-Backlash Gear ..................................................................................................... 175
Install The Wrist Coupling ............................................................................................................ 175
Complete The Installation ............................................................................................................. 175
Zero The Wrist...................................................................................................................................... 176
Wrist Potentiometer Replacement Procedure..........................................................................179
Procedure Scope ................................................................................................................................... 179
Parts Required ............................................................................................................................... 179
Tools Required .............................................................................................................................. 179
Disassembly.......................................................................................................................................... 179
Remove The Potentiometer ........................................................................................................... 180
Installation ............................................................................................................................................ 181
Install The New Potentiometer...................................................................................................... 181
Set The Potentiometer ................................................................................................................... 181
Zero The Wrist...................................................................................................................................... 182
Wrist Replacement Procedure ...................................................................................................185
Procedure Scope ................................................................................................................................... 185
Parts Required ............................................................................................................................... 185
Tools Required .............................................................................................................................. 185
Disassembly.......................................................................................................................................... 185
Remove The Coil Cords ................................................................................................................ 186

xiv Table of Contents
Remove The Old Wrist.................................................................................................................. 187

Installation ............................................................................................................................................ 187
Install The New Wrist ................................................................................................................... 187
Level The Wrist............................................................................................................................. 188
Zero The Wrist...................................................................................................................................... 188
System V Controller Replacement Overview ...........................................................................191
System V Controller’s Disk Drive Replacement Procedure ...................................................193
Procedure Scope ................................................................................................................................... 193
Parts Required ............................................................................................................................... 193
Tools Required .............................................................................................................................. 193
Preliminary ........................................................................................................................................... 193
Removing The CPU Board................................................................................................................... 194
Installing The New Disk Drive............................................................................................................. 195
Installing The CPU Board .................................................................................................................... 196
Verifying Operation.............................................................................................................................. 197
System V Controller’s CPU Board Replacement Procedure..................................................199
Procedure Scope ................................................................................................................................... 199
Parts Required ............................................................................................................................... 199
Tools Required .............................................................................................................................. 199
Preliminary ........................................................................................................................................... 199
Removing The CPU Board................................................................................................................... 200
Installing The New CPU Board............................................................................................................ 201
System V Controller’s Module Support Board Replacement Procedure ..............................203
Procedure Scope ................................................................................................................................... 203
Parts Required ............................................................................................................................... 203
Tools Required .............................................................................................................................. 203
Preliminary ........................................................................................................................................... 203
Removing The Module Support Board................................................................................................. 204
Installing The New Module Support Board.......................................................................................... 205
System V Controller’s Power Supply Replacement Procedure..............................................207
Procedure Scope ................................................................................................................................... 207
Parts Required ............................................................................................................................... 207
Tools Required .............................................................................................................................. 207
Preliminary ........................................................................................................................................... 207
Installing The New Power Supply........................................................................................................ 209
Removing the CPU Board ............................................................................................................. 209
Replacing the Power Supply ......................................................................................................... 209
Replacing the CPU Board ............................................................................................................. 210
Adjusting The Power Supply................................................................................................................ 211
Reassembling The System V Controller............................................................................................... 211
Index .............................................................................................................................................213

Table of Contents xv
Reference Number List
No. Procedure Page

R101 Post Bearing Replacement Procedure............................................................ 43
R108 Reach Timing Belt Replacement Procedure................................................... 85
R111 Reach Bearing Adjustment Procedure........................................................... 51
R114 Rotary Motor Replacement Procedure........................................................... 101
R115 Vertical Spring Cable Replacement Procedure.............................................. 153
R120 Vertical Motor Replacement Procedure......................................................... 139
R122 Turntable to Wrist Coil Cord Replacement Procedure................................ 125
R123 Arm Housing to Turntable Coil Cord Replacement Procedure.................. 13
R124 Arm Housing to Wrist Coil Cord Replacement Procedure......................... 17
R128 Rotary Servo Cable Replacement Procedure................................................ 113
R133 Reach Potentiometer Replacement Procedure.............................................. 77
R134 Wrist Potentiometer Replacement Procedure............................................... 179
R135 Wrist Cable and Flex Coupling Replacement Procedure............................. 159
R136 Wrist Coupling Pin Replacement Procedure................................................. 167
R137 Wrist Motor Replacement Procedure............................................................. 171
R139 Wrist Replacement Procedure ....................................................................... 185
R140 Reach Bearing Replacement Procedure......................................................... 57
R143 Reach Motor Replacement Procedure........................................................... 71
R144 Arm Housing Interconnect Board Replacement Procedure....................... 9
R145 Turntable Interconnect Board Replacement Procedure.............................. 123
R146 Wrist Interconnect Board Replacement Procedure..................................... 169
R150 Flex Circuit Replacement Procedure.............................................................. 35
R155 Vertical Potentiometer Replacement Procedure........................................... 145
R160 Fan Replacement Procedure........................................................................... 31
R165 Rotary Drive Cable Replacement Procedure................................................. 89
R170 Arm and Column Wipers Replacement Procedure....................................... 5
R176 Baseboard Replacement Procedure................................................................ 23
R187 Rotary Potentiometer Replacement Procedure............................................. 107
R191 Vertical Cable Replacement Procedure.......................................................... 131
R192 Reach Cables Replacement Procedure.......................................................... 63

xvi Table of Contents
No. Procedure Page

- System V Controller Replacement Overview................................................ 191
C90 System V Controller’s Disk Drive Replacement Procedure........................ 193
C91 System V Controller’s CPU Board Replacement Procedure....................... 199
C92 System V Controller’s Module Support Board Replacement Procedure.. 203
C93 System V Controller’s Power Supply Replacement Procedure.................. 207

XP Robot Troubleshooting 1
XP Robot Troubleshooting
Use this section of the manual if you are having problems with your XP
Robot, or if you notice positioning problems on the benchtop. If you are
experiencing problems not covered in the troubleshooting section, refer
to the Error Recovery and Troubleshooting – Section 7 in the Zymate
System User’s Guide for Windows – Volume 1.
If you need additional help, call the Zymark Technical Support Center at
(508) 435-9761 or FAX (508) 435-0950. For support in Europe, contact
Zymark LTD, Runcorn, UK +44-1928-711448 or FAX +44-1928-
791228.
Besides the troubleshooting information, this section of the manual also

contains information on the XP Robot’s baseboard diagnostic LED’s.

2 XP Robot Troubleshooting
The troubleshooting chart lists common symptoms, probable causes,
and solutions for the XP Robot.
Symptom Probable Cause Solution
Positions off at all benchtop Potentiometer worn and out of Verify Accutrak error by confirming
positions. Accutrak compensation limits that baseboard LED D13, D16, or
D19 is on. Replace the defective
potentiometer according to
replacement procedures (R133,
R134, R155, or R187) in this
manual, then recalibrate the robot.
Calibration settings not correct Recalibrate and check positions. If
due to return to factory problem persists contact the Zymark
calibration factors. Technical Support Center.
Defective baseboard. Replace baseboard according to
procedure R176.
Arm is loose in arm housing. Adjust reach bearings according to
procedure R111.
Bent or damaged fingers. Contact Zymark Technical Support
Center for replacement fingers.
Wrist zero not correct. Rezero wrist according to XP Zero
and Calibration Procedure.
Positions off at one benchtop Station or PyPlate loose. Resecure station or PyPlate and
location. reteach position.
Benchtop not level. Move station or PyPlate to different
location.
Robot stops and error message Probable motor wear due to age If message appears frequently, motor
“xxx Thermal protection of motor, continuous robot may have to be replaced. Contact
active” appears, where xxx = operation for extended periods, Zymark Technical Support Center
the affected axis—for ex. etc. for more details. Refer to the
“rotary.” Robot remains shut appropriate motor replacement
down for approximately 3 procedures (R114, R120, R137, and
minutes until affected axis R134).
cools.

XP Robot Troubleshooting 3
XP Robot Troubleshooting (Continued)

Symptom Probable Cause Solution
Robot stops and error message Potentiometer wear, cable If Accutrak Error LED for the
“xxx Not in Position” appears, tension not correct, motor wear affected axis is on, replace the
where xxx = the affected axis or, defective baseboard, etc. If potentiometer according to the
for example “reach.” error in reach axis, reach belt procedures (R133, R134, R155, or
could be defective. R187).
If LED is not on, check cable tension

for affected axis.
If problem is with the reach belt,

refer to procedure R108.
If problem persists, contact Zymark

Technical Support Center.
Robot not responding and error Robot has no power. Make sure the robot power switch is ON.
message “Fatal Robot Make sure the power strip is ON. Check
communications error, Type 129” power cord/power strip connections.
or “Type 130” appears. Check the robots’ fuse.
Robot module card is not fully Turn controller off, reseat module card,
seated in controller, or module card and try again. If the module card is bad,
is defective. replace the card.
Communication cable between Check communications cable
module card and robot is not connections. Replace cable if necessary.
properly connected, or is defective.
Baseboard is defective. Replace baseboard according to
procedure R176.
Robot making usual noises. Vertical spring cable broken. Check to make sure no loose screws.
When power is off, arm housing
falls to bottom of vertical travel. Replace vertical spring cable according
to procedure R115.

4 XP Robot Troubleshooting
This page intentionally left blank.

R170 Arm and Column Wipers Replacement Procedure 5
Arm and Column Wipers

Replacement Procedure
Procedure Scope
This procedure describes how to replace the arm and column wipers in
the Zymate XP Robot.
Parts Required
• Oiled arm wiper (1) and column wipers (2)
Tools Required
• Screwdriver, flatblade
• Wire cutter
• Tape, masking or other
Remove The Old Wipers

WARNING
Turn OFF the system power before beginning these procedures.
1. Turn the Controller’s power OFF.

2. Turn the Robot’s power OFF and unplug the power cord.
3. Remove the three screws that secure the arm housing cover. Set the
screws aside.
4. Pull the arm fully outward, then slide the arm housing cover
upward and tape it into position at the top of the columns.

6 Arm and Column Wipers Replacement Procedure R170
5. Locate the arm wiper assembly at the front of the arm housing.
6. Remove the two screws that secure the arm wiper assembly to the
arm housing. Remove the assembly and set the screws aside.
7. Separate the arm wiper from the front and rear wiper plates.

R170 Arm and Column Wipers Replacement Procedure 7
8. Remove the nylon spacers from the two holes in the wiper. Set the
spacers aside and discard the wiper.
9. Locate the two column wipers. These are located on the columns,
above the arm housing.
10. Remove the column wipers and discard.
NOTE
You may have to cut the old wipers to remove them from the
columns.
Install The New Wipers

1. Insert the two nylon spacers into the holes of the new arm wiper,
then sandwich the new arm wiper between the two arm wiper
plates.
2. Secure the new arm wiper and arm wiper plates to the arm housing
with the two screws previously removed. Make sure the new arm
wiper is positioned so it touches the top surface of the arm.
3. Install a new column wiper around each column. Make sure the cut
in the wiper does not align with one of the column bearings.
4. Remove the tape that secures the arm housing cover to the column
cap.
5. Extend the robot’s reach fully out, then slide the arm housing cover
downward and over the arm housing.
6. With the arm fully out, there should be 15 coil cord wraps on the
left side of the arm, and 16 coil cord wraps on the right side of the
arm.

8 Arm and Column Wipers Replacement Procedure R170
7. Make sure the coil cords are correctly seated in the cutouts on the
front of the arm housing cover.
8. Align the three holes in the top of the arm housing cover with the
three threaded holes in the housing. Insert the three previously
removed screws in the threaded holes and tighten them to secure
the arm housing cover.
9. Plug in the Robot’s power cord and turn the power ON.
WARNING
Plug the power cord only into a properly grounded outlet supplying the
correct voltage.
Use only a standard IEC 320-style power cord appropriate for your
country.
10. Turn the Controller’s power ON.

R124 Arm Housing Interconnect Board Replacement Procedure 9
Arm Housing Interconnect

Board Replacement
Procedure
Procedure Scope
This procedure describes how to replace the arm housing interconnect
board in the Zymate XP Robot.
Parts Required
• Arm housing interconnect board
Tools Required
Remove The Old Board

WARNING

screws aside.
4. Pull the arm fully outward, then slide the arm housing cover
upward and tape it into position at the top of the columns.
5. Locate the arm housing interconnect board at the back of the arm
housing, note the location of the five cables connected to the board,
then unplug the cables.

10 Arm Housing Interconnect Board Replacement Procedure R144
6. Remove the two screws that secure the arm housing interconnect
board to the housing. Remove the arm housing interconnect board
and set the screws aside.
Install The New Board

1. Secure the new arm housing interconnect board with the two
screws previously removed.
2. Plug the five cables into the receptacles on the new arm housing
board.
arm.

R124 Arm Housing Interconnect Board Replacement Procedure 11
6. Align the three holes in the top of the cover with the three threaded
holes in the housing. Insert the three previously removed screws to
secure the arm housing cover.
WARNING
correct voltage.
country.

12 Arm Housing Interconnect Board Replacement Procedure R144

R123 Arm Housing to Turntable Coil Cord Replacement Procedure 13
Arm Housing to Turntable Coil

Cord Replacement Procedure
Procedure Scope
This procedure describes how to replace the coil cord that runs from the
arm housing to the turntable in the Zymate XP Robot.
Parts Required
• Coil cord, arm housing to turntable
• Ty-wrap
Tools Required
• Wire cutters
Remove The Old Covers

WARNING

3. Move the arm housing upward near the mid point on the columns.
screws aside.
5. Pull the arm fully out and slide the arm housing cover up. Tape the
cover near the top of the columns.
6. Remove the two screws that secure the turntable cover. Set the
screws aside.
7. Move the turntable cover upward and tape it to the bottom of the
arm housing.

14 Arm Housing to Turntable Coil Cord Replacement Procedure R123
Remove The Old Coil Cord

1. Follow the routing of the coil cord as it extends from the arm
housing to the turntable. Remembering this routing will help when
installing the new coil cord.
2. Unplug the coil cord from the interconnect board on the rear of the
arm housing.
3. Unplug the opposite end of the coil cord from the turntable
interconnect board next to the vertical motor on the turntable.

R123 Arm Housing to Turntable Coil Cord Replacement Procedure 15
4. Remove the screw from the white coil cord clamps on the arm
housing and turntable.
5. Carefully cut the ty-wrap near the turntable interconnect board.
6. Pull the coil cord up through the coil cord guide in the arm housing.
7. Remove the two coil cord clamps from the old coil cord and
transfer them to the same positions on the new coil cord.
Install The New Coil Cord

1. Slide the new coil cord into the arm housing’s coil cord guide and
route the turntable-end of the coil cord to the turntable interconnect
board.
2. Plug the coil cord into the connector on the turntable interconnect
board.
3. Plug the opposite end of the coil cord into the connector on the arm
housing interconnect board.
4. Insert the coil cord into the groove at the top of the arm housing.
5. Secure the coil cord to the turntable and arm housing using the coil
cord clamps and screws.
6. Pull downward slightly on the coils to ensure that the coil cord does
not bind within the coil cord guide.
7. Install a new ty-wrap near the turntable interconnect board.
Reinstall The Covers

1. Remove the tape that secures the turntable housing to the arm
housing.
2. Reinstall the turntable cover with the two screws previously
removed.
3. Remove the tape that secures the arm housing cover to the top of
the columns.
left side of the arm and 16 coil cord wraps on the right side of the
arm.

16 Arm Housing to Turntable Coil Cord Replacement Procedure R123
secure the cover.
WARNING
correct voltage.
country.
9. Turn the controller’s power ON.

R124 Arm Housing to Wrist Coil Cord Replacement Procedure 17
Arm Housing to Wrist Coil

Cord Replacement Procedure
Procedure Scope
arm housing to the wrist in the Zymate XP Robot.
Parts Required
• Coil cord, arm housing to wrist
• Ty-wraps
Tools Required
• Wire cutters
• Ruler
Remove The Covers

WARNING

3. Move the arm housing upward near the mid-point on the columns.
screws aside.
6. Remove the screw that secures the wrist cover. Remove the cover
and set it aside with the screw.

18 Arm Housing to Wrist Coil Cord Replacement Procedure R124
7. Pull the arm out to help with the removal of the old coil cord.

1. Following the routing of the coil cord as it extends from the arm
housing to the wrist. Remembering this routing helps when
installing the new coil cord.
2. Unplug the coil cord from the interconnect board on the rear of the
arm housing.
3. Unplug the opposite end of the coil cord from the wrist interconnect
board.
4. Carefully cut any ty-wraps that secure the coil cord to the arm
housing.
5. Loosen the two screws that secure the coil cord tube to the wrist
box.

6. Slide the tube and coil cord out of the wrist box. Allow the rubber
grommet at the end of the tube to slip from its notch. This helps with
coil cord tube and coil cord removal.
7. Remove the rubber grommet from the coil cord and set it aside.
8. Slide the coil cord tube off the coil cord and set it aside.
9. Remove the coil cord from the horizontal coil cord support.

1. With the longer tail of the new coil cord towards the arm housing,
slide the loop of coils onto the horizontal coil cord support.
NOTE
When correctly positioned, the coil cord loop nearest the arm housing
should cross to the inside of the support.
2. Plug in the end of the coil cord to its connector on the arm housing
interconnect board.
3. Secure the coil cord to the arm housing with ty-wraps.
4. Slide the coil cord tube over the loops of coils on the horizontal
support.
5. Install the rubber grommet 2.5" (6.4 cm) from the inside surface of
the coil cord’s wrist connector.
6. Move the arm IN and feed the end of the coil cord and the coil cord
tube into the wrist box. When correctly positioned, the tube should
be flush with the front of the wrist box, the notch should face up,
and the notch should hold the grommet and cord.
7. Tighten the two screws to secure the coil cord tube to the wrist box.
8. Plug the coil cord into its connector on the wrist interconnect board.

Verify Smooth Reach Operation

1. Manually push the arm IN and verify that there is no binding or
resistance in the coil cord as the back of the wrist box comes close
to the arm housing.
2. If binding or resistance is noted, check the following:
a. The coil cord loop nearest the arm housing crosses to the inside
of the support. See diagram on previous page. If the loop does
not pass to the inside of the support, repeat the Remove the Old
Coil Cord, Install the New Coil Cord, and Verify Smooth Reach
Operation procedures.
b. The coil cord support passes through the center of the coils. If
the support does not pass through the center, carefully bend the
horizontal coil cord support until it passes through the center
of the coils.
Reassemble The Robot

1. Install the wrist cover and secure it with the screw previously
removed.
2. Remove the tape that held the arm housing cover to the top of the
columns.
left side of the arm and 16 coil cord wraps on the right side of the
arm.

secure the cover.
WARNING
correct voltage.
country.


