Replacing the Motor or the Gearbox on the Rotational Axis

Overview

The use and application of the information contained herein require expertise in the design and programming of automated control systems. Only you, the user, machine builder or integrator, can be aware of all the conditions and factors present during installation and setup, operation, repair, and maintenance of the machine or process.

You must also consider any applicable standards and/or regulations with respect to grounding of all equipment. Verify compliance with any safety information, different electrical requirements, and normative standards that apply to your machine or process in the use of this equipment.

DANGER
	ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Disconnect all power from all equipment including connected devices prior to removing any covers or doors, or installing or removing any accessories, hardware, cables, or wires except under the specific conditions specified in the appropriate hardware guide for this equipment. Always use a properly rated voltage sensing device to confirm the power is off where and when indicated. Operate electrical components only with a connected protective ground (earth) cable. Verify the secure connection of the protective ground (earth) cable to all electrical devices to ensure that connection complies with the connection diagram. Do not touch the electrical connection points of the components when the module is energized. Provide protection against indirect contact. Insulate any unused conductors on both ends of the motor cable. Failure to follow these instructions will result in death or serious injury.

DANGER

ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

Disconnect all power from all equipment including connected devices prior to removing any covers or doors, or installing or removing any accessories, hardware, cables, or wires except under the specific conditions specified in the appropriate hardware guide for this equipment.
Always use a properly rated voltage sensing device to confirm the power is off where and when indicated.
Operate electrical components only with a connected protective ground (earth) cable.
Verify the secure connection of the protective ground (earth) cable to all electrical devices to ensure that connection complies with the connection diagram.
Do not touch the electrical connection points of the components when the module is energized.
Provide protection against indirect contact.
Insulate any unused conductors on both ends of the motor cable.

Failure to follow these instructions will result in death or serious injury.

Procedure Overview

Perform the following procedures to replace the motor or the gearbox on the rotational axis:

Removing the motor and the gearbox
Removing the motor from the gearbox
Mounting the new motor and/or the new gearbox
Cabling the motor and the gearbox
Calibrating the robot and closing the housing

Removing the Motor and the Gearbox

NOTICE
	LOSS OF IP65 DEGREE OF PROTECTION Replace each sealing gasket every time you remove the media cover. Failure to follow these instructions can result in equipment damage.

Step	Action
1	Remove the telescopic axis as described in Replacing the Telescopic Axis.
2	Remove the maintenance cover at the end of motor A. For further information on the position of the motor, refer to the detail drawing of the main body in Mechanical and Electrical Data.
3	Disconnect the motor supply cable. For further information, observe the respective operating instructions of the motors: VRKP0 / VRKP1: MH3 Servo motor Motor Manual VRKP2S0 / VRKP4S0 / VRKP5S0 / VRKP6S0: SH3 Servo motor Motor Manual VRKP2L0 / VRKP4L0 / VRKP5L0 / VRKP6L0: Lexium 62 ILM Hardware Guide
4	Remove the hexagon cap from the ground connection at the motor.
5	Disconnect the ground cable.
6	Remove the four bolts (1) on the underside of the robot housing around the output shaft of the gearbox.
7	Carefully pull the motor and the gearbox upwards.
8	Remove the motor and the gearbox from the robot housing.

Removing the Motor from the Gearbox

Step	Action
1	Remove the O-ring (1) from the gearbox flange.
2	Remove the plug screw (2) from the gearbox flange.
3	Remove the four screws (3) at the motor by means of which the motor is attached to the gearbox.
4	Carefully rotate the motor until the screw (4) on the clamping ring appears in the aperture of the plug screw.
5	Loosen this screw.
6	Carefully remove the motor from the gearbox.

Mounting the New Motor and/or the New Gearbox

Step	Action
1	Ensure that the gearbox and the housing are at the same temperature, as otherwise - in the case of a temperature difference - the gearbox may not fit into the aperture provided.
2	Attach the motor to the gearbox according to the specifications of the manufacturer: Tightening torque of the motor: 3.5 Nm (31 lbf-in) Screw on the clamping ring: 4.5 Nm (40 lbf-in) NOTE: Position the motor and the gearbox vertically during mounting if possible.
3	Insert the plug screw into the gearbox flange.
4	Place a new O-ring to the gearbox.
5	Attach the motor/gearbox combination in the orientation specified to the robot housing. Tightening torque: 3.5 Nm (31 lbf-in) For further information, refer to the detail drawing in Mechanical and Electrical Data.
6	Use new sealing washers in order to maintain the leak tightness of the housing.

DANGER
	ELECTRIC SHOCK CAUSED BY INSUFFICIENT CONDUCTIVITY Only use the bolts and bolt seals specified in order to maintain electric conductivity. Failure to follow these instructions will result in death or serious injury.

NOTICE
	DAMAGE TO MOTOR AND GEARBOX Only fasten motor and gearbox with all components at the same ambient temperature. Failure to follow these instructions can result in equipment damage.

Cabling the Motor and the Gearbox

Step	Action
1	Attach the ground strap to the motor. Tightening torque: 2.5 Nm (22 lbf-in) NOTE: When routing the cables, ensure that the grounding cap remains on the ground connection of the motors. The motor supply cable may become damaged by the thread of the ground strap attachment.
2	Put the hexagon cap on the ground connection at the motor. For further information, observe the respective operating instructions of the motors: VRKP0 / VRKP1: MH3 Servo motor Motor Manual VRKP2S0 / VRKP4S0 / VRKP5S0 / VRKP6S0: SH3 Servo motor Motor Manual VRKP2L0 / VRKP4L0 / VRKP5L0 / VRKP6L0: Lexium 62 ILM Hardware Guide
3	Attach the motor supply cables and lock them in position.
4	Mount the telescopic axis as described in Replacing the Telescopic Axis.
5	Calibrate the robot mechanics.

DANGER
	ELECTRIC SHOCK DUE TO DAMAGED CABLES Verify that the grounding cap is placed correctly on the grounding connection of the motor. Failure to follow these instructions will result in death or serious injury.

Calibrating the Robot and Closing the Housing

NOTICE
	LOSS OF IP65 DEGREE OF PROTECTION Replace each sealing gasket every time you remove the maintenance cover(s). Failure to follow these instructions can result in equipment damage.

Step	Action
1	Mount the telescopic axis as described in Replacing the Telescopic Axis.
2	Calibrate the robot mechanics.
3	Mount the maintenance cover. NOTE: Use a new seal in order to maintain the leak tightness of the housing. For further information, refer to the detail drawing in Mechanical and Electrical Data.

Step

Action

1

Mount the telescopic axis as described in Replacing the Telescopic Axis.

2

Calibrate the robot mechanics.

3

Mount the maintenance cover.

NOTE: Use a new seal in order to maintain the leak tightness of the housing.

For further information, refer to the detail drawing in Mechanical and Electrical Data.

WARNING
	COLLISION OF COMPONENTS Calibrate the robot mechanics after the replacement of an upper arm, a motor, or a gearbox. Failure to follow these instructions can result in death, serious injury, or equipment damage.