Datasheet

Operating and
Maintenance Instructions
DK Part Number: 157359-1CD
Revision: 0
TYPE: DK-250, DK-500, DK-1000, DK-1500,

DK-2500 for NX 100 control Please read these instructions before operation and then
keep them for later reference.
Document no. MRD64092EN.5.I

MRD64092EN.5.I
TABLE OF CONTENS
1 Safety specifications ............................................................................................................. 5

1.1 General .................................................................................................................................... 5
1.2 Type overview.......................................................................................................................... 5
1.3 Symbols and marks on the system / component ..................................................................... 6
1.4 Danger and warning notes in this safety information............................................................... 6
2 Safety-related duties of the owner ....................................................................................... 8
2.1 Requirement for operating personnel ...................................................................................... 8
2.2 Particular risks due to electric current...................................................................................... 9
2.3 Safety instructions on electrical commissioning .................................................................... 10
2.4 Safety instructions on mechanical commissioning ................................................................ 12
2.5 Safety instructions on maintenance and service ................................................................... 14
3 Installing protective devices............................................................................................... 15
4 Using the positioner/component........................................................................................ 16
4.1 Proper use ............................................................................................................................. 16
4.2 Improper use.......................................................................................................................... 16
5 Transport instruction .......................................................................................................... 17
5.1 Transport with crane or forklift ............................................................................................... 18
6 Setup instructions ............................................................................................................... 34
6.1 Structure and attachment ...................................................................................................... 34
6.2 Assembly instruction for the base of the positioner ............................................................... 36
6.3 Overtravel measurement log ................................................................................................. 38
6.4 Mounting and fastening with compensating plates for exact leveling. ................................... 39
7 Wiring