R176 Baseboard Replacement Procedure 23
Baseboard Replacement
Procedure
Procedure Scope
This procedure describes how to replace the baseboard in the Zymate
XP Robot.
Parts Required
• Baseboard
Tools Required
• Allen wrench, 1/4"
• 12 or 18 inch metal ruler (or metric equivalent)
Remove The Covers

WARNING

3. Move the arm housing upward near the top of the columns.
screws aside.
5. Move the cover upward and tape it to the bottom of the arm
housing.
6. Remove the two screws that secure the base cover. Remove the
cover and set it aside with the two screws.

24 Baseboard Replacement Procedure R176
Remove The Old Baseboard

1. Locate the baseboard and carefully unplug all connectors, taking
note of connector locations on the board.
2. Remove the eight screws that secure the baseboard to the base
plate. Five are located on the board itself, and three are located
along the top of the heat sink.
3. Remove the baseboard and set it aside with the fasteners.
Install The New Baseboard

1. Position the new baseboard on the Robot.
2. Secure the new baseboard with the fasteners previously removed.
Make sure that the screw closest to the fan is tight.
3. Plug all connectors into their appropriate receptacles on the new
baseboard. Make sure the connectors are properly aligned and fully
seated.
4. Reinstall the base cover and secure it using the two previously
removed screws.
5. Remove the tape holding the turntable cover to the bottom of the
arm housing.

6. Reinstall the turntable cover and secure it using the two previously
removed screws.
Check The Reach and Vertical Zero Settings

WARNING
Plug the power cord only into a properly grounded outlet

supplying the correct voltage.
Only use a standard IEC 320-style power cord appropriate for

your country.

3. Click on the System V Terminal Icon to run the System V Terminal
Program.
4. Click on the Options menu pull-down and select Show Dictionary.
5. In the Show Dictionary list window, click on the Options menu
pull-down and select Module SetUp.
6. Select the Zymate XP Robot from the Module SetUp list.
WARNING
Always keep body parts hair, jewelry, and clothing away from the
robot. The robot may move unexpectedly in any direction.
7. From the ZYMATE XP PROGRAMMING screen, move the Robot

to reach and vertical zero.
8. Verify that the following is true:
a. There is approximately 1/8" (32 mm) of space between the
bottom of the arm housing and the top of the turntable cover.
If your Robot is different, perform the SET ROTARY AND
VERTICAL ZERO procedure to adjust the vertical zero before
continuing.
b. There is approximately 1/4" (64 mm) of space between the
back of the wrist box and the arm housing cover. If your Robot
is different, perform the SET REACH ZERO procedure to
adjust the reach zero.
9. Click on the File menu pull-down and select Exit.
10. At the Z>, run the SET.ACCUTRAK program to store Accutrak
correction factors. The program runs for 15 minutes.

Set Robot Zeros and Calibrate

After running the SET.ACCUTRAK program, follow the procedures
below to set the Robot zeros and calibrate.
Set Wrist Zero

1. Place a monument in an easily accessed hand parking station.
Program.
pull-down and select Module SetUp.
5. Select the Zymate XP Robot from the Module SetUp list.
6. From the ZYMATE XP PROGRAMMING screen, move to:
0.0 wrist, 0.6 vertical, and 0.0 reach.
7. Move to a rotary position that aligns the arm with the hand parking
station (a rotary move of 7.5 x parking station sector number
achieves rotary alignment). For example, if your parking station is
located at sector 24, move to a rotary position of 7.5 x 24, or 180°.
8. Move to a reach position of 29.5.
9. If necessary, make any rotary adjustments as required.
10. Look through the holes and observe the alignment of the holes in
the monument and the wrist pins. If the pins are aligned with the
holes, no zero adjustment is necessary; go to the “Calibrate Wrist”
procedure.
11. If the pins are not aligned with the holes, set the correct wrist zero
as follows:
a. From the ZYMATE XP PROGRAMMING screen, press the
F8 key to select the ZYMATE XP HAND PROGRAMMING
screen.
b. Press the “0” key to access the ROBOT WRIST
CALIBRATION options, then press the “Z” key to select the
zero function.
c. Use the clockwise/counter-clockwise function keys to move
the wrist until the pins are aligned with the monument holes.
Example:
Wrist pins not aligned--movement of the wrist coupling in a

clockwise direction is required.
d. Press the ESC key to store the wrist zero value.
e. Press the ESC key again to go back to the ZYMATE XP
HAND PROGRAMMING screen.

f. Press the F7 key to go back to the ZYMATE XP

PROGRAMMING screen.
Calibrate Wrist
1. From the ZYMATE XP PROGRAMMING screen, move the reach
IN so that the wrist pins are clear of the monument.
2. Next, move to a wrist angle of 360°.
3. Move the reach OUT so the pins are just about to enter the
monument holes.
4. Press the F8 key to enter the ZYMATE XP HAND
PROGRAMMING screen. Then use the clockwise/counter-
clockwise function keys to move the wrist until the pins are aligned
with the monument holes.
5. When aligned, press the “0” key to access the ROBOT WRIST
CALIBRATION options.
6. Press the “C” key to select the calibration function.
7. Enter a wrist angle of 360°. Press the Enter key three times to store
the calibration value.
8. Press the ESC key to exit the calibration screen.
Set Rotary and Vertical Zero

1. Place a hand parking station with monument at sector 48 on the
Robot locator plate. Make sure the station is centered within the
locating holes.
NOTE
If your system already has a PyStation in this sectior and you

perfer not to move it, refer to Alternative Rotary and Vertical Zero
Setting procedure.
2. From the ZYMATE XP PROGRAMMING screen, move to the

following coordinates: vertical - 0.6, reach - 0, rotary - 0, and
wrist - 0.
3. Now move the reach to 29.5.
4. Press the “0" key to access the ROBOT AXIS CALIBRATION
options. Then press the “Z” key to select the zero function.
5. Use the rotary and vertical function keys to align the wrist pins with
the holes in the monument. Do NOT move the reach axis.
Example:

Wrist pins not aligned — movement of the base axis in a

counterclockwise and down direction is required.
6. When satisfied with the alignment, press the ESC key to store the
vertical and rotary zero values. Then press the ESC key again to
exit the calibration screen.
Check Rotary 360°

This procedure checks the span of the Robot by comparing the 360°
position with the 0° position.
1. From Manual Control, set S:SPEED = 1.
2. From the ZYMATE XP PROGRAMMING screen, set reach to 0.
3. Now move to a rotary position of 10°.
4. Move to the 0° rotary position and a reach position of 29.5. Observe
alignment between the wrist pins and the holes in the monument.
5. Move the reach IN slightly, then move to the 370° rotary position.
6. Move back to 360°, move the reach to 29.5, and again observe
alignment between the pins and monument holes. If it takes more
than one function key hit to correct alignment at 360°, re-run the
SET.ACCUTRAK PROGRAM, and repeat the “Set Rotary and
Vertical Zero” procedure and this Check Rotary 360° procedure.
Calibrate Vertical
1. Run a GET.HAND program to attach a hand that is located at an
easily accessed position on the benchtop.
2. From the ZYMATE XP PROGRAMMING screen, move to vertical
31.1.
3. Now move to reach 31.1. The hand should now be positioned
directly over the empty parking station.
4. Use the metal ruler to measure from the bottom surface of the hand
to the top surface of the hand parking station. The measurement
should be 12.0" (30.5 cm).

5. If different, use the function key(s) from the ZYMATE XP

PROGRAMMING screen to move up or down as necessary.
6. Press the “0” key to access the ROBOT AXIS CALIBRATION
options. Then press the “C” key to select the calibrate function.
7. Enter 31.1 for the vertical height. Press the Enter key twice.
Set Reach Zero

1. Remove any hand that may be attached and move the reach to zero
from the ZYMATE XP PROGRAMMING screen.
2. Press the “0” key to enter the ROBOT AXIS CALIBRATION
screen. Then press the “Z” key to select the zero function.
3. Measure from the flat, inside surface of the arm housing to the
inside surface of the wrist box. The measurement should be 1.1"
(28 mm).
4. If required, use the reach function key(s) to move the arm until the
measurement is correct.
5. Press the ESC key to store the reach zero value. Press the ESC key
again to exit the calibration screen.
Calibrate Reach
1. Remove any hand that may be attached and place a monument in an
easily accessed hand parking station.
2. Move to 0.6 vertical.
4. Move the reach to 31.1. When properly adjusted, the front surface
of the wrist should just touch the inside of the monument.

5. If different, use the reach function key(s) from the ZYMATE XP

PROGRAMMING SCREEN to move the arm until the criteria in
step 4 is met.
6. When properly adjusted, press the “0” key to access to the ROBOT
AXIS CALIBRATION options. Then press the “C” key to select
the calibration function.
7. Enter a reach calibration value of 31.1. Press the Enter key.
Alternative Rotary and Vertical Zero Settings

Follow this procedure to set the rotary and vertical zeros only if you
have a PyStation positioned at sector #48. Otherwise, follow the “Set
Rotary and Vertical Zero” procedure.
1. Remove any hand that may be attached, and place a monument in a
conveniently located hand parking station. Make sure the parking
station is centered within the locator plate holes.
2. Move to 0.6 vertical and 0.0 reach.
4. Now move the reach to 29.5.
5. Press the “0” key to access the ROBOT AXIS CALIBRATION
options. Then press the “Z” key to select the zero function.
6. Use the rotary and vertical function keys to align the wrist pins with
the holes in the monument. Do NOT move the reach axis.
7. When satisfied with the alignment, press the ESC key to store the
vertical and rotary zero values. Press the ESC key again to exit the
calibration screen.
8. Go to the Calibrate Vertical procedure.

R160 Fan Replacement Procedure 31
Fan Replacement Procedure

Procedure Scope
This procedure describes how to replace the fan located in the Zymate
XP Robot’s power assembly.
Parts Required
• Fan
Tools Required
• Screwdriver, flatblade, small and medium
• Needlenose pliers, or 1/4" wrench
• Fine-tipped felt marker
Remove The Covers

WARNING

screws aside.
4. Slide the cover upward and tape it into position beneath the arm
housing.
5. Remove the two screws that secure the base cover and set them
aside. Unsnap and remove the base cover.

32 Fan Replacement Procedure R160
Remove The Old Fan

1. Unplug the red and black fan wires from the Robot baseboard.
2. Make a mark at each end of the power assembly bracket that
indicates the position of the bracket on the baseplate.
3. Loosen, but do not remove the two screws that secure the power
assembly bracket to the baseplate.
4. Rotate the left end of the bracket outward until you have easy
access to the fan.
5. Remove the fasteners that secure the fan and fan guard to the power
assembly bracket. Set the fan guard and fasteners aside for later and
remove the fan.

R160 Fan Replacement Procedure 33
Install The New Fan

1. Position the new fan on the inside of the power assembly bracket.
Make sure the arrow on the top of the fan faces towards the Robot,
and the red and black wires exit from the bottom of the fan.
2. Position the fan guard over the fan and secure the fan and guard in
place with the fasteners previously removed.
3. Rotate the power assembly bracket so that it aligns with the marks
you made on the base plate.
4. Tighten the two screws that secure the power assembly bracket to
the baseplate.
5. Plug in the new fan’s red and black wires to the receptacle on the
baseboard.
WARNING
correct voltage.
country.
7. Verify that the fan operates. If the fan does not work, recheck that
the wires are connected to the baseboard. If it still fails to work,
contact the Zymark Technical Support Center at (508)-435-9761.

1. Turn the Robot’s power OFF.
2. Reinstall the base cover and secure it in place with the two screws
previously removed.
3. Remove the tape that holds the turntable cover in position beneath
the arm housing.
4. Reinstall the turntable cover and secure it in place with the two
screws previously removed.
5. Turn the Robot’s power ON.

34 Fan Replacement Procedure

R150 Flex Circuit Replacement Procedure 35
Flex Circuit Replacement

Procedure
Procedure Scope
This procedure describes how to replace the Zymate XP Robot’s flex
circuit.
NOTE
This replacement procedure only applies to Zymate XP robots with a

turntable interconnect board and a flex circuit held in place on the
turntable base by a plastic platform strip.
If your robot has an old turntable interconnect board, and the flex circuit
is held in place on the turntable base by a metal clamp, do not continue
with this procedure. Instead, you should order the Flex Circuit Upgrade
Kit (P/N 45792).
Parts Required
• Flex circuit
• Push rivet
Tools Required
• Wire cutters
Remove The Covers

WARNING

3. Move the arm housing upward near the top of the columns.
screws aside.

36 Flex Circuit Replacement Procedure R150
housing.
6. Remove the two screws that secure the base cover. Remove the
cover and set it aside with the two screws.
Remove The Old Flex Circuit

1. Locate the interconnect board next to the vertical motor, and unplug
the flex circuit's connector from the board.
2. Unplug the flex circuit connector from JP1 on the CPU board.

3. Remove the push rivet that holds the flex circuit to the turntable by
pulling down on the rivet.
4. Remove the flex circuit from the turntable and discard it along with
the push rivet just removed.
Fold The New FlexCircuit

1. Position the flex circuit as shown and locate the area denoted by the
dotted line.
2. Carefully fold the flex circuit along the line.

Install The New Flex Circuit

1. Place the folded flex circuit around the turntable base and insert the
fold into the open end of the platform. When correctly positioned,
the inside edge of the flex circuit should be concentric with the
turntable's cylinder, with a gap of approximately 1/16" (1.6 mm)
between the circuit and the cylinder.
2. Plug in the new flex circuit’s connector into JP1 on the CPU board.
3. Manually rotate the turntable so that it is positioned as shown in
step 5. When correctly positioned, the cutout indicated should face
the CPU board.
4. Grasp the unattached flex circuit connector and loop it back
towards the CPU board.
5. Insert the new push rivet through the flex circuit and into the hole
on the turntable’s plate.

6. Fold the end of the circuit and insert it through the hole in the
turntable.
7. Carefully pull the folded end of the flex circuit through the hole and
unfold it.
8. Connect the flex circuit to connector on the turntable interconnect
board.

9. Rotate the turntable through its full range of motion and observe the
flex circuit. If correctly installed, you should see no flex circuit
binding as the turntable is rotated. If you notice binding or
resistance, try repositioning the flex circuit in the platform.


1. Reinstall base cover and secure it with the two screws previously
removed.
2. Reinstall the turntable cover and secure it with the two screws
previously removed.
WARNING
correct voltage.
country.


R101 Post Bearing Replacement Procedure 43
Post Bearing Replacement

Procedure
Procedure Scope
This service procedure describes how to replace the post bearings in the
Zymate XP Robot.
Parts Required
• Bearings (12)
• Washers (24)
• Rings (4)
• Setscrews (4)
• Ty-wraps (2)
Tools Required
• Screwdriver, flatblade 1/8", 1/4", 5/32"
• Screwdriver, holding
• Screwdriver, Phillips, #1
• Driver, ball-end hex, 9/64"
• Wrench, Allen, 3/32"
• Masking tape
• Hand-held nut driver handle and 0.050" Allen driver blade
• Spring clip tool
Optional
• Robot post clamp
Disassembly
WARNING

44 Post Bearing Replacement Procedure R101
Remove Covers
3. Move the arm vertically to mid height.
4. Loosen the two screws that secure the turntable cover. Move the
cover upward and secure it to the bottom of the arm housing.
aside. Remove the cover.
6. Remove the two screws that secure the column cap cover and set
them aside. Remove the cover.

Remove Cable Tension and Secure The Cables

1. Using the 9/64" driver, loosen the vertical adjustment screw on the
underside of the column cap.
2. Turn the compression screw next to the vertical cable pulley fully
clockwise to relax cable tension.
3. Place the spring clip tool under the spring column.
4. Slowly raise arm housing to about 1.5" (38 mm) from the bottom of
the column cap. The spring cable slackens as the arm housing
moves close to the column cap, allowing you to remove the cable
clamp in step 6.
5. Secure the vertical cables to the drive drum with tape.
6. Use a Phillips head screwdriver to remove the upper cable clamp
and cables from arm housing. Set the clamp and screws aside.
7. Loosen the two screws on the lower cable clamp and remove the
cable.

8. Tape the lower vertical drive cable to the column.

Remove The Column Cap and Arm Housing

1. Loosen the two Allen screws that secure the column cap.
2. Carefully slide the column cap up and over the cables. Set the cap
aside.
3. Remove the two retaining rings from the columns and set them
aside.
4. Unplug the two coil cords from their receptacles on the turntable
interconnect board.
5. Remove the screws from the white cable clamps and remove the
cable clamps.
6. Cut any ty-wraps that secure the coil cord along the turntable.
7. Carefully slide the arm assembly up and off the columns.
Remove The Old Post Bearings

1. Remove the three screws that secure the arm housing cover, and set
them aside.
2. Push the arm fully forward, then pull the arm housing cover off the
housing. Set the cover aside.
3. Locate the four set screws that hold the post bearing ring shafts in
place. There is one set screw for each ring shaft.
4. Loosen each set screw slightly until the ring shafts move freely
when pushed.
5. Turn the housing on its side, then rotate one of the ring shafts so the
bearings and washers can be removed. Repeat this step for all
bearings.
6. Use a flat blade screwdriver to pry the ring shafts out of the
housing.

Install The New Bearings

1. Install three of the new bearings and washer sets onto one of the
new post bearing ring shafts. Make sure a washer is located on each
side of the three bearings.
2. Slide the bearings and washers along the post bearing ring shaft so
they align with the holes in the arm housing, then press the post
bearing ring shaft and bearings into the housing.
3. Tighten the set screw for the post bearing ring shaft just installed.
NOTE
To ensure the shaft locks into position, push the shaft away from the set
screw while tightening.
4. Repeat steps 1 through 3 for all bearings.
Reassembly
Reassemble The Arm Housing And Column Cap
1. Hold the arm assembly just above the columns and insert the
vertical cables up through the holes in the housing.
2. Carefully slide the arm housing onto the columns. Use a post clamp
to support the housing a few inches below the top of the housing.
3. Pull the coil cords downward through the turntable cover.
4. Plug the end of the coil cords into the turntable interconnect board
and secure the coil cord that runs next to the rotary flex circuit with
the ty-wrap provided.
arm.

secure the cover.
9. Reinstall the two retaining rings at the top of the columns.
10. Reinstall the column cap and tighten the Allen screws to secure.
Reattach The Cables

1. Loop the long vertical cable that connects from the drive drum over
the pulley at the top of the column cap. Then insert the end of the
cable through the hole in the center of the cap.
2. Follow the same steps for the second cable (the vertical spring
cable) on the column cap.
3. Slide the ferrule of the long vertical cable into the cable clamp
cutout that faces the arm's elbow.
4. Slide the ferrule of the vertical spring cable into the cable clamp
cutout that faces the wrist.
5. Secure the cable clamp with the attached cables to the upper arm
housing.
NOTE
It may be necessary to move the arm housing up slightly to allow the

retainer to be secured.
6. Remove any vertical cable slack from above the arm housing by
carefully lowering the arm housing until the slack is just removed.
Resecure the arm housing.

7. Slide the short vertical cable through the slot in the turntable cover
and insert the ferrule into the cable clamp at the bottom of the
housing.
8. Tighten the two screws to secure the cable clamp to the arm
housing.
9. Loosen the compression screw in the top of the column cap
assembly.
Tension The Cables

1. Remove the tape from the drum.
2. Remove the arm housing support.
3. Remove spring clip tool from the bottom of the spring column.
4. Turn the vertical adjustment screw (located on the underside of the
column cap assembly) counter-clockwise until a slight resistance is
felt. This resistance is the first contact between the adjustment
screw and the cable-tensioning device within the column cap
assembly.
5. Continue to turn the screw counter-clockwise one more turn. When
correctly adjusted, a force of approximately 2 lbs. should move the
center of the cable 0.20 to 0.25 inch (5 to 6 mm).

1. Reinstall the column cap cover.
2. Reinstall the base cover.
3. Reinstall the turntable cover and secure it with the two screws.
WARNING
correct voltage.
country.

R111 Reach Bearing Adjustment Procedure 51
Reach Bearing Adjustment

Procedure
Procedure Scope
This service procedure describes how to adjust the reach bearings in the
Zymate XP Robot. Follow this procedure when you notice excessive
play in the arm, or if you notice binding of the arm and/or metal flaking
on the arm surface.
Parts Required
• NONE
Tools Required
• Screwdriver, blade, 1/8"
• Screwdriver, Phillips #2
Optional
Bearing Adjustment
WARNING
Position The Robot

3. Move the arm so that the wrist box is positioned in a convenient
location over the benchtop.
NOTE
This location must not have a rotary position value greater than 360° or
less than 0°.
4. Position the arm vertically at zero.

52 Reach Bearing Adjustment Procedure R111
5. Remove the arm housing cover and support the cover at the top of
the columns with a clamp.
6. Remove the two screws that secure the arm wiper to the arm
housing and set the screws and wiper pieces aside.
Arm housing
Adjust The Bearings

1. Push the arm out to maximum reach.
2. From the wrist end of arm, locate the contact point between the
upper front bearings and the top of the arm.
Bearing
No gap here
Arm
3. Follow these steps to adjust the front bearing assembly:

a. Loosen the Phillips head locking screw directly above the front
bearing assembly.
b. Locate the hole to the front of the locking screw and use the
ball-end driver to turn the adjusting screw clockwise while
observing the bearing surface on the arm. Turn until a small
gap appears.

c. Now turn the adjusting screw counter-clockwise until the

bearing surface just contacts the surface of the arm.
d. Turn the adjusting screw counter-clockwise an additional
1/32 turn.
e. Tighten the front locking screw to hold the bearing assembly in
position.
f. Verify that the bearings just contact the arm. If not, repeat steps
a through f until the adjustment is correct.
4. From the elbow end of arm, locate the contact point between the
lower rear bearings and the bottom of the arm.
Arm
No gap here
Bearing
5. Follow these steps to adjust the rear bearing assembly:

a. Loosen the Phillips head locking screw directly above the rear
bearing assembly.
b. Locate the hole to the front of the locking screw and use the
ball-end driver to turn the adjusting screw clockwise while
observing the bearing surface on the arm. Turn until a small
gap appears.
c. Now turn the adjusting screw counter-clockwise until the
bearing surface just contacts the surface of the arm.
d. Turn the adjusting screw counter-clockwise an additional 1/32
turn.
e. Tighten the front locking screw to hold the bearing assembly in
position.
f. Verify that the bearings just contact the arm. If not, repeat steps
a through f until adjustment is correct.

Recheck Adjustment
1. Slowly move the arm in and out and verify that all bearings are
rotating. Bearings that are not rotating indicate that a gap exists
between the arm and bearings. If this is the case, readjust the
bearings as required and recheck the adjustment.
2. Grab the wrist box firmly and rock from side to side. A gentle
twisting of the arm should produce no motion with properly
adjusted bearings. If motion is detected, readjust the bearings as
required and recheck the adjustment.
3. Manually extend the arm through its full reach. Check for any
binding while the arm moves through its reach travel. If binding is
detected, readjust the bearings and recheck the adjustment.
If a binding problem cannot be corrected by bearing adjustment, replace

the arm. Refer to procedure R140, ROBOT REACH BEARING
REPLACEMENT.
Reassemble Robot
1. Reinstall the arm wiper to the housing using the two screws
previously removed. Make sure you push the wiper downward so it
presses against the arm.
2. Remove the clamp that supports the arm housing cover, then slide
the cover over the housing.
arm.

secure the cover.
WARNING
correct voltage.
country.


R140 Reach Bearing Replacement Procedure 57
Reach Bearing Replacement

Procedure
Procedure Scope
This service procedure describes how to replace the reach bearings in
Parts Required
• Bearings (8)
• Mounting screws (8)
• Washers (8)
• Spacers (8)
Tools Required
• Phillips Screwdriver, #2
• Flatblade Screwdriver, medium
• Driver, Ball-end hex, 5/32"
• Wire cutters
Optional
• Post clamp
Bearing Replacement
WARNING
Remove The Arm Housing Cover

3. Position the arm vertically at zero.
4. Remove the arm housing cover and support the cover at the top of
the columns with a clamp.
5. Remove the arm wiper assembly from the front of the housing.

58 Reach Bearing Replacement Procedure R140
Remove The Upper Bearing Assembly

1. Remove the two locking screws that secure the upper bearing
assembly.
2. Fully loosen the two upper bearing adjustment screws by turning
the screws clockwise.
3. Loosen the two screws on the upper cable retainer slightly.
4. Slide the upper bearing assembly toward the elbow and out of the
housing.
NOTE
It helps to push downward on both ends of the arm when sliding the
assembly.

Replace The Upper Bearings

1. Remove the screws that secure the bearings to the bearing
assembly.
2. Pull the four bearings off the assembly. Discard the old bearings.
3. Slide the new bearings onto the bearing mounts.
4. Apply LOCTITE® 222 to the four screws, and secure the new
bearings to the assembly.
NOTE
Do not reinstall the bearing assembly in the housing at this time.
Prepare to Replace The Lower Bearings

1. Move the arm housing up near the top of the columns.
2. Loosen the two vertical cable clamp screws at the bottom of the
housing. This will allow the lower bearing assembly to slide in the
housing.
NOTE
Do NOT remove the screws, but loosen them until the top of the screws
are flush with the bottom-inside of the arm housing. Move the housing
downward slightly to view the top of the screws.
3. Remove the two locking screws that secure the lower bearing
assembly.

60 Reach Bearing Replacement Procedure R140
4. Carefully cut any ty-wraps that secure the motor, potentiometer,

and sensor wires to the coil cord.
5. Unplug the motor, potentiometer, and sensor wires from the
interconnect board.
Replace The Lower Rear Bearings

1. Remove the two screws that secure the two lower rear bearings to
the bearing assembly.
2. Pull the two bearings off the assembly. Discard the old bearings.
4. Apply LOCTITE® 222 to the two screws, and secure the new
NOTE
Brass shims may be installed under the front or rear lower bearing
assembly. You are instructed to slide the bearing assembly in the steps
that follow. Doing so may likely dislodge the shims. Make sure you
observe the location of any shims so they can be correctly replaced after
new bearings are installed.
Replace The Lower Front Bearings

1. Slide the lower bearing assembly towards the arm’s elbow until you
can access the two lower front bearings.
2. Remove the two screws that secure the lower front bearings to the
bearing assembly.

3. Pull the two bearings off the assembly. Discard the old bearings.
5. Apply LOCTITE® 222 to the two screws, and secure the new
Resecure The Bearing Assemblies

1. Slide the lower bearing assembly back toward the wrist. Make sure
the tension adjuster is inserted into the hole in the housing.
2. Replace any brass shims that may have been removed earlier.
3. Move the arm housing up to gain access to the bottom of the
housing.
4. Retighten the two vertical cable clamp screws at the bottom of the
housing.
5. Reinstall the two lower locking screws that secure the bearing
assembly.
6. Reconnect the motor, potentiometer, and sensor wires to the
interconnect board.
7. Secure the cables to the coil cord cable with the ty-wraps provided.
8. Move the arm housing downward, then slide the upper bearing
assembly into the housing. Retighten the upper cable retainer
screws.
9. Secure the bearing assembly with the two locking screws.
10. Review the Adjust The Bearings, Recheck Adjustment, and
Reassemble sections in the “Reach Bearing Adjustment Procedure”
.

62 Reach Bearing Replacement Procedure

R192 Reach Cables Replacement Procedure 63
Reach Cables Replacement

Procedure
Procedure Scope
This service procedure describes how to remove and install the reach
cables in the Zymate XP Robot.
Parts Required
• Reach cables (2)
Tools Required
• Phillips head screwdriver
• Allen wrench
• Ruler, 12" (30 cm)
Remove The Old Cables

WARNING

2. Turn the Robot’s power OFF and disconnect the power cord.
3. Remove the three screws on the top of the arm housing cover. Set
the screws aside.
4. Pull the robotic arm fully out and slide the arm housing cover up.
Tape the cover near the top of the columns.

64 Reach Cables Replacement Procedure R192
Check Set Screw Position

1. Move the arm horizontally so there is a distance of 7.3" (18.5 cm)
from the lower-front surface of the arm housing to the inside
surface of the wrist.
2. Verify that the set screws on the reach potentiometer assembly's

flex coupling are accessible. If the screws are accessible, go to
“Remove The Old Cables” on the next page. If the set screws are
not accessible, do the following:
a. Move the arm slightly until the set screws are accessible.
b. Loosen the flex coupling set screw nearest the drive drum.
c. Move the arm to the position set in step 1, and secure the arm
in place.
d. If necessary, rotate the flex coupling until the set screws are
accessible, and retighten the set screw loosened in step 2b.

Remove The Old Cables

1. If necessary, move the arm in or out slightly until you have access
to the set screws in the reach potentiometer’s flexible coupling.
2. Loosen the set screw closest to the magnetic wheel. Do NOT

loosen the other set screw.
3. Remove the arm stop at the top-rear of the arm. Set it aside for later.
4. Turn the reach cable tension screw counter-clockwise six to eight

turns to relax cable tension.
5. Remove the V-shaped cable retainer at the front of the arm.
Disconnect the reach cable and set the retainer and screws aside.

6. Loosen the reach cable tension screw until it almost comes in

contact with the pulley.
7. Move the arm forward slightly, remove the arm cap and pulley, and
disconnect the reach cable from the tension block. Set the cap and
pulley aside.
8. Carefully slide the arm forward and out of the arm housing.
Position the arm near the robot base.
9. Remove the reach cables from the drum and discard.
Install The New Cables

Wrap The New Cables
1. Remove one of the new reach cables from the bag (both reach
cables are identical), and insert the ferrule with the short reach
cable end into the left hole of the reach drum.
Reach Cable
Long cable end
Short cable end
Ferrule
Ferrule
2. Now hold the other end of the reach cable so the cable extends
horizontally outward, toward the back of the arm housing.
3. Keeping tension on the reach cable, turn the large reach pulley
wheel counter-clockwise, and carefully wrap the reach cable onto
the drum. Continue until the drum is completely filled with wraps.
NOTE
When finished, there should not be any unwrapped cable left, and the
right ferrule hole should be facing up.
4. Holding the first reach cable in place on the drum, insert the short
cable end of the second reach cable through the front of the arm
housing and into the right hole in the drum.

5. Hold the unattached ferrule of the first reach cable with one hand,
and the unattached ferrule of the second reach cable with your other
hand.
6. Maintaining tension on the second cable, slowly pull horizontally
on the first reach cable. This wraps the second reach cable onto the
drum and unwraps the first reach cable. Continue until both
unwrapped reach cable lengths are equal.
7. Place a piece of tape across the reach cables on the drum.
Reassemble The Arm and Attach The Cables

1. Verify that both unwrapped reach cable lengths pass through the
center of the reach bearings.
2. Carefully slide the arm back into the housing. Make sure the coil
cord cables are correctly looped over the horizontal supports.
3. Insert the ferrule of the reach cable that extends toward the rear of
the arm housing into the tension block in the rear of the arm. Make
sure the ferrule is inserted within the tension block’s cutout.
4. Near the opening at the rear of the arm, loop the reach cable over
the pulley.
5. With the reach cable still around the pulley, slide the arm cap over
the pulley, and insert the cap and pulley into the arm.
6. Move the arm back slightly to increase reach cable tension and
keep the reach cable on the pulley. Secure the arm’s position.
7. Insert the ferrule of the remaining reach cable into the V-shaped
retainer. Make sure the reach cable’s tail is at the bottom of the
retainer.
8. Secure the retainer to the arm with the two screws previously
removed.
9. Tighten the tension screw until all slack is removed from the reach
cables.
10. Reinstall the arm stop previously removed.
11. Remove the tape from the drum.
Tension The New Cables

1. Slowly move the arm in and out a few times to evenly distribute
reach cable tension.
2. Tighten the tension screw one or two turns, then repeat step 1.
3. Tighten or loosen the tension screw as necessary, making sure you
move the arm in and out a few times before rechecking tension.

Reset The Potentiometer

1. Move the arm horizontally so there is a distance of 7.3" (18.5 cm)
from the lower-front surface of the arm housing to the inside
surface of the wrist. Secure the arm in this position.
WARNING
correct voltage.
country.
3. Observe the yellow LED in the column of LEDs marked RCH. The
LED should be on at this arm position. If the yellow LED is not on,
move the arm slightly in either direction until it comes on. Resecure
the arm in the new position.
4. Now rotate the magnetic wheel until the green LED in the column
of LEDs just comes on.
5. Tighten the flex coupling set screw closest to the drive drum. This
set screw was loosened in the Check Set Screw Position procedure.
6. Turn the power OFF and unplug the Robot’s power cord before you
begin the next procedure.

WARNING
Turn OFF system power before beginning these procedures.
cap.
arm.

Check Zero and Calibration

Check, and if necessary, reset the reach zero and calibrate the reach.
Refer to the section, “Zero and Calibrate the Zymate XP Robot,” in the
Zymate XP Robot Module User’s Guide (P/N 45461) for these
procedures.


R143 Reach Motor Replacement Procedure 71
Reach Motor Replacement

Procedure
Procedure Scope
This service procedure describes how to replace the reach motor in the
Zymate XP Robot.
Parts Required
• Reach motor
• Ty-wraps
Tools Required
• Screwdriver, holding - (optional)
• Allen Wrench, 5/64"
• Wrench, open end, 3/8"
• Wire cutters
• Retaining ring pliers
• LOCTITE® 222
Remove The Old Motor

WARNING

the screws aside.

72 Reach Motor Replacement Procedure R143
Remove The Motor

Refer to this diagram in the steps that follow.
1. Locate the reach motor’s wires and carefully cut any ty-wraps that
secure the wires. Unplug the motor wires from the receptacle on the
interconnect board.
2. Holding the tension adjuster with the 3/8" wrench, use a 11/32"
wrench to loosen the locking nut (about 6 full turns).
3. Now loosen the tension adjuster until it contacts the locking nut.

4. Remove the two screws and washers that secure the motor bracket,
and set them aside.
5. Disconnect the belt from the small gear, then remove the motor
assembly from the housing.
6. Remove the retaining ring and set it aside.
7. Slide the tension assembly off the shaft. Set the tension assembly
aside.
8. Remove the nylon spacer (under the tension assembly) and set it
aside.
9. Use a 9/64" Allen wrench to remove the set screw that secures the
large timing pulley to the shaft.
10. Now slide the large timing pulley off the shaft and set it aside.
11. Remove the three Phillips head screws that secure the motor
bracket to the motor. Set the screws and bracket aside.
Install The New Motor

Install The Bracket and Tension Assembly On The Motor
1. Secure the motor bracket to the new motor with the three
previously removed Phillips head screws. Secure with a small
amount LOCTITE® 222.
2. Slide the large timing pulley onto the motor shaft. Position the large
timing pulley so that there is a 1/8" (32 mm) space between the
large timing pulley and the motor bracket.
3. Align the set screw hole in the gear with the flat of the shaft.
4. Apply LOCTITE® 222 to the set screw and insert it into the gear.
Tighten the screw against the flat of the shaft.
5. Slide the nylon spacer onto the shaft.

6. Slide the tension assembly onto the shaft so there is a 1/16"

(16 mm) space between the inside of the tension assembly and the
outside of the large timing pulley.
7. Replace the retaining ring on the motor shaft.
8. Loop the belt over the large timing pulley.
Install The Motor Assembly

1. Slide the motor assembly into position on the arm housing,
inserting the end of the tension assembly into the hole in the arm
housing.
2. Loop the belt over the small gear.
3. Apply LOCTITE® 222 to the two screws previously removed (see
Step 4 in “Remove The Motor” ), then insert the screws and
washers loosely into the housing to secure the motor assembly.
4. Pull the motor assembly so the belt is taut, then finger tighten the
two screws. (Don’t tighten all the way!)
NOTE
Make sure the motor does not come into contact with the reach cable at
the bottom of the arm.
5. Turn the tension adjuster until it contacts the arm housing.

6. While holding the tension adjuster in place with the 3/8" wrench,
turn the locking nut until it is snug against the tension adjuster.
7. Use a flathead screwdriver to finish tightening the screw-in washers
from step 4.
8. Plug the motor wires into the receptacle on the interconnect board.
9. Secure the wires using the ty-wraps provided.

cap.
arm.

WARNING
correct voltage.
country.


R133 Reach Potentiometer Replacement Procedure 77
Reach Potentiometer
Procedure Scope
This procedure describes how to replace the Zymate XP Robot’s reach
potentiometer.
Parts Required
• Reach potentiometer
Tools Required
• Digital voltmeter (DVM)
• Metal rule, 12" (30cm)
Remove The Covers

WARNING

3. Use a small screwdriver to disconnect the Robot Communication
cable from the receptacle at the rear of the Robot.
screws aside.
5. Slide the turntable cover upward and tape it into position beneath
the arm housing.
screws aside.

78 Reach Potentiometer Replacement Procedure R133
WARNING
correct voltage.
country.

Remove The Old Reach Potentiometer

1. Move the arm horizontally so that there is a distance of 7.40"
(18.8 cm) from the lower-front surface of the arm housing to the
inside surface of the wrist.
2. Observe the yellow LED on the baseboard in the column of LEDs

marked RCH. The LED should be on at 7.40" (18.8 cm). If the
yellow LED is not on, move the arm in either direction until it
comes on.
NOTE
There is no specified tolerance for the reach length. The arm should
only have to be moved slightly for the yellow LED to come on.
3. Secure the arm in place, then turn the Robot’s power OFF.
WARNING
Turn OFF THE system power before continuing this procedure.

4. Unplug the Reach potentiometer plug from connector P3 on the

arm housing interconnect board.
5. Locate the magnetic wheel that the reach potentiometer connects to.
Use a 0.50" (1/20") Allen wrench to loosen the wheel’s set screw
one turn.
P3 (top)
6. Loosen the potentiometer adjusting screws and turn the cleats so

the flat part of the cleat faces the potentiometer. Retighten the
screws slightly to maintain the cleats’ position.
7. Remove the potentiometer.
Set and Install The New Reach Potentiometer

1. With the new potentiometer still disconnected from the Robot, set
the DVM to read ohms, then attach one DVM lead to the
potentiometer’s black terminal and the other lead to the
potentiometer’s red terminal.
2. Turn the potentiometer’s shaft until the DVM reads 5.97K Ω.
3. Insert the potentiometer’s shaft into the magnetic wheel.
4. Loosen the adjusting screws within the cleats, then rotate the cleats
so the flat part of the cleat faces outward, away from the
potentiometer.
5. Now tighten the adjusting screws until snug to secure the
potentiometer.
6. Tighten the magnetic wheel’s set screw to secure the potentiometer.
7. Plug in the new potentiometer wires into connector P3 on the arm
housing interconnect board.

Adjust The Potentiometer

WARNING
correct voltage.
country.
WARNING
Be sure that the Robot Communication cable is disconnected between

the Robot and the Controller before performing this procedure.
2. Verify that the yellow LED in the column of LEDs marked RCH is
ON, and the measurement taken in the old potentiometer removal
procedure, step 1 is still correct. If the yellow LED is not ON,
and/or the measurement is not correct, remove the potentiometer
and repeat the potentiometer removal, set, installation, and
adjustment procedures.
3. Loosen the two potentiometer adjusting screws slightly.

4. Carefully turn the potentiometer body (clockwise or counter-
clockwise) until the green LED in the RCH column comes ON.
NOTE
The yellow LED should also be ON. If the green and yellow LEDs are
not on, remove the potentiometer and repeat the potentiometer removal,
set, installation, and adjustment procedures.

5. Tighten the potentiometer adjusting screws, and verify that the

green and yellow LEDs are still ON.

WARNING
Turn OFF system power before beginning these procedures.
1. Turn the power OFF again and plug in the Robot-Controller

communication cable into the rear of the receptacle at the rear of
the Robot.
2. Reinstall the base cover and secure it with the two screws
previously removed.
3. Remove the tape that holds the turntable cover to the bottom of the
arm housing.
previously removed.
cap.
arm.

WARNING
correct voltage.
country.

Program.
13. At the Z>, run SET.ACCUTRAK to store the position values for
the new potentiometer.


R108 Reach Timing Belt Replacement Procedure 85
Reach Timing Belt

Procedure Scope
This service procedure describes how to replace a defective or broken
reach timing belt in the Zymate XP Robot.
Parts Required
• Reach timing belt
Tools Required
• Screwdriver, flat-blade
• Screwdriver, holding - (optional)
Remove The Defective Belt

WARNING

the screws aside.

86 Reach Timing Belt Replacement Procedure R108
Remove The Belt

1. Holding the tension adjuster with the 3/8" wrench, use the 11/32"
wrench to loosen the locking nut about 6 full turns.
2. Now loosen the tension adjuster until it contacts the locking nut.
3. Referring to the diagram, remove the motor bracket screw and
washer nearest the robot, and loosen the second motor bracket
screw. Set the screw and washer aside.
4. Remove the belt from the small gear.

R108 Reach Timing Belt Replacement Procedure 87
5. Slide the motor away from the robot until the tension assembly
pulls out of the hole in the arm housing, then fully remove the belt.
Discard the old belt.
Install The New Belt

Install The Belt
Small gear
1. Loop the new belt over the large gear.

2. Slide the tension assembly into position on the arm housing,
inserting the end of the tension assembly into the hole in the arm
housing.
3. Loop the belt over the small gear (located to the left of the large
gear).
4. Insert the screw and washer previously removed into the housing to
secure the assembly. Do not tighten the screw at this time.
5. Pull the motor assembly so the belt is taught, then fully tighten the
two screws. Make sure the motor does not come into contact with
the reach cable at the bottom of the arm.
6. Turn the tension adjuster until it contacts the arm housing.
7. While holding the adjuster in place with the 3/8" wrench, turn the
locking nut until it is snug against the tension adjuster.

88 Reach Timing Belt Replacement Procedure R108

cap.
arm.
secure the cover.
WARNING
correct voltage.
country.

R165 Rotary Drive Cable Replacement Procedure 89
Rotary Drive Cable

Procedure Scope
This service procedure describes how to remove and install the rotary
drive cables in the Zymate XP Robot’s rotary pulley mount assembly.
Parts Required
• Fixed End Cable, 73 1/4" (186 cm)
• Tensioning Screw Cable, 67 1/4"(171 cm)
Tools Required
• Screwdriver, flatblade, 1/4"
• Wrench, hex (Allen), 3/32"
• Wire cutters
• LOCTITE® 222
• Masking tape
• Flashlight or penlight
Optional
Disassembly
WARNING
Position The Robot and Remove Covers

screws aside.
housing.

90 Rotary Drive Cable Replacement Procedure R165
6. Locate the turntable interconnect board. Unplug the orange and

purple vertical motor wires and lower coil cord from the board.
This will help during cable removal and installation.
Remove The Tensioning Screw Cable

1. Release tension on the cable by turning the rotary cable tensioning
screw counter-clockwise.
2. Continue turning the screw until the tension adapter block has
moved to the point where the cable ferrule can be easily removed
from the block.
3. Remove the cable by pulling the ferrule through the hole in the
turntable and unwrapping the cable.

Remove The Fixed End Cable

1. Release tension on the cable by manually rotating the arm counter-
clockwise.
2. Lift the spring cable connector off the roll pin post.
3. Remove the cable ferrule from the spring cable connector and set
the connector aside.
4. Unwrap the cable from the turntable.
Remove The Rotary Drive Drum

With the set screws in the drum facing outward as in the diagram below:
1. Using the 3/32" Allen wrench, remove the two set screws from the
drum.
2. Using a small flatblade screwdriver, gently move the shaft on the
right side of the drum part-way out 1/4" to 3/8" (64 to 95 mm.)
3. Remove the four motor mounting screws and washers.
4. Slide the motor out of the pulley mount assembly.
5. Pull the shaft the rest of the way out of the drum.
6. Remove the drum from the pulley mount assembly.
7. Unwrap both cables from the drum.

Installation
Wrap Fixed End Cable (Longer cable)
1. Prepare two pieces of tape 1-1/8” (28.6 mm) long.
2. Holding the drum with the set screw holes positioned above the
ferrule holes, insert one end of the longer cable into the left ferrule
hole.
Long cable
3. Wrap the cable DOWN and UNDER the drum for 6 1/2 turns. Use
the ferrule hole as a reference point.
4. Secure the cable in place by using one of the pieces of tape. Be sure
not to cover the right section of the drum with the tape.
Wrap Tensioning Screw Cable (Shorter cable)

1. Holding the drum as before, insert one end of the shorter cable into
the right ferrule hole.
2. Wrap the cable UP and OVER the drum for 6 full turns, again using
the ferrule hole as a reference point.

3. Secure the shorter cable by placing the second piece of tape

perpendicular to the direction of the cable wraps, directly over the
two ferrule holes. Do NOT extend the tape onto the flat ends of the
drum.
4. Carefully remove the first piece of tape (from step 4 of Wrapping
the Fixed End Cable procedure) and place it so that it runs parallel
to the second piece. Make sure it is positioned 180° opposite the
second piece of tape.
Reinstall The Rotary Drive Drum

1. Orient the drum near the outer opening in the pulley mount
assembly so that the two set screw holes face upward, with the
longer cable located nearest the turntable.
2. Insert the longer cable through the outer opening in the pulley
mount assembly.
3. Place the drum in the pulley mount assembly with the set screw
holes facing out (away from the turntable).

4. With the flat facing outward, insert the shaft through the bearing
and into the right side of the drum.
5. With the motor shaft flat facing outward and the motor terminals
up, slide the rotary motor into position through the left side of the
drum. Using the holding screwdriver, secure the motor with the
four screws and washers previously removed.
6. Center the drum in the pulley mount assembly.
7. If possible, use a flashlight to look through the set screw holes and
verify that the motor shaft flat faces outward.
8. Apply a drop of LOCTITE® 222 to the threads of one of the set
screws and insert it into the hole on the motor side of the drum.
Tighten until snug.
9. Verify that the set screw is aligned with the flat of the shaft on the
motor by doing the following:
a. Loosen the set screw 1/8 to 1/4 turn keeping the Allen wrench
in position on the set screw.
b. Place a finger on the tail shaft protruding from the left end of
the motor.
c. Using the Allen wrench as a lever, rotate the drum back and
forth (approximately 10°) in each direction. If properly
aligned, contact made between the set screw and the flat part of
the shaft as the drum is rotated will stop the drum from rotating
more than 10° or so in each direction. Also, the tail shaft of the
motor moves slightly each time contact is made.
d. Continue to slowly rotate the drum while simultaneously
tightening down on the set screw. This insures that the set
screw is centered on the flat part of the shaft. Tighten securely.
e. If the tail shaft did not move and contact was not made, remove
the set screw and motor. Repeat steps 5-9.

10. Look through the right hole in the drum and verify that the flat part
of the shaft is aligned with the hole opening. If necessary, turn the
motor tail shaft to rotate the drum to a position that will allow for
easier viewing. Turn the end of the shaft until the flat part of the
shaft aligns with the hole.
11. Apply LOCTITE® 222 to the second set screw, insert it into the
hole on the right side of the drum and tighten it securely against the
flat part of the shaft.
Dress The Cables Over The Pulleys

1. Turn the motor tail shaft counter-clockwise until the two set screws
in the drum face UP.
2. While facing the pulley mount assembly, wrap the front (short)
cable around the front and top left pulleys. Secure the cable to each
pulley with a piece of tape. In the next step, make sure you pass the
long cable UNDER the short cable as shown in the diagram with
step 3.
3. Wrap the rear (long) cable around the rear and top right pulleys as
shown below. Secure the cable to each pulley with a piece of tape.

Wrap The Fixed (Long) Cable Around The Turntable

1. Manually rotate the arm counter-clockwise from the 180° position
to approximately 150°. This increases the effective cable length,
helping you during the wrapping procedure.
2. Wrap (from the middle down) the longer, fixed-end cable clockwise
around the top groove of the turntable approximately 2-1/4 turns.
Maintain tension on the cable, taping it in place if necessary.
3. Insert the cable end through the lower-left hole in the turntable’s
top groove.
4. Insert the cable end into the cable spring connector.
5. Slide the cable spring connector over the roll pin post.
6. Being careful not to allow any turning of the rotary drive drum,
rotate the turntable clockwise to remove any slack in the cable.
Wrap The Tensioning Screw Cable Around The Turntable

1. Wrap (from the middle up) the shorter, tensioning screw cable
counter-clockwise around the top groove of the turntable
approximately 2 turns.
2. Insert the cable end through the upper-right hole in the turntable's
top groove. Slacken the upper two rows of the cable to facilitate the
insertion.
NOTE
Do NOT use metal-tipped tools to slacken the cable Use your fingers, a
nylon screwdriver, or nylon tweezers.
3. Insert the cable end into the slot in the tension adapter block. If
necessary, turn the rotary cable tensioning screw counter-clockwise
allowing the cable end to be easily inserted.

4. Once inserted, turn the rotary cable tensioning screw clockwise

until any visible cable slack is JUST removed.
Adjustment and Reassemble

Cable Adjustment
1. Remove any tape used during cable installation.
2. Insert the 3/32" Allen wrench into the left set screw in the drum.
NOTE
The wrench acts as a brake lever during the tensioning operation.
CAUTION
Check that the Allen wrench is securely inserted into the left rotary drive
drum set screw so that it will act properly as a brake lever during rotary
drive cable tensioning.
3. Push the wrist box in a clockwise direction using approximately

5 lbs (2.2 kg) of force. Maintain this force. Observe that the Allen
wrench stops further rotation by hitting the skirt bracket.
4. While maintaining the 5 lbs (2.2 kg) of force on the wrist box, turn
the rotary cable tensioning screw clockwise to remove any visible
cable slack.

5. Check the cable tension:

a. Grasp the longer of the cable sections between the turntable
and pulley mount assembly and pull the cable sideways.
b. A force of approximately 2 lbs (0.9 kg) should move the cable
0.04 to 0.08 inch (1 to 2 mm). When correctly tensioned, this
cable should feel tight.
6. Make any necessary adjustments to attain the tension requirements
in step #5b.
7. Remove the Allen wrench.
Position Adjustment
1. Connect the coil cord and motor wires to the turntable interconnect
board.
2. Unplug the Robot-Controller communication cable from the
receptacle on the back of the Robot.
WARNING
Turn OFF system power and disconnect the robot communication cable
before beginning these procedures.
WARNING
correct voltage.
country.

4. Slowly rotate the Robot to the 183° position. Align the hole on the
turntable with the sensor.
5. Rotate the Robot back and forth slightly while observing the yellow
LED in the column of LEDs marked ROT on the baseboard. It
should be ON at 183°.
6. Rotate the Robot carefully until the yellow LED is in the center of
its ON range.
8. Carefully turn the potentiometer body until the green LED in the
column of LEDs marked ROT just changes state; OFF to ON, or
ON to OFF.
NOTE
The yellow LED should also be ON at this time.

green and yellow LEDs have maintained their status.
10. Slowly rotate the Robot counter-clockwise to approximately 180°.
11. Very slowly, rotate the Robot back to 183°. and observe the
following LED sequence as the arm moves to 183°:
a. the yellow LED comes ON first
b. the green LED comes ON next, and the yellow LED remains
ON
c. the yellow LED turns OFF if 183° is passed.
12. If the LED sequence is correct, no further adjustment is required. If
the LED sequence is not correct, for example the sequence is
reversed, remove the old potentiometer, set, install and adjust the
new potentiometer as shown in the “Rotary Potentiometer
Replacement Procedure” (page 109).


1. Turn the Robot’s power OFF again, and plug in the Robot
Controller communication cable into the receptacle on the back of
the Robot.
2. Reinstall the base cover and secure with the two previously
removed screws.
3. Remove the tape which secures the turntable cover beneath the arm
housing.
4. Reinstall the turntable cover and secure it with the two previously
removed screws.
WARNING
correct voltage.
country.
WARNING
Always keep body parts hair, jewelry, and clothing away from the robot.
The robot may move unexpectedly in any direction.

Program.
8. At the Z>, run SET.ACCUTRAK to store new rotary position
values.

R114 Rotary Motor Replacement Procedure 101
Rotary Motor Replacement

Procedure
Procedure Scope
This service procedure describes how to replace the rotary motor in the
Zymate XP Robot.
Parts Required
• Rotary motor
• Set screw, 10-32 x 1/2
• Ty-wraps
Tools Required
• Screwdriver, flatblade, 3/16 x 6" min.
• Wrench, adjustable
• Wire cutters
• LOCTITE ® 222
Disassembly
WARNING
Position The Robot

3. Remove the two screws that secure the turntable cover, set it aside
with the screws.
housing.
5. Remove the two screws that secure the base cover, remove the
cover, and set it aside with the screws.

102 Rotary Motor Replacement Procedure R114
6. Turn the arm to about the 270° rotary position.

7. Locate the drive drum on the end of the rotary motor shaft.
8. Continue moving the arm’s rotary position until the set screws in
the drum are accessible.
Relax Cable Tension

1. Locate the rotary drive cable tensioning screw.

2. Turn the rotary drive cable tensioning screw on the turntable until
the cable has visible slack.
Disconnect The Motor

1. Unplug the orange and purple rotary motor leads from receptacle
P2 on the baseboard. Receptacle P2 is located near the large, blue
capacitors.
Remove The Motor

1. Remove the set screw nearest the rotary motor in the motor drive
drum.
2. Remove the four motor mounting screws and washers.
3. Remove the motor.
NOTE
It may be necessary to push down gently on the left side of the drive
drum while removing the motor.

Installation
Mount The New Motor
1. Position the new motor with the electrical terminals facing UP.
2. Using an adjustable wrench, turn the motor shaft until the flat part
of the motor shaft aligns with the set screw hole in the drum.
3. Draw a black line on the flat part of the motor shaft.
4. Slide the motor into position and secure it with the four mounting
screws.
NOTES
It may be necessary to push down gently on the drive drum to align its
center hole with the motor shaft while sliding the motor in place.
A holding screwdriver is helpful in starting the mounting screws.
5. Using a flashlight, look through the set screw hole and confirm that
the flat part of the motor shaft is aligned with the hole.
NOTE
This can be done by looking for the black line on the flat part of the
motor shaft.

6. Apply LOCTITE® 222 to set screw.

a. Using the 3/32" Allen wrench, tighten the set screw until it is
snug and then loosen it 1/8 to 1/4 turn.
b. With the Allen wrench still in position on the set screw, use one
hand to slightly rotate the arm. Use your other hand to hold
onto the Allen wrench.
c. If properly aligned, contact made between the set screw and
the flat part of the motor shaft (as the drum is moved) stops the
drum from rotating more than 10°. This contact is also felt
through the Allen wrench.
d. After verifying alignment in the above manner, fully tighten
the set screw against the flat part of the motor shaft.
7. Install a ty-wrap securing both sets of leads at the tie point.
Connect The Motor

1. Dress the motor leads near the potentiometer cable and plug the
orange and purple rotary motor leads into its receptacle on the
baseboard.
Set Cable Tension and Install Covers

1. Insert an Allen wrench into the left rotary drive drum set screw. The
Allen wrench acts like a “brake lever” during the tensioning
operation.
CAUTION
Check that the Allen wrench is securely inserted into the left rotary drive
drum set screw so that it acts properly as a brake lever during rotary
drive cable tensioning.
2. Move the arm to maximum reach and push the wrist box in a
clockwise rotary direction. The Allen wrench should move towards
the bench surface and then stop further drum rotation.
3. Continue pushing the wrist box with about 5 lbs (2.3 kg) force
while tightening the rotary drive cable tensioning screw clockwise
to remove any visible cable slack.

4. Remove the Allen wrench.

5. Remove the tape that secures the turntable cover to the arm
housing.
previously removed.
previously removed.
WARNING
correct voltage.
country.

R187 Rotary Potentiometer Replacement Procedure 107
Rotary Potentiometer
Procedure Scope
This procedure describes how to replace the Zymate XP Robot’s rotary
potentiometer.
Parts Required
• Rotary potentiometer
Tools Required
• Allen wrench, 0.050"
Remove The Covers

WARNING

3. Use a small screwdriver to disconnect the Robot Controller
communication cable from the receptacle at the rear of the Robot.
WARNING
Turn OFF the system power and disconnect the Robot Communication
cable before beginning these procedures.
screws aside.
housing.
6. Remove the two screws that tape the base cover and set them aside.
Unsnap and remove the base cover.

108 Rotary Potentiometer Replacement Procedure R187
Remove The Old Potentiometer

1. Slowly rotate the arm fully counter-clockwise.
2. Loosen the lower set screw on the flexible coupling one turn.
3. Loosen the potentiometer adjusting screws and turn the cleats so

the flats face the potentiometer. Retighten the screws slightly to
maintain the cleats’ position.
4. Pull the potentiometer downward and slide it out of the housing.
5. Unplug the potentiometer’s wires from receptacle P7 on the
baseboard.

Set and Install The New Potentiometer

the DVM to ohms, then attach one DVM lead to the
potentiometer’s black terminal and the other DVM lead to the
yellow terminal.
2. Turn the potentiometer’s shaft until the DVM reads 1000 Ω.
NOTE
Before performing step 3, make sure the robot is rotated to its full
counter-clockwise position.
3. With the terminals on the new potentiometer facing away from the
mounting bracket, insert the potentiometer’s shaft into the flexible
coupling.
potentiometer.
potentiometer.
6. Tighten the lower set screw on the flexible coupling to secure the
potentiometer to the coupling.
7. Plug in the new potentiometer wires to receptacle P7 on the
baseboard.


NOTE
Check that the Robot Communication cable is disconnected before

performing this procedure.
2. Slowly rotate the Robot to the 183° position, by aligning the hole
on the side of the turntable with the sensor.
its ON range.
ON to OFF.
NOTE


9. Very slowly, rotate the Robot back to 183° and observe the
following LED sequence as the arm moves to 183°:
ON
10. If the LED sequence is correct, no further adjustment is required. If
if the LED sequence is not correct, for example the sequence is
reversed, remove the potentiometer and repeat the Set, Install and
Adjust Potentiometer procedures.
Complete The Installation

1. Turn the Robot’s power OFF again and plug the Robot
Communication cable into the receptacle on the back of the Robot.
2. Reinstall the base cover and secure it with the two previously
removed screws.
3. Remove the tape which secures the turntable cover beneath the arm
housing.
removed screws.
WARNING
correct voltage.
country.
WARNING

Program.
values.


R128 Rotary Servo Cable Replacement Procedure 113
Rotary Servo Cable

Procedure Scope
This service procedure describes how to remove and install the rotary
servo cable in the Zymate XP Robot.
Parts Required
• Rotary servo cable (2)
• Cable tie, 4"
Tools Required
• Wrench, Allen, 0.050, 3/32"
• Tweezers or needlenose pliers
• Wire cutters
• Masking tape
Optional
Disassembly
WARNING
Position The Robot and Remove Covers

screws aside.
housing.

114 Rotary Servo Cable Replacement Procedure R128
Remove The Cables

1. Using the 9/64" ball-end hex driver, loosen the two Allen screws
that secure the rotary potentiometer assembly to the base.
2. Turn the servo cable adjustment screw counter-clockwise until the
rotary potentiometer assembly moves as close as possible to the
turntable (approximately 3 to 4 turns).

Shaft
Rotary pot
Servo cable drum assembly
Set screw
Flex coupling
Allen head (1 of 2)
Upper set screw
Servo cable
adjustment screw
3. Using tweezers or needlenose pliers, remove the cable ends from

the turntable.
4. Unwind the cables from the turntable.
5. Using the 3/32" Allen wrench, remove the set screw in the servo
cable drum and set aside.
6. Loosen the UPPER set screw on the flex coupling.
7. Lift the shaft out of the top of the servo cable drum using the
needlenose pliers.
8. Slide the servo cable drum out of the rotary potentiometer
assembly.
9. Unwind and remove both cables from the servo cable drum.

Installation
Replace The Cables
Prepare two lengths of tape about 5/8" (16mm) long before proceeding
with the following steps.
1. Insert one of the cables into the hole nearest the wide shoulder of
the servo cable drum.
2. Holding the servo cable drum with the wide shoulder to the left,
wrap the cable UP and OVER the drum 5-1/2 turns. Use the ferrule
hole in the drum as the reference point when wrapping.
3. Secure the cable to the servo cable drum with tape, making sure the
right side of the servo cable drum is not covered.
4. Insert the second cable into the remaining hole in the right side of

5. Holding the servo cable drum in the same manner as in step #2,
wrap the second cable DOWN and UNDER the servo cable drum
6 1/2 turns. As before, use the ferrule hole as a reference point.
NOTE
It is necessary to remove the piece of tape securing the first cable to the
servo cable drum before performing the next step. Hold the cables in
place on the servo cable drum with your finger to insure correct
wrapping.
6. Secure both cables to the servo cable drum with a piece of tape run
across the cables 180° opposite the ferrule holes. If correctly
placed, both cable ends will be equal in length. Make sure that the
tape does not extend to the flat surfaces on the top and bottom of
7. With the piece of tape facing away from the turntable and the wide
shoulder at the top, insert the wrapped servo cable drum into the
rotary potentiometer assembly.
8. Insert the shaft through the bearing and servo cable drum, lining up
the flat part of the motor shaft with the set screw hole on the side of
9. Install the set screw against the flat part of the motor shaft.
10. Tighten the top set screw of the flex coupling.

Wrap The Bottom Cable Around The Turntable

Manually move the arm to the 180° position to perform the following
steps.
1. To prevent the servo cable drum from turning, place a 3 to 4" (7.6 to
10.2 cm) piece of tape across the top of the rotary potentiometer
assembly and down the front of the servo cable drum (over the tape
used in step 6 of “Replace The Cables” ), finally securing to the flex
coupling beneath the servo cable drum.

2. Wrap the cable that is hanging from the left side of the servo cable
drum clockwise around the bottom groove of the turntable
approximately 1-3/4 turns. Wrap the cable from the top down. If
helpful, use small pieces of tape to secure the cable in place while
wrapping.
3. Insert the cable ferrule into the turntable so that its end is flush with
the outside surface of the turntable.
4. While holding the drum securely in place within the rotary
potentiometer assembly, manually rotate the turntable clockwise
until all cable slack is removed.
5. Push the wrapped cable down towards the bottom section of the
groove. This allows sufficient room in the upper half of the groove
for wrapping the second cable.
Wrap The Top Cable Around The Turntable

1. Wrap the second cable to the right and counter-clockwise around
the upper half of the bottom groove approximately 1-3/4 turns.
Wrap the cable from the middle up. Again, use small pieces of tape
to secure the cable in place while wrapping.
2. Insert the cable ferrule into the turntable so that its end is flush with
the outside surface of the turntable.

Cable Adjustment
1. Tighten the cables by turning the servo cable adjustment screw
clockwise (moves rotary potentiometer assembly away from
turntable) until all slack is removed.
2. Use the 9/64" ball-end driver to slightly tighten the two Allen head
screws on the bottom of the rotary potentiometer assembly.
3. Remove all tape from the rotary potentiometer assembly and
drums.
4. Slowly, rotate the Robot manually through its rotary axis, and
verify that the servo cables operate smoothly as rotation occurs.
5. Adjust cable tension by grasping either section of the cable between
the turntable and the rotary potentiometer assembly and pulling the
cable sideways. A force of approximately 2 lbs should move the
cable 0.15 to 0.20 inch (38 to 51mm).
6. Once cable tension is correct, use the 9/64" ball-end driver to fully
tighten the two screws on the bottom of the rotary potentiometer
assembly.
Position Adjustment
1. Unplug the Robot-Controller communication cable from the back
of the Robot.
WARNING
Be sure that the communication cable is disconnected between the

Robot and the Controller before performing this procedure.
WARNING
correct voltage.
country.
3. Slowly rotate the Robot to the 183° position so that the alignment
hole on the turntable is lined up with the sensor.

WARNING
Always keep body parts hair, jewelry, and clothing away from the
turntable to avoid a possible pinch point hazard between the turntable
and the mechanical assemblies.
its ON range.
ON to OFF.
NOTE

10. Very slowly, rotate the Robot back to 183° and observe the
following LED sequence as the arm moves to 183°.

ON
11. If the LED sequence is correct in step 10, no further adjustment is
required. If the LED sequence is not correct, for example the
sequence is reversed, remove the potentiometer and refer to
“Rotary Potentiometer Replacement Procedure” . In this procedure
you set, install, and adjust a new potentiometer.

1. Turn the Robot’s power OFF again and plug in the Robot Controller
Communication cable in back of the Robot.
WARNING
removed screws.
3. Remove the tape that secures the turntable cover to the arm
housing.
4. Install the turntable cover and secure it with the two previously
removed screws.
WARNING

Program.
values.

R145 Turntable Interconnect Board Replacement Procedure 123
Turntable Interconnect Board

Procedure Scope
This procedure describes how to replace the turntable interconnect
board in the Zymate XP Robot.
Parts Required
• Turntable interconnect board
• Ty-wrap(s)
Tools Required
• Wire cutters

WARNING

screws aside.

124 Turntable Interconnect Board Replacement Procedure R145
housing.
5. Locate the turntable interconnect board next to the vertical motor,
note the location of the six cables connected to the board, and
unplug the cables.
6. Remove the two screws and two spacers that secure the turntable
interconnect board to the turntable.
7. Remove the turntable interconnect board and set the screws and
spacers aside.
Install The New Board

1. Install the new turntable interconnect board with the two screws
and two spacers previously removed. Make sure the spacers are
placed on the back of the board.
2. Plug the six cables into the receptacles on the new board.
3. Secure the cables with the new ty-wrap.
4. Remove the tape that secures the turntable cover to the bottom of
the arm housing.
previously removed.
WARNING
correct voltage.

R122 Turntable to Wrist Coil Cord Replacement Procedure 125
Turntable to Wrist Coil Cord

Procedure Scope
turntable to the wrist in the Zymate XP Robot.
Parts Required
• Coil cord, turntable to wrist
• Ty-wraps
Tools Required
• Wire cutters
• Ruler
Remove The Covers

WARNING

3. Move the arm housing upward near the mid point on the columns.
screws aside.
screws aside.
8. Slide the turntable cover upward and tape it beneath the arm
housing.

126 Turntable to Wrist Coil Cord Replacement Procedure R122
9. Pull the arm out to help with the removal of the old coil cord.

1. Follow the routing of the coil cord as it extends from the turntable
to the wrist. Remembering this routing helps when installing the
new coil cord.
2. Unplug the coil cord from its receptacle on the turntable
interconnect board.
3. Unplug the opposite end of the coil cord from its receptacle on the
wrist interconnect board.

4. Carefully cut any ty-wraps that secure the coil cord along the
turntable.
5. Remove the screws from the two white cable clamps. One is
located on the top of the arm housing, the second is located on the
side of the turntable. Set the screws aside.
6. Loosen the two screws that secure the coil cord tube to the wrist
box.
7. Slide the tube and coil cord out of the wrist box. Allow the rubber
grommet at the coil cord end of the tube to slip from its notch, as
this helps with tube and coil cord removal.
8. Remove the rubber grommet from the coil cord and set it aside.
9. Slide the coil cord tube and horizontal coil cord support off the coil
cord. Set them aside.
10. Pull the coil cord upward through the coil cord tube in the arm
housing, then slide the coil cord off the horizontal coil cord support.

Before installing the new coil cord, transfer the two white cable clamps
from the old coil cord to the new coil cord. Use the positioning of the
clamps on the old coil cord as a guide.
1. Slide the longer loop of coils downward through the coil cord tube
in the arm housing.
2. Secure the coil cord to the top of the arm housing and to the side of
the turntable with the two cable clamps. Make sure the coil cord is
inserted within the groove at the top of the arm housing.
3. Now slide the shorter loop of coils onto the horizontal support.
When correctly positioned, the coil cord loop nearest the arm
housing should cross to the outside of the support.

4. Slide the coil cord tube over the loop of coils on the horizontal
support.
5. Install the rubber grommet 3.5" (8.9 cm) from the inside surface of
the coil cord's wrist connector.
6. Move the arm IN and feed the end of the coil cord and the coil cord
tube into the wrist box. When correctly positioned, the tube should
be flush with the front of the wrist box; the notch should face up to
hold the grommet and cord.
7. Tighten the two screws to secure the coil cord tube to the wrist box.
8. Plug the coil cord's connector into its receptacle on the wrist
interconnect board.
9. Plug the other end of the coil cord into its receptacle on the
turntable interconnect board.
10. Secure the coil cord to the arm housing and turntable with ty-wraps.
Verify Smooth Reach Operation

1. Manually push the arm IN and verify that there is no binding or
resistance in the coil cord as the back of the wrist box comes close
to the arm housing.
2. If binding or resistance is noted, check the following:
a. The coil cord loop nearest the arm housing crosses to the
outside of the support. See the diagram on previous page. If the
loop does not pass to the outside of the support, repeat the
Remove the Old Coil Cord, Install the New Coil Cord, and
Verify Smooth Reach Operation procedures.
b. The coil cord support passes through the center of the coils. If
the support does not pass through the center of the coils,
carefully bend the coil cord support until it does pass through
the center of the coils.

1. Reinstall the wrist cover and secure it with the screw previously
removed.
2. Remove the tape that secures the turntable cover beneath the arm
housing.

previously removed.
arm.
secure the cover.
WARNING
correct voltage.
country.


R191 Vertical Cable Replacement Procedure 131
Vertical Cable Replacement

Procedure
Procedure Scope
This service procedure describes how to replace the vertical cables in
Parts Required
• Cable, Vertical (long)
• Cable, Vertical (short)
Tools Required
• Screwdriver, flatblade, 1/8", 1/4", 5/32"
• Screwdriver, ball-end hex, 9/64"
• Wrench, Allen, 3/32"
• Masking tape
• LOCTITE® 222
• Light hammer
• Flashlight or penlight
Optional
Disassembly
WARNING

3. Move the arm vertically to mid height. Install a post clamp (or other
means of support) to hold the arm housing in position.
4. Loosen the two screws that secure the turntable cover. Move the
cover upward and secure it to the bottom of the arm housing.

132 Vertical Cable Replacement Procedure R191
aside. Remove the cover.
6. Remove the two screws that secure the column cap cover and set
them aside. Remove the cover.
Remove Cable Tension

1. Using the 9/64" driver, loosen the vertical cable tension adjustment
on the underside of the column cap.
2. Turn the compression screw next to the vertical cable pulley fully
clockwise to relax cable tension.

3. Place the spring clip tool under the vertical spring column.
4. Slowly raise arm housing. The spring cable will slacken as the arm
housing moves close to the column cap, allowing you to remove the
cable clamp in the next step.
5. Use a Phillips head screwdriver to remove upper cable clamp and
cables from arm housing.
6. Move the arm to mid height and clamp in place.
7. Loosen the two screws on the lower cable clamp and remove the
cable.
8. Turn the motor shaft until the two set screws face out.

Remove The Drive Drum

1. Remove the vertical potentiometer and flex coupling:
a. Remove the set screw on the potentiometer side of the drum by
tapping the Allen wrench into the screw with the hammer. This
ensures that the wrench is fully seated within the screw. Since
the set screws are held in place with LOCTITE® 222 it may be
necessary to grasp the Allen wrench with two hands to
generate enough force to loosen the screw.
b. Remove the two screws that secure the potentiometer/coupling
assembly to the turntable.
c. Remove the pot/coupling assembly.
2. Remove the vertical motor.
With the set screws in the drum facing outward:
a. Using the hammer as in step 1a, remove the set screw on the
motor side of the drum.
b. Remove the three motor mounting screws and lock washers.
c. Slide the motor out of position and set aside.
3. Remove the drive drum and cables.
Installation
Wrap The New Cables
1. Prepare two pieces of tape 1-1/8" (29 mm) long.
2. Holding the vertical drum with the shoulder to the right, insert the
ferrule of the new, long cable into the right hole of the drum.
3. Wrap the cable UP and OVER the drum for 4 turns. Use the ferrule
hole as the reference point.
4. Secure the cable in place by using one of the pieces of tape. Be sure
not to cover the left section of the drum with the tape.

5. Insert the ferrule of the new, short cable into the left hole of the
drum.
6. Wrap the cable DOWN and UNDER the drum for 3 1/2 turns, again
using the ferrule hole as a reference point.
7. Secure the short cable by placing the second piece of tape

perpendicular to the direction of the cable wraps, directly across the
two ferrule holes. Do NOT extend the tape onto the sides of the
drum.
8. Carefully remove the first piece of tape (see step 4) and reposition it
so that it runs parallel to the second piece. Make sure it is
positioned 180° opposite the second piece of tape.
Reinstall The Drum

1. Insert the drum into position within the turntable housing. Position
the drum so that the set screw holes face outward and the shoulder
is to the right.

2. Insert the potentiometer/coupling assembly into the right end of the

drum with the flat part of the shaft facing outward. Secure the
assembly with the two screws previously removed.
3. Slide the motor into position with the flat part of the shaft facing
outward and secure it in place with the three screws and lock
washers.
4. Push the drum to the right side of the housing, and use the flashlight
to look through the set screw holes to verify that both flat parts of
the shaft face outward.
5. Apply a drop of LOCTITE® 222 to the threads of one of the set
screws and insert it into the hole on the motor side of the drum.
Tighten until snug.
6. Verify that the set screw is aligned with the flat part of the shaft on
the motor by doing the following:
a. Loosen the set screw 1/8 to 1/4 turn. (Keep the Allen wrench in
position on the set screw).
b. Place a finger on the tail shaft protruding from the right end of
the motor.
c. Using the Allen wrench as a lever, rotate the drum back and
forth (approximately 10°) in each direction. If properly
aligned, contact made between the set screw and the flat part of
the shaft (as the drum is rotated) stops the drum from rotating
more than 10° or so in each direction. Also, the tail shaft of the
motor moves slightly each time contact is made.
d. Continue to slowly rotate the drum while simultaneously
tightening down on the set screw. This insures that the set
screw is centered on the flat part of the shaft. Tighten securely.
e. If the tail shaft did not move and contact was not made, remove
the set screw and motor and repeat steps 3-6.

7. After applying LOCTITE® to the second set screw, insert it into the
left side of the drum. Make sure the potentiometer/coupling
assembly is pushed fully into the drum. Securely tighten the set
screw against the flat part of the shaft.
8. Locate the tail shaft as it protrudes from the back of the vertical
motor.
9. Turn the shaft clockwise until the two set screws in the drum face
UP.
10. Carefully pull the short vertical cable up through the opening
between the two columns.
Attach The Short Cable

1. Slide the short vertical cable through the slot in the turntable cover
and insert the ferrule into the cable clamp at the bottom of the arm
housing.
2. Tighten the two screws to secure the cable clamp to the arm
housing.
Attach The Long Cable

1. Take the long vertical cable and push it up through the column until
it reaches the top.
2. Run the cable over the pulley and down through the hole in the
bottom of the column cap assembly.
3. Securely tape the cable in place on the pulley.
4. Slide the long vertical cable through the upper cable clamp and
insert the ferrule into the hole facing the elbow.
5. Loosen the compression screw in the top of the column cap
assembly. When correct, it should be approximately level with the
top of the pulley.
6. Move the arm housing up slightly, and install vertical spring cable
ferrule into the cable clamp hole facing the wrist.
7. Secure the clamp and attached vertical cable to the top of the arm
housing with the two Phillips screws previously removed.
8. Remove any vertical cable slack from above the arm housing by
carefully lowering the arm housing until the slack is just removed.
Resecure the arm housing.
Tension The Cables

1. Remove the tape from the drum and the pulley.
2. Remove the arm housing support.
3. Remove spring clip tool from the bottom of the spring column.
4. Turn the vertical drive tensioning adjustment (located on the
underside of the column cap assembly counter-clockwise until a
slight resistance is felt. This resistance is the first contact between
the adjusting screw and the cable-tensioning device within the
column cap assembly.

5. Continue to turn the adjustment counter-clockwise one more turn.

If correctly adjusted, a force of approximately 2 lbs. (0.9 kg) should
move the center of the cable 0.20" to 0.25" (5 to 6 mm).

Replace The Covers
1. Reinstall the column cap cover and secure it with the two screws
previously removed screws.
2. Make sure the motor and potentiometer cables are connected.
removed screws.
removed screws.
Verify Operation
WARNING
correct voltage.
country.

Program.
pull-down and select Module Setup.
6. Select the Zymate XP Robot from the module setup list.
Set Vertical Zero and Check Calibration

1. Perform the vertical zero procedure and check vertical calibration
as described in the “Zero and Calibrate” section of the Zymate XP
Robot Module User’s Guide (P/N 45461).

R120 Vertical Motor Replacement Procedure 139
Vertical Motor Replacement

Procedure
Procedure Scope
This service procedure describes how to replace the vertical motor in the
Zymate XP Robot.
Parts Required
• Vertical motor
• Set screw, 10/32" x 1/2"
• Ty-wraps
Tools Required
• Wrench, hex (Allen) 3/32"
• Wrench, adjustable
• Wire cutters
• LOCTITE® 222
Optional
Disassembly
WARNING
Position The Robot

3. Loosen the two turntable cover screws and tape the turntable cover
beneath the arm housing.

140 Vertical Motor Replacement Procedure R120
4. Remove the two base cover screws, remove the base cover, and set
it aside with the two screws.
5. Turn the arm so that the wrist is to your right and the vertical drum
faces you.
NOTE
Do not position the arm in a rotary location greater than 360° or less
than 0°.
6. Locate the vertical drive drum on the end of the vertical motor
shaft.
7. Move the arm housing vertically upward on the columns until the
set screws in the drum are accessible.
8. Install a post clamp (or other means of support) to support the arm
housing in this position.

Relax Cable Tension

1. Using a 9/64" ball-end hex driver, turn the vertical cable tensioning
adjustment clockwise two turns.
This adjustment is made through a small hole in the BOTTOM
SIDE of the column cap assembly at the top of the Robot. Refer to
the diagram for the adjustment location.
NOTE
Clockwise/counter-clockwise motion is relative to the end of the driver

handle.

Disconnect The Motor

1. Cut the ty-wraps securing the motor leads.
2. Unplug the vertical motor leads at the interconnection board.
Remove The Motor

1. Using the 3/32" Allen wrench, remove the set screw nearest the
motor in the drive drum.
NOTE
The set screw is held in place with LOCTITE® 222. It may be necessary
to grasp Allen wrench with two hands to generate enough force to
loosen the set screw.
2. Remove the three motor mounting screws and lock washers. Set
them aside for later use.
Installation
Mount The New Motor
1. Position the new motor with the electrical terminals toward the
interconnect board. The motor shaft is pointing away from you.
2. Using an adjustable wrench, turn the motor shaft until the flat part
of the motor shaft aligns with the set screw hole in the drum.
3. Slide the motor into position and secure it with the three mounting
screws and lock washers.

NOTE
It may be necessary to push down gently on the drive drum to align its
center hole with the motor shaft while sliding the motor in place.
NOTE
A holding screwdriver is helpful in starting the mounting screws.
4. Look through the set screw hole and confirm that the flat part of the
motor shaft is aligned with the set screw hole.
5. Apply LOCTITE® 222 to set screw.
a. Using the 3/32" Allen wrench, tighten the set screw until it is
snug and then loosen it 1/8 to 1/4 turn.
b. With the Allen wrench still in position on the set screw, use one
hand to slightly move the arm housing up. Use your other hand
to hold onto the Allen wrench.
c. If properly aligned, contact made between the set screw and
the flat part of the motor (as the drum is moved) stops the drum
from rotating more than 10°. This contact is also felt through
the Allen wrench.
d. After verifying alignment in the above manner, fully tighten
the set screw against the flat part of the motor shaft.
Connect The Motor

1. Plug the vertical motor leads connector into the interconnection
board.
2. Dress both sets of motor leads carefully and install a ty-wrap.
3. Reinstall the base cover and secure it with the two screws.
Set Cable Tension and Install Covers

Choose one of the following methods for setting correct cable tension
and installing the covers.
METHOD #1
1. Remove the post clamp (or other arm housing support means).
2. Turn the vertical cable tensioning adjustment (located on underside
of column cap) counter-clockwise (as viewed from handle end) two
turns to retension the cable.

WARNING
correct voltage.
country.
METHOD #2
1. Turn the adjustment several turns clockwise to fully disengage it.
2. Advance the vertical cable tensioning adjustment counter-
clockwise until a slight resistance is felt. This resistance is the
FIRST contact between the adjusting screw and the cable
tensioning device within the column cap assembly.
3. Continue to turn the vertical cable tensioning adjustment counter-
clockwise one more turn.
WARNING
correct voltage.
country.

R155 Vertical Potentiometer Replacement Procedure 145
Vertical Potentiometer
Procedure Scope
This procedure describes how to replace the Zymate XP Robot’s vertical
potentiometer.
Parts Required
• Vertical potentiometer
Tools Required
• Metal rule, 12" (30 cm)
Remove The Covers

WARNING

3. Use a small screwdriver to disconnect the Robot Communication
cable from the receptacle at the rear of the Robot.
WARNING
Disconnect the Robot Communication cable before continuing with

these procedures.
screws aside.
5. Slide the turntable cover upward and secure it with tape beneath the
arm housing.

146 Vertical Potentiometer Replacement Procedure R155
7. Remove the two screws that secure the column cap cover. Set the
screws and cover aside.
Remove The Old Potentiometer

1. Slowly rotate the arm to the 90° position. This positions the wrist
over the Robot baseboard.
WARNING
correct voltage.
country.
3. Move the arm vertically so there is a distance of 6.1” (15.5 cm)

from the bottom surface of the column cap to the top of the cable
retainer.

4. Observe the yellow LED on the baseboard in the column of LEDs

marked VER. The LED should be on at the 6.1" (15.5 cm) distance
measurement. If it is not on, move the arm housing slightly up or
down until the yellow LED comes on.
NOTE
There is no specified tolerance for the vertical length. The arm should
only have to be moved slightly for the yellow LED to come on.
5. Secure the arm housing to maintain the position, then turn the
Robot’s power OFF.
WARNING

6. Locate connector P4 on the turntable interconnect and unplug it.
P1
P2
P4
P5
P3
WARNING
Use care when unplugging wires from the interconnect board when
power is applied, as components could be damaged if they are short
circuited.
7. Locate the magnetic wheel that the vertical potentiometer connects

to, and loosen the wheel’s set screw one turn.
8. Loosen the vertical potentiometer adjusting screws and turn the

cleats so the flat part of the cleat faces the vertical potentiometer.
Retighten the screws slightly to maintain the cleats’ position.
9. Remove the vertical potentiometer.

Set and Install The New Potentiometer

the DVM to ohms, then attach one DVM lead to the
potentiometer’s black terminal and the other DVM lead to the
yellow terminal.
2. Turn the potentiometer’s shaft until the DVM reads 4.05K Ω.
3. Orient the terminals of the potentiometer to be between the cleats.
This allows you to fine-tune and have clear access to the screws
when tightening the potentiometer.
4. Insert the potentiometer’s shaft into the magnetic wheel.
potentiometer.
potentiometer.
7. Tighten the wheel’s set screw to secure the potentiometer.
8. Plug in the new potentiometer wires into connector P4 on the
turntable interconnect board.

WARNING
correct voltage.
country.
CAUTION
Make sure that the Robot Communication cable is not connected before
performing this procedure.
2. Verify that the yellow LED in the column of LEDs marked VER is
ON, and the measurement from the column cap to the retainer is
still correct. If the yellow LED is not on, and/or the measurement is
not correct, remove the potentiometer. Set, install, and adjust a new
potentiometer.


4. Carefully turn the potentiometer body clockwise/counter-clockwise
until the green LED in the VER column comes ON. Note that the
yellow LED should also be ON. If the green and yellow LEDs are
not on, remove the potentiometer. Set, install, and adjust a new
potentiometer.
green and yellow LEDs are still ON.

WARNING
1. Turn the power OFF again and plug in the Robot Controller
communication cable into the rear of the receptacle at the rear of
the Robot.
2. Reinstall the column cap cover and secure it with the two screws
previously removed.
previously removed.
4. Remove the tape that holds the turntable cover to the bottom of the
arm housing.
previously removed.
cap.
arm.

WARNING
correct voltage.
Program.
14. At the Z>, run SET.ACCUTRAK to store the position values for
the new potentiometer.


R115 Vertical Spring Cable Replacement Procedure 153
Vertical Spring Cable

Procedure Scope
This service procedure describes how to replace the vertical spring cable
in the Zymate XP Robot.
Parts Required
• Vertical spring cable
Tools Required
• Ball-end driver, 9/64"
• Screwdriver, Phillips head
• Needlenose pliers
• Cable-feeding tool
Disassembly
WARNING
Remove Covers
screws aside.
housing.

154 Vertical Spring Cable Replacement Procedure R115
6. Remove the two screws that secure the column cap cover. Remove
the cover and set it aside with the screws.
Remove The Old Cable

1. Find and unplug the flex circuit from the turntable interconnect
board. Tape the flex circuit so you have access to the bottom of the
vertical spring column.

2. Slightly loosen the two screws that secure the upper cable retainer.
3. With the arm at about mid-height, use the 9/64" driver to loosen the
tension adjustment on the underside of the column cap.
NOTE
Do not turn the compression screw at the top of the column cap.
WARNING
Use caution when grasping the vertical cable. This cable is set at a
specific tension and could cause a pinch point hazard between the
column cap assembly and the cable retainer.

4. Install the spring clip tool into position on the underside of the
vertical spring column.
5. Move the arm housing up until the tension on the vertical drive
cable is removed. Move the housing another 1/4" (6mm) or so, then
firmly secure the housing with the clamp.
6. Remove the vertical spring pulley and set it aside.
7. Tighten down on the compression screw three or four full turns, or
until some of the vertical drive cable tension is removed.
8. Tape the lower vertical drive cable to the column beneath the arm
housing. Tape the upper vertical drive cable to the column above
the arm housing.
9. Remove the two screws that secure the upper cable retainer,
disconnect the cables, and set the retainer and screws aside.
10. Remove the old spring cable by pushing the cable downward
slightly through the column to remove the spring cable retainer,
then pulling the cable up through the column to remove the cable.
Set the retainer aside.

Installation
Install The New Cable
Refer to the following illustration.
1. Slide the hooked end of the cable-feeding tool downward through

the top of the vertical spring column.
2. Attach a ferrule from either end of the new spring cable to the
hooked end of the tool.
3. Pull the cable upward through the vertical spring column until
approximately two inches of cable extends from the bottom of the
vertical spring column. Detach the cable-feeding tool.
4. Attach the previously removed spring cable retainer to the ferrule at
the bottom of the housing. Pull the spring cable upward until the
retainer seats itself in the spring guide
5. Insert the other end of the new cable through the center slot in the
column cap.
6. Now attach the ferrule of the new vertical spring cable and the
ferrule of the vertical drive cable to the previously removed upper
cable retainer. Make sure the vertical spring cable’s ferrule is
attached to the slot in the retainer closest to the front of the arm.
7. Secure the retainer and cables to the arm housing with the two
screws previously removed. Do NOT fully tighten the screws.

Re-tension and Complete The Cable Installation

1. Use the 9/64" driver to turn the tensioning adjustment on the
underside of the column cap assembly counter-clockwise to
increase drive cable tension. Remove the tape pieces from the upper
and lower vertical drive cables.
2. Insert the vertical spring pulley into position, then push the arm
housing upward to slacken the vertical cable. Now loop the new
vertical cable over the pulley.
3. Remove the robot post clamp beneath the arm housing.
4. Move the arm down slightly, and remove the spring clip tool from
the bottom of the column.
5. Fully tighten the two upper cable retainer screws.
6. Now move the arm up and verify that the spring cable retainer at
the bottom of the column is fully seated within the spring guide. If
it is not fully seated, use a pair of needlenose pliers to realign the
retainer with the hole in the spring guide.
NOTE
When realigned, spring tension seats the retainer correctly.
7. Reconnect the flex circuit to the turntable interconnect board.

8. Turn the compression screw counter-clockwise three or four full
turns to raise the screw.
9. Now use the 9/64" driver again to turn the tensioning adjustment
counter-clockwise until cable tension is correct.

1. Reinstall the column cap cover, and secure it with the two screws.
3. Remove the tape that secures the turntable cover beneath the arm
housing.
WARNING
correct voltage.
country.

R135 Wrist Cable and Flex Coupling Replacement Procedure 159
Wrist Cable and Flex Coupling

Procedure Scope
This service procedure describes how to replace a defective ribbon cable
in the Zymate XP Robot’s wrist.
Parts Required
• Wrist Cable
• Ribbon Cable Clamp
• Flex Coupling
• #2 Flathead Screws
• Ty-wrap
Tools Required
• Wrench, small adjustable
• Wrenches, Allen: 3/32", 0.050"
• Steel rule, 12" (30 cm) or longer
• Wire cutters
• LOCTITE® 222
Disassembly
WARNING
Remove The Wrist Cover


160 Wrist Cable and Flex Coupling Replacement Procedure R135
Refer to this exploded view of the wrist for the remaining disassembly
and installation steps.
Remove The Wrist Interconnect Board and Coil Cords

1. Taking note of the ty-wrap’s location, carefully cut the ty-wrap that
holds the two coil cords together.
2. Unplug the coil cords, ribbon cable, potentiometer wires, and motor
wires from the wrist interconnect board.
3. Remove the two screws that hold the wrist interconnect board,
remove the board then set the board and screws aside.
4. Loosen the two screws that secure one of the coil cord tubes to the
wrist box.
5. Slide one of the coil cord tubes towards the back of the wrist
approximately 1.5" (3.8 cm).
6. Detach the rubber grommet and coil cord from the notch in the coil
cord tube.
7. Slide the coil cord tube and coil cord out of the wrist box.
8. Repeat steps 4 through 7 for the remaining coil cord tube and coil
cord.
Remove The Wrist Coupling

1. From the wrist’s zero position, rotate the wrist clockwise
approximately 45°. This allows you to access the two set screws in
the flex coupling.

2. Remove the two Allen head set screws from the flex coupling. The
set screws are located under the ribbon cable and are 90° apart.
Refer to the following illustrations.
Ribbon Cable Attachment on Flex Coupling - Top View
3. Unwind the ribbon cable from the wrist.

4. Remove the retaining ring.
5. Slide the wrist coupling assembly out of the wrist front.
Disassemble The Wrist Coupling (Old Style)

1. Remove the three screws next to the electrical pins at the front of
the wrist coupling. Remove the phenolic piece and set all pieces
aside.
2. Separate the flex coupling from the front section of the wrist
coupling.
3. Remove the two sets of electrical pins from the ribbon cable
connectors. Set the electrical pins aside and discard the old ribbon
cable.
Disassemble The Wrist Coupling (New Style)

1. Remove the three screws next to the electrical pins at the front of
the wrist coupling. Place tweezers into the screw holes, grab the
wrist pin holder assembly, and remove it.
2. Set the wrist pin holder assembly aside for later use.

Installation
Fold and Attach The New Cable
1. Fold the new ribbon cable as indicated in the diagram below. Make
sure the connector on top says “Top Right” and the text “Top Right”
is installed upside down. Make sure that the connector on the
bottom says “Top Left” and the text “Top Left” is on the reverse
side.
2. Attach the new cable to the flex coupling as in the “Ribbon Cable
Attachment on Flex Coupling - Top View” illustration shown on
page 161. When the flex coupling is oriented as in the illustration,
the set screws should be on the top and to the left with the three
screw holes facing you.
3. Place the flex cable in the coupling such that the two cutouts on the
connectors are facing out. One cutout is marked “Top Right” on the
right side with the text “Top Right” facing away from the flex
coupling body. The other is marked “Top Left” on the left side with
the text “Top Left” facing towards the flex coupling body.
Reassemble The Wrist Pin Holder Assembly (Old Style)

1. Insert the electrical pins into the holder with the counter sunk holes
facing outward.
2. Carefully slide the flex coupling with attached cable into the wrist
coupling. Make sure the flex coupling is fully inserted.
3. Insert the phenolic holder with electrical pins into the front of the
wrist coupling, using only the short screw that goes in the holder’s
middle hole.
4. Make sure the wrist stop is oriented so the pin on the inside of the
stop is positioned between the two stop pins.
NOTE
If correctly installed, the wrist stop should only rotate a few degrees.
5. Reinstall the mylar washer in front of the wrist stop.

6. Insert the wrist coupling assembly into the wrist front and slide the
race and retaining ring over the end of the ribbon cable.
7. Push the wrist coupling fully in, being careful not to pinch the
ribbon cable.
8. Reinstall the retaining ring, making sure the ring is correctly seated.
9. Wind the cable by turning the wrist clockwise six full turns.
10. Turn the wrist coupling an additional 10° clockwise so you have
access to both set screw holes in the coupling. Reinstall the set
screws using LOCTITE® 222.

Reassemble The Wrist Pin Holder Assembly (New Style)

1. Insert the delrin holder over the soldered wrist pin assembly with
the counter sunk holes facing outward.
2. Carefully slide the flex coupling with attached cable into the wrist
coupling. Make sure the flex coupling is fully inserted.
3. Insert the phenolic holder with electrical pins into the front of the
wrist coupling, using only the short screw that goes in the holder’s
middle hole.
4. Make sure the wrist stop is oriented so the pin on the inside of the
stop is positioned between the two stop pins.
NOTE
If correctly installed, the wrist stop should only rotate a few degrees.
5. Reinstall the mylar washer in front of the wrist stop.

race and retaining ring over the end of the ribbon cable.
ribbon cable.

1. Slide one of the tubes with coil cord into the wrist with the notch in
the tube facing up.
2. Capture the rubber grommet in the notch to secure the cord to the
tube.
3. Make sure the tube is flush with the wrist’s front plate, then rotate
the tube slightly so the notch is angled inward about 10°.
4. Tighten the two screws to secure the tube. Repeat steps 3 through 6
for the remaining tube and coil cord.
5. Reinstall the wrist interconnect board with the two screws
previously removed.
6. Connect the pot wires, motor wires, wrist cable, and coil cords to
the interconnect board.
7. Ty-wrap the coil cords together, then re-fasten the wrist cover.

Zero The Wrist

WARNING
Turn ON the system power before beginning the WRIST ZERO check.
1. Turn the Robot’s power ON.

WARNING
Always keep body parts, hair, jewelry, and clothing away from the robot.
3. From the ZYMATE XP PROGRAMMING screen, set the wrist

angle to 0°.
4. Place a monument into a hand parking station, then use the function
keys to move the Robot so that the wrist pins are just about to enter
the two holes in the monument.
the monument and pins in the hand. If the pins are aligned with the
holes, no adjustment is required. If the pins are not aligned with the
holes, correct the alignment by adjusting the wrist as follows:
screen.
zero function.
c. Use the CLOCKWISE/COUNTER-CLOCKWISE function
keys to move the wrist until the pins are aligned with the
monument holes.
Example:
Wrist pins not aligned -- movement of the wrist coupling in a


f. Press the F7 key to return to the ZYMATE XP

PROGRAMMING screen.
Calibrate The Wrist

IN so that the pins are clear of the monument.
monument holes.
PROGRAMMING screen. Then use the CLOCKWISE/
COUNTER-CLOCKWISE function keys to move the wrist until
the pins are aligned with the monument holes.


R136 Wrist Coupling Pin Replacement Procedure 167
Wrist Coupling Pin

Procedure Scope
This service procedure describes how to replace the wrist coupling pins
Parts Required
• Wrist pin holder
• Wrist pins: two, six-position sets
Tools Required
• Needlenose pliers
• Screwdriver, Phillips head
• LOCTITE® 222
Remove The Old Pins

WARNING
1. Move the wrist to its zero position.
NOTE
Do NOT rotate the wrist in the steps that follow. Make sure you
maintain the wrist’s zero position.

4. Locate and remove the upper and lower Phillips head screws that
secure the wrist pins and wrist pin holder. Set the two screws aside.
Do NOT remove the middle Phillips head screw.

168 Wrist Coupling Pin Replacement Procedure R136
Wrist pin holder

Upper Phillips head screw
Wrist pins
Lower Phillips head screw
Wrist - Front View

5. Grasp the wrist pin holder with the needlenose pliers and pull it
outward to remove it.
NOTE
The wrist pins may be attached to the holder when it is removed.
6. Use the needlenose pliers to remove any wrist pins that remain
inside the wrist assembly.
Install The New Pins

1. Insert the two new sets of wrist pins into the back of the new wrist
pin holder as shown below. The front of the wrist pin holder can be
identified by the two counter-sunk holes.
2. Align the wrist pin holder and wrist pins with the holes in the wrist
assembly. Slide the wrist holder and wrist pins into place.
3. Apply a drop of LOCTITE® 222 to each of the two previously
removed screws and insert the screws into the wrist pin holder.
Alternately tighten each screw to secure the new wrist pins and
wrist holder.

R146 Wrist Interconnect Board Replacement Procedure 169
Wrist Interconnect Board

Procedure Scope
This procedure describes how to replace the wrist interconnect board in
Parts Required
• Wrist interconnect board
• Ty-wrap(s)
Tools Required
• Screwdriver, flatblade, small
• Wire cutters

WARNING

3. Remove the screw that secures the wrist cover, set the screw aside,
and remove the wrist cover.

170 Wrist Interconnect Board Replacement Procedure R146
4. Carefully cut the ty-wrap at the coil cords. Note the orientation of
the two cords.
5. Unplug the two coil cords by pushing the tab up against the clip at
the bottom of each connector with the flatblade screwdriver.
6. Unplug the wrist motor and wrist potentiometer cables from their
receptacles on the board.
7. Carefully unplug the ribbon cable connector from its socket on the
board.
8. Remove the two screws that secure the wrist interconnect board and
set the screws aside.
9. Remove the old wrist interconnect board.
Install The New Board and Verify Operation

1. Position the new wrist interconnect board in the wrist and secure it
with the two screws previously removed.
2. Carefully plug in the ribbon cable connector in the receptacle on the
new board. Make sure none of the pins are bent and are all correctly
seated within the socket.
3. Plug the motor, potentiometer, and two coil cord cables into their
receptacles on the new board.
4. Secure the coil cords with a ty-wrap as previously noted.
5. Reinstall the wrist cover and secure it with the screw previously
removed.
WARNING
correct voltage.
country.

Program.
11. Select the Zymate XP Robot.
12. Run a program to attach a hand.
13. Go to the Zymate XP Hand Programming screen and verify that all
wrist and hand functions are operational.

R137 Wrist Motor Replacement Procedure 171
Wrist Motor Replacement

Procedure
Procedure Scope
This service procedure describes how to replace a defective wrist motor
Parts Required
• Wrist motor
• Ty-wrap
• Set screw assortment
Tools Required
• Flatblade screwdriver, 1/4"
• Right-angled Phillips head screwdriver
• Wrench, small adjustable
• Wrenches, Allen: 3/32", 0.050"
• Wire cutters
• LOCTITE® 222
Disassembly
WARNING


172 Wrist Motor Replacement Procedure R137
Refer to this exploded view of the wrist for the remaining disassembly
and installation steps.

Remove The Wrist Interconnect Board and Coil Cords

1. Taking note of the ty-wrap’s location, carefully cut the ty-wrap that
2. Unplug the coil cords, ribbon cable, potentiometer wires, and motor
wires from the wrist interconnect board.
3. Remove the two screws that hold the wrist interconnect board,
remove the board, then set the board and screws aside.
wrist box.
5. Slide one of the coil cord tubes towards the back of the wrist,
approximately 1.5" (3.8 cm).
6. Detach the rubber grommet and coil cord from the notch in the coil
cord tube.
7. Slide the coil cord tube and coil cord out of the wrist box.
8. Repeat steps 4 through 7 for the remaining coil cord tube and coil
cord.
Remove The Wrist Coupling

1. Manually rotate the wrist fully-clockwise to the stop position. This
allows you to access the anti-backlash gear set screw later.
2. Remove the two Allen head set screws from the flex coupling.
NOTE
The screws are located under the ribbon cable and are 90° apart. Refer
to the exploded view on page 172.
3. Unwind the ribbon cable from the wrist.

4. Remove the retaining ring.
5. Slide the wrist coupling assembly out of the wrist front.
Remove The Wrist Stop and Anti-Backlash Gear

1. Remove the large mylar washer.
2. Remove the wrist stop.
3. Remove the two screws from the potentiometer support, remove the
potentiometer support, and set it aside with the screws.
4. Loosen the set screw in the anti-backlash gear. The set screw is
located in the cutout where the gear connects to the potentiometer.
5. Remove the anti-backlash gear and set it aside.

Remove The Motor

1. Remove the six screws that hold the base plate. Set the plate and
screws aside.
2. Remove the two Phillips head screws from the rear plate, remove
the plate, and set it aside with the screws.
3. Remove the two set screws from the motor gear. Remove the gear
and discard the screws.
4. Remove the small mylar washer.
5. Remove the three Phillips head screws from the motor front.
WARNING
Do not remove or loosen the four Phillips head screws on the wrist’s
front plate.
Installation
Install The New Motor
1. Apply LOCTITE® 222 to the three motor screws and firmly secure
the new motor into place.
NOTE
Make sure the short screw goes into the large counter-bored area.
2. Use a small adjustable wrench to rotate the motor shaft as indicated

below.
3. Slide the small mylar washer onto the motor shaft.

4. Slide the motor gear onto the motor shaft.
5. Apply LOCTITE® 222 to the two new set screws and insert them
into the motor gear. Make sure the set screws rest against the flat
part of the motor shaft. Wipe off any excess LOCTITE®.

Set screw
Install The Anti-Backlash Gear

1. With the set screw for the anti-backlash gear facing up, install the
gear by:
a. positioning the gear so that only the teeth on the inner gear are
engaged with the motor gear’s teeth.
b. rotating the outer gear clockwise over the inner gear 3-1/2
teeth; this sets the correct spring tension.
c. maintaining this position and pushing in so the outer gear's
teeth also engage the motor gear.
2. Reinstall the potentiometer support using the two screws previously
removed.
3. Insert a new set screw into the anti-backlash gear, slide the gear
forward towards the wrist front as far as possible, then fully tighten
the set screw.
Install The Wrist Coupling

1. Install the wrist stop so the pin on the inside of the stop is
positioned between the two stop pins. If correctly installed, the
wrist stop should only rotate a few degrees.
2. Reinstall the large mylar washer in front of the wrist stop.
race ring and retaining ring over the end of the ribbon cable.
ribbon cable.

1. Reinstall the rear plate using LOCTITE® 222 on the threads of the
two screws previously removed.
2. Reinstall the base plate with the six screws previously removed.
3. Slide the coil cord tube with long coil cord into the right slot in the
wrist (when facing the front of the wrist). Make sure the notch in
the coil cord tube faces up.
4. Place the rubber grommet in the coil cord tube notch to secure the
coil cord to the tube.

5. Make sure the coil cord tube is flush with the wrist’s front plate,
then rotate the coil cord tube slightly so the coil cord notch is
angled inward about 10°. Tighten the two screws to secure the coil
cord tube.
6. Install the short coil cord and coil cord tube in the left coil cord tube
slot in the same way.
7. Reinstall the wrist interconnect board with the two screws
previously removed.
8. Connect the potentiometer wires, motor wires, wrist cable, and coil
cords to the interconnect board.
9. Ty-wrap the coil cords together, then re-fasten the wrist cover.
Zero The Wrist

WARNING
correct voltage.
country.
WARNING

Program.
angle to 0°.


screen.
zero function.
Example:

Wrist pins not aligned — movement of the wrist coupling in a
PROGRAMMING screen.
Calibrate The Wrist

monument holes.
5. When aligned, press the “0” key; to access the ROBOT WRIST


R134 Wrist Potentiometer Replacement Procedure 179
Wrist Potentiometer
Procedure Scope
This service procedure describes how to replace a defective wrist
potentiometer in the Zymate XP Robot.
Parts Required
• Wrist potentiometer
Tools Required
• Allen Wrench 0.050"
• Digital Voltmeter (DVM)
Disassembly
WARNING

4. Locate the wrist interconnect board and disconnect the
potentiometer wires from the baseboard.

180 Wrist Potentiometer Replacement Procedure R134
Refer to the following exploded view of the wrist for the remaining
disassembly and installation steps.
Remove The Potentiometer

1. Manually rotate the wrist to the fully clockwise position. This
allows you to access the anti-backlash gear set screw in the next
step.
2. Loosen the set screw in the anti-backlash gear. The set screw is
located in the cutout where the gear connects to the potentiometer.
3. Loosen the two potentiometer adjusting screws.

4. Rotate the cleats so the flat part of the cleat faces the potentiometer
body, then retighten the two pot adjusting screws.
5. Remove the potentiometer.
Installation
Install The New Potentiometer
1. Insert the new potentiometer into position within the wrist.
2. Loosen the two potentiometer adjusting screws, rotate the cleats so
the flat part faces away from the potentiometer body, then tighten
the screws slightly to secure the potentiometer.
3. Slide the small mylar washer onto the motor shaft.
4. Slide the motor gear onto the motor shaft.
5. Apply LOCTITE® 222 to the two new set screws and insert them
into the motor gear. Make sure the set screws rest against the flat
part of the motor shaft. Wipe off any excess LOCTITE®.
6. Connect the potentiometer wires to the wrist interconnect board.
Set The Potentiometer

1. Turn the Robot’s power ON. Make sure the Controller’s power
remains off.
2. Slowly turn the wrist coupling by hand fully clockwise.
3. Place the DVM’s ground lead on the potentiometer’s black terminal
and the DVM’s positive lead on the potentiometer’s yellow
terminal.
4. Set the DVM to DC volts and read the voltage. The potentiometer
voltage should read 0.14 volts DC at the fully-clockwise wrist
coupling position.
5. If the voltage is not correct, loosen the two potentiometer adjusting
screws slightly, then rotate the potentiometer body until the voltage
is correct.
6. When the voltage is correct, retighten the two potentiometer
adjusting screws. Recheck the voltage.
7. Secure the wrist cover with the screw previously removed.

Zero The Wrist

WARNING
correct voltage.
country.
1. Plug in the Robot’s power cord and turn the Robot’s power ON.
WARNING

angle to 0°.
screen.
b. Press “0” to access the ROBOT WRIST CALIBRATION
options, then press “Z” to select the zero function.
Example:

e. Press the ESC key again to return to the ZYMATE XP HAND
PROGRAMMING screen.
f. Press the F7 key to return to the ZYMATE XP
PROGRAMMING screen.

Calibrate The Wrist

2. Move to a wrist angle of 360°.
monument holes.
5. When aligned, press the “0" key to access the ROBOT WRIST
6. Press the “C" key to select the calibration function.


R139 Wrist Replacement Procedure 185
Wrist Replacement Procedure

Procedure Scope
This service procedure describes how to replace a wrist assembly in the
Zymate XP Robot.
Parts Required
• Wrist assembly
• Hex bolts and washers
• Ty-wraps
Tools Required
• Wrench, open end, 5/16" or small adjustable
• Wire cutters
• LOCTITE® 242
Disassembly
WARNING


186 Wrist Replacement Procedure R139
Remove The Coil Cords

1. Remove the two screws that hold the wrist interconnect board. This
will allow you more room to remove the coil cords.
2. Taking note of the ty-wraps location, carefully cut the ty-wrap that
3. Unplug the coil cords from the wrist interconnect board by pressing
against the small clips on the underside of the cords.
4. Loosen the two screws that secure each coil cord tube to the wrist
box.
5. Slide one of the tubes toward the back of the wrist approximately
1.5" (3.8 cm). Then pull the end of the coil cord out of the tube.
Make sure the rubber grommet remains attached to the coil cord.
6. Perform the same sequence for the other coil cord.

Remove The Old Wrist

1. Use an open end or adjustable wrench to remove the bolts and
washers that secure the wrist to the arm.
2. Remove the wrist.
Installation
Install The New Wrist
1. Remove the hex bolts and washers from the new wrist. Set them
aside for later.
2. Apply LOCTITE® 242 to the threads on the hex bolts.
3. Attach the new wrist to the arm using the hex bolts and washers. Do
NOT fully tighten the bolts at this time.
4. Remove the two screws that hold the wrist interconnect board to the
wrist. This allows you more room to install the coil cords.

new wrist box, then slide the coil cord tube completely out of the
wrist.
6. Insert one of the coil cords into the coil cord tube and pull the coil
cord's connector out the opposite end of the coil cord tube.
7. Slide the coil cord tube and coil cord into the new wrist with the
notch in the coil cord tube facing up.
8. Place the rubber grommet in the notch to secure the coil cord to the
coil cord tube.
9. Making sure the coil cord tube is flush with the wrist's front plate,
tighten the two screws to secure the coil cord tube.
10. Perform steps 5 through 9 for the second tube and coil cord.
11. Secure the wrist interconnect board to the wrist, then connect both
coil cords.
12. Ty-wrap the two cords together as previously noted.
Level The Wrist

1. Manually position the Robot so that the arm is about 1/3 high on the
column above the turntable cover and the front of the wrist faces
towards you.
2. With one end of a ruler on the benchtop or PyPlate beneath the
wrist, note the measurement from the benchtop to the bottom-left of
the wrist.
3. Reposition the ruler and make a similar measurement from the
benchtop to the bottom-right of the wrist.
4. Adjust the wrist until the two measurements are within 1/16" to
1/32" (1.6 mm to 0.8 mm).
5. Use the open end (or adjustable) wrench to fully tighten the
fasteners that secure the wrist to the arm.
6. Recheck the measurements. If necessary, loosen the fasteners
slightly and repeat steps 2 through 6 until the measurements are
correct.
7. Secure the wrist cover with the screw previously removed.
Zero The Wrist

WARNING
correct voltage.
country.

2. Turn the Controller power ON.
WARNING

Program.
pull-down and select Module-Setup.
angle to 0°.
screen.
zero function.
c. Use the clockwise/counter-counter-clockwise function keys to
move the wrist until the pins are aligned with the monument
holes.
Example:
Wrist pins not aligned — movement of the wrist coupling in a

PROGRAMMING screen.

Calibrate The Wrist

monument holes.

System V Controller Replacement Overview 191
System V Controller
Replacement Overview
Use this section of the manual if you need to replace any of the
following in the System V Controller:
• Disk Drive
• CPU Board
• Module Support Board
• Power Supply
If you need additional help, call the Zymark Technical Support Center at
(508) 435-9761.

192 System V Controller Replacement Overview

C90 System V Controller’s Disk Drive Replacement Procedure 193
System V Controller’s Disk

Drive Replacement Procedure
Procedure Scope
This procedure covers the steps to replace a defective disk drive in the
System V Controller, as well as the steps used to verify operation of the
replacement disk drive. Replacement of the disk drive also may require
that you replace EPROM U16 on the CPU board.
Parts Required
• Replacement Floppy Disk Drive (3-1/2") with power and signal
cables
• Replacement EPROM V2.1 (U16 for CPU board)
Tools Required
• Flatblade screwdriver
• Flatblade screwdriver, small (for removing old EPROM)
• Nutdriver, 3/16"
Preliminary
Before you start, find a suitable work area to place the System V
Controller on, approximately 2 x 3 ft (0.6 m to 0.9 m). Then do the
following:
NOTE
Save the Dictionary before beginning this procedure.
WARNING
1. Turn the System V Controller OFF.

2. Unplug the power cord, Hand Held Operator Terminal cable, and
the PC communication cable from the back of the System V
Controller.

194 System V Controller’s Disk Drive Replacement Procedure C90
3. Remove all module cards from the back of the System V Controller.
4. Place the System V Controller upside down on the work area.
5. Insert the Phillips head screwdriver through the holes in the bottom
of the System V Controller and loosen the four screws, but do not
remove them.
6. Slide the System V Controller’s expansion unit(s) forward about
1/2" (1.27 cm) towards the System V Controller front. Lift and
hinge the expansion unit(s) along the System V Controller’s front
edge, and position them board-side-up, next to the System V
Controller.
Removing The CPU Board

1. Disconnect all cables from the CPU board: signal cable, four power
cables, RELOAD switch cable, and disk drive cable.
Capacitor C13
J5
Disk Drive Cable

(J10)
Signal Cable (J9)

2. Using the flatblade screwdriver, remove the four screws that secure
the CPU board to the System V Controller housing.
3. Using the 3/16" nutdriver, remove the four fasteners that secure the
serial ports (computer and Hand Held Operator Terminal ports) to
the back of the System V Controller.
4. Slide the CPU board towards the front of the System V Controller,
and carefully lift it out and set it aside.
Installing The New Disk Drive

1. Use the 5/16" nutdriver to loosen the four nuts that secure the disk
drive to the System V Controller.
2. Slide the disk drive towards the rear of the System V Controller
until the four threaded studs extend through the four large keyhole
slots on the disk drive bracket. Then, lift the disk drive out of the
System V Controller.
3. Remove the disk drive bracket from the old disk drive using the
flatblade screwdriver. Retain the bracket and screws.
4. Remove the new disk drive from its box.

5. Using the flatblade screwdriver, attach the disk drive bracket to the
new disk drive.

6. Install the new disk drive in the System V Controller by positioning

the four large keyhole slots on the bracket over the four threaded
studs. Then slide the disk drive forward as far as possible.
7. Tighten the four nuts to secure the disk drive to the System V
Controller.
Installing The CPU Board

1. Roughly position the new CPU board so that the two serial ports
can be inserted through their respective holes in the back of the
2. Connect the disk drive’s power cable to connector J5 on the CPU
board and the disk drive’s signal cable to connector J10 on the CPU
board. Align the holes on the CPU board with the four standoffs in
the base of the System V Controller.
3. Insert the four fasteners into the two serial ports on the back of the
CPU board. Use the nutdriver to turn each fastener approximately
two turns. Do NOT fully tighten the fasteners.
4. Secure the CPU board to the System V Controller standoffs by
inserting the four previously removed screws. Tighten the screws
until snug.
5. Use the nutdriver to fully tighten the four serial port fasteners until
snug.
6. Connect the four power cables, RELOAD switch cable, and signal
cable to their appropriate jacks on the new CPU board.
NOTE
The power cable to connector J6 comes from the power supply, and the
power cable to connector J7 goes to the expansion unit(s).
NOTE
If the EPROM is labeled V2.1 or later, skip this step 7.
7. Locate EPROM U16 on the CPU board. Using a small screwdriver,

carefully pry the old EPROM out of its socket. Aligning the slot in
the new EPROM with the slot in the socket, use your thumbs to
push the EPROM into the socket. Make sure none of the legs are
bent, and all legs are fully inserted.
8. Carefully position the expansion unit(s) onto the System V
Controller, making sure no cables or wires are in the way.
9. Slide the expansion unit(s) towards the rear of the System V
Controller until both sections are flush.
10. Tighten the four Phillips head screws.

11. Reinstall the module cards in the System V Controller.

12. Plug all cables (PC communication and Hand Held Operator
Terminal), and the power cord into the back of the System V
Controller.
WARNING
correct voltage.
country.
Verifying Operation
With the System V Controller’s power OFF, and a System Disk inserted
in the drive, do the following:
1. Turn the PC ON.
2. Turn the System V Controller ON and press the RELOAD button.
3. Verify that the system boots and the System V Terminal Icon
appears on the screen.
Program.
7. Verify that all the modules installed in the system are shown in the
module setup list.
8. Click on the Options menu pull-down and select Load Dictionary.
9. Type the name of a .ZYD dictionary file in the Load Dictionary
window.
10. Click on the Options menu pull-down and select Save Dictionary.
11. Remove the System Disk from the System V Controller and replace
it with a blank, formatted disk.
12. From the Z> prompt, type DIR and press the Enter key. Verify that
the .ZYD file you saved is listed.


C91 System V Controller’s CPU Board Replacement Procedure 199
System V Controller’s CPU

Board Replacement
Procedure
Procedure Scope
This procedure covers the steps to replace a defective CPU board in the
System V Controller. This procedure also contains steps to verify
operation of the replacement CPU board.
Parts Required
• CPU Board
Tools Required
• Flathead screwdriver
Preliminary
Controller on, approximately 2 x 3 ft. (0.6 m to 0.9 m). Then do the
following:
NOTE
WARNING

Controller.

200 System V Controller’s CPU Board Replacement Procedure C91
remove them.
Controller.
Removing The CPU Board

2. Using the flathead screwdriver, remove the four screws that secure
Capacitor C13
J5
Disk Drive Cable

(J10)
Signal Cable (J9)

C91 System V Controller’s CPU Board Replacement Procedure 201
3. Using the 3/16" nutdriver, remove the four fasteners that secure the
serial ports (computer and Hand Held Operator Terminal ports) to
the back of the System V Controller.
4. Slide the CPU board towards the front of the System V Controller
and carefully lift it out.
Installing The New CPU Board

1. Roughly position the new CPU board so that the two serial ports
2. Connect the disk drive’s power cable to connector J5 on the CPU
board, and the disk drive's signal cable to connector J10 on the CPU
board. Align the holes on the CPU board with the four standoffs in
the base of the System V Controller.
3. Insert the four fasteners into the two serial ports on the back of the
two turns
NOTE
Do NOT fully tighten the fasteners.
4. Secure the CPU board to the System V Controller standoffs by

until snug.
5. Use the nutdriver to fully tighten the four serial port fasteners until
snug.
6. Connect the four power cables, RELOAD switch cable, and signal
cables to their appropriate jacks on the new CPU board.
NOTE
The power cable to connector J6 comes from the power supply, and the
power cable to connector J7 goes to the expansion unit(s).

Controller.

202 System V Controller’s CPU Board Replacement Procedure C91
WARNING
correct voltage.
country.
Verifying Operation
1. Turn the PC ON.
Program.
module setup list.
8. Click on the Options menu pull-down and select Load Dictionary.
window.
10. Click on the Options menu pull-down and select Save Dictionary.
11. Turn the PC and System V Controller OFF.
12. Turn the PC ON.
13. Turn the System V Controller ON, but DO NOT press the
RELOAD button.
Program.
17. Verify that the dictionary entries listed when you load the .ZYD file
are correct. This verifies that the CPU’s battery back-up is working.

C92 System V Controller’s Module Support Board Replacement Procedure 203
System V Controller’s Module

Support Board Replacement
Procedure
Procedure Scope
This procedure covers the steps to replace a defective module support
board in the System V Controller. This procedure also contains steps to
verify operation of the replacement module support board.
Parts Required
• Module Support Board
Tools Required
• Flathead screwdriver
Preliminary
Before you start find a suitable work area to place the System V
Controller on, approximately 2 x 3 ft. (0.6 - 0.9m). Then do the
following:
NOTE
WARNING

Controller.

204 System V Controller’s Module Support Board Replacement Procedure C92
remove them.
Controller.
Removing The Module Support Board

1. Locate the defective module support board and carefully disconnect
the power and signal cables from the board.
2. Remove the five screws that secure the module support board to the
expansion unit housing. Set the screws aside.
3. Remove the defective board.

C92 System V Controller’s Module Support Board Replacement Procedure 205
Installing The New Module Support Board

1. Position the new module support board within the expansion unit
housing.
2. Secure the board in place using the five screws just removed.
3. Connect the power and signal cables to their appropriate jacks on
the new module support board.
4. Carefully reposition the expansion unit(s) onto the System V
5. Tighten the four screws that secure the inner expansion unit to the
6. Align the baseplate over the bottom expansion unit, and insert the
four screws through the baseplate and into the System V Controller.
Tighten all screws securely.
Controller.
WARNING
correct voltage.
country.

206 System V Controller’s Module Support Board Replacement Procedure C92
Verifying Operation
1. Turn the PC ON.
Program.
module setup list.
8. Sequentially choose each module from the module setup list and
verify that each module’s teaching screen can be accessed and
exited from.

C93 System V Controller’s Power Supply Replacement Procedure 207
System V Controller’s Power

Supply Replacement
Procedure
Procedure Scope
This procedure covers the steps to replace a defective power supply in
the System V Controller. This procedure also contains steps to adjust the
replacement power supply and verify its operation.
Parts Required
• Power Supply, Controller
• Two mounting brackets with hardware
• Power cable
• Power entry module
Tools Required
• Screwdriver, Phillips no. 2
• Screwdriver, flatblade, precision
• Digital Voltmeter (DVM)
Preliminary
Controller on, approximately 2 x 3 ft. (0.6 m to 0.9 m). Then do the
following:
NOTE
WARNING

208 System V Controller’s Power Supply Replacement Procedure C93
Controller.
remove them.
6. Slide the System V Controller's expansion unit(s) forward about
Controller.

Installing The New Power Supply

It will be necessary to remove the CPU board before installing the new
power supply. Refer to the drawing below during these procedures.
Capacitor C13
J5
Disk Drive Cable

(J10)
Signal Cable (J9)
Removing the CPU Board

2. Using the flathead screwdriver, remove the four screws that secure
3. Using the 3/16 in. nutdriver, remove the four fasteners that secure
the serial ports (computer and Hand Held Operator Terminal ports)
to the back of the System V Controller.
4. Slide the CPU board towards the front of the System V Controller
and carefully lift it out.
Replacing the Power Supply

1. Lift the insulator away from the power supply (early System V
Controllers may not contain the power supply insulator).
2. Disconnect all cables from the old power supply: CPU power
cables, two brown cables from the power entry port, and the black
and white twisted pair from the power entry port.
3. Remove the four screws that secure the power supply to the System
V Controller. Set the screws aside.

4. Remove the power supply from the System V Controller.

5. Unpack the new power supply from its shipping container.
6. Remove the power entry unit and replace with the one provided in
the kit. Make sure that the power entry unit is configured for the
proper input voltage and that the fuses are installed. Don’t forget
the ground wire.
7. Mount the two brackets to the four standoffs with four of the flat-
head screws provided.
8. Mount the new power supply to the brackets with the two binder
flat screws provided. The smaller connector on the power supply
(TB1) goes towards the power entry module.
9. Connect all cables to the power supply:
a. New CPU power cable (provided) to TB2 on the power supply.
b. Brown and blue twisted pair from the power entry module to
TB1 on the power supply.
10. Position the insulator so that its end tucks under the lip of the
System V Controller housing.
11. Replace the CPU board.
Replacing the CPU Board

1 Roughly position the new CPU board so that the two serial ports
2 Connect the disk drive’s power cable to connector J5 on the CPU

board, and the disk drive’s signal cable to connector J10 on the
CPU board. Align the holes on the CPU board with the four
standoffs in the base of the System V Controller.

3 Insert the four fasteners into the two serial ports on the back of the
two turns. NOTE: Do not fully tighten the fasteners.
4 Secure the CPU board to the System V Controller standoffs by

until snug.
5 Use the nut driver to fully tighten the four serial port fasteners until
snug.
6 Connect the four power cables, RELOAD switch cable, and signal
cables to their appropriate jacks on the new CPU board.
Adjusting The Power Supply

1. Plug the power cable into the back of the System V Controller and
turn ON the power switch.
2. Locate capacitor C13 on the CPU board and potentiometer R21 on
the power supply.
3. Set your DVM to VOLTS, DC, 20V scale. Carefully connect the
positive lead to the (+) end of capacitor C13 and the negative lead
to the (-) end of the capacitor.
4. Use a small screwdriver or potentiometer adjuster to set
potentiometer R21 until you read 5.10V across C13.
5. Turn OFF System V Controller power and unplug the power cord.
Reassembling The System V Controller

Controller.
WARNING
correct voltage.
country.

Verifying Operation
1. Turn the PC ON.
Program.
module setup list.
8. Click in the Options menu pull-down and select Load dictionary.
window.
10. Click on the Options menu pull-down and select save Dictionary.
11. Turn the PC and System V Controller power OFF.
12. Turn the PC ON.
13. Turn the System V Controller ON, but do not press the RELOAD
button.
Program.
17. Verify that the dictionary entries listed when you loaded the .ZYD
file are correct.

Index 213
Index M
Motor
A vertical, replacing, 139
Arm and column wipers, replacing, 5 wrist, replacing, 171
Arm housing P
interconnect board, replacing, 9
Post bearing
turntable coil cord, replacing, 13
replacing, 43
wrist coil cord, replacing, 17
Power supply, System V
B replacing, 207
Baseboard, replacing, 23 R
Bearings, post, 48
R101 - Post Bearing Replacement, 43
Bearings, reach, 51, 57
R108 - Reach Timing Belt Replacement, 85
C R111 - Reach Bearing Adjustment, 51
C90 - System V Controller’s Disk Drive R114 - Rotary Motor Replacement, 101
Replacement Procedure, 193 R115 - Vertical Spring Cable
C91 - System V Controller’s CPU Board Replacement, 153
Replacement Procedure, 199 R120 - Vertical Motor Replacement, 139
C92 - System V Controller’s Module Sup- R122 - Turntable to Wrist Coil Cord
port Board Replacement Procedure, 203 Replacement, 125
C93 - System V Controller’s Power Supply R123 - Arm Housing to Turntable Coil
Replacement Procedure, 207 Cord Replacement, 13
Cable R124 - Arm Housing Interconnect Board
servo Replacement, 9
replacing, 113 R124 - Arm Housing to Wrist Coil Cord
vertical spring Replacement, 17
replacing, 153 R128 - Rotary Servo Cable
CPU board, replacing, 199 Replacement, 113
D
R133 - Reach Potentiometer
Replacement, 77
Drive cable R134 - Wrist Potentiometer
replacing, 89 Replacement, 179
Drum, rotary drive R135 - Wrist Cable and Flex Coupling
installing, 93 Replacement, 159
removing, 91 R136 - Wrist Coupling Pin
F Replacement, 167
R137 - Wrist Motor Replacement, 171
Fan, replacing, 31
R139 - Wrist Replacement, 185
Flex
R140 - Reach Bearing Replacement, 57
circuit, replacing, 35
R143 - Reach Motor Replacement, 71
coupling, replacing, 159
R145 - Turntable Interconnect Board
Replacement, 123
R146 - Wrist Interconnect Board

214 Index
Replacement, 169 replacing controller power supply, 207

R150 - Flex Circuit Replacement, 35 replacing CPU board, 199
R155 - Vertical Potentiometer replacing disk drive, 193
Replacement, 145 replacing module support board, 203
R160 - Fan Replacement, 31 T
R165 - Rotary Drive Cable
Replacement, 89 Timing belt
R170 - Arm and Column Replacement, 5 replacing, 85
R170 - Arm and Column Wipers Troubleshooting, 1
Replacement, 5 fatal robot communications, 3
R176 - Baseboard Replacement, 23 not in position, 3
R187 - Rotary Potentiometer positions are off, 2
Replacement, 107 robot noisy, 3
R191 - Vertical Cable Replacement, 131 robot stops, 2, 3
R192 - Reach Cables Replacement, 63 thermal protection active, 2
Reach type 129 error message, 3
arm type 130 error message, 3
calibrating, 29 Turntable
zero setting, 29 coil cord, replacing, 125
bearing interconnect board, replacing, 123
adjusting, 51 V
replacing, 57 Vertical cable, replacing, 131
cables, replacing, 63 Vertical motor, replacing, 139
checing the setting, 25 Vertical potentiometer, replacing, 145
motor, replacing, 71 Vertical spring cable, replacing, 153
potentiometer, replacing, 77 Vertical zero settings, checking, 25
timing belt, replacing, 85
W
Ribbon cable, wrist
replacing, 159 Wrist
Robot zeros, calibrating, 26 assembly, 187
Rotary cable, replacing, 159
drive cable, replacing, 89 calibrating, 27
motor, replacing, 101 coil cord, replacing, 125
potentiometer, replacing, 107 coupling pin, replacing, 167
servo cable, replacing, 113 potentiometer, replacing, 179
setting 360 degree, 28 replacing, 185
zero setting, 27 zero setting, 26
S Z
System V Zymark Technical Support Center, 1

controller replacement overview, 191

Zymark Corporation
Zymark Center
Hopkinton, Massachusetts 01748
TEL 508 435-9500
FAX 508 435-3439
http://www.zymark.com

Zymark XP Manual

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Zymate XP Robot

System V Controller Service Manual

The information in this manual may contain typographical errors or

Statement of Proper Use

It is the customer’s reponsibility to keep the Robot and System V

• Use this product only in the manner described in this manual.

P/N 63004 Rev. 3 XP Robot/System V Controller Service Manual Zymark Corporation

The Technical Support Center hours of operation are Monday through

For support in Europe contact Zymark LTD, Runcorn, UK

Operation of this equipment in a residential area is likely to cause

Changes or modifications to this equipment not expressly

Zymark Corporation XP Robot/System V Controller Service Manual P/N 63004 Rev. 3

The Zymate XP Robot operates at high speeds. Use care when

WARNING: A potentially hazardous situation, which,

NOTE: A cautionary statement; an operating tip or

Risk of body parts, hair, jewelry, or clothing getting

Risk of puncture injury.

Risk of eye injury; wear safety glasses.

P/N 63004 Rev. 3 XP Robot/System V Controller Service Manual Zymark Corporation

Table 1. Symbols (Continued)

Protective ground symbol.

Signifies that the unit has passed safety tests for

Equipment Yellow Caution, risk of danger

Zymark Corporation XP Robot/System V Controller Service Manual P/N 63004 Rev. 3

P/N 63004 Rev. 3 XP Robot/System V Controller Service Manual Zymark Corporation

Zymark Corporation XP Robot/System V Controller Service Manual P/N 63004 Rev. 3

Procedure Scope ..................................................................................................................................... 57

P/N 63004 Rev. 3 XP Robot/System V Controller Service Manual Zymark Corporation

Parts Required ................................................................................................................................. 85

Zymark Corporation XP Robot/System V Controller Service Manual P/N 63004 Rev. 3

Complete The Installation..................................................................................................................... 111

P/N 63004 Rev. 3 XP Robot/System V Controller Service Manual Zymark Corporation

Vertical Motor Replacement Procedure ...................................................................................139

Zymark Corporation XP Robot/System V Controller Service Manual P/N 63004 Rev. 3

Calibrate The Wrist............................................................................................................................... 165

P/N 63004 Rev. 3 XP Robot/System V Controller Service Manual Zymark Corporation

Remove The Old Wrist.................................................................................................................. 187

Zymark Corporation XP Robot/System V Controller Service Manual P/N 63004 Rev. 3

Reference Number List

No. Procedure Page

P/N 63004 Rev. 3 XP Robot/System V Controller Service Manual Zymark Corporation

No. Procedure Page

Zymark Corporation XP Robot/System V Controller Service Manual P/N 63004 Rev. 3

Besides the troubleshooting information, this section of the manual also

P/N 63004 Rev. 3 XP Robot/System V Controller Service Manual Zymark Corporation

Zymark Corporation XP Robot/System V Controller Service Manual P/N 63004 Rev. 3

XP Robot Troubleshooting (Continued)

If LED is not on, check cable tension

If problem is with the reach belt,

If problem persists, contact Zymark

P/N 63004 Rev. 3 XP Robot/System V Controller Service Manual Zymark Corporation

This page intentionally left blank.

Zymark Corporation XP Robot/System V Controller Service Manual P/N 63004 Rev. 3

Arm and Column Wipers

Remove The Old Wipers

Turn OFF the system power before beginning these procedures.

1. Turn the Controller’s power OFF.

P/N 63004 Rev. 3 XP Robot/System V Controller Service Manual Zymark Corporation

Zymark Corporation XP Robot/System V Controller Service Manual P/N 63004 Rev. 3

Install The New Wipers

P/N 63004 Rev. 3 XP Robot/System V Controller Service Manual Zymark Corporation

10. Turn the Controller’s power ON.

Zymark Corporation XP Robot/System V Controller Service Manual P/N 63004 Rev. 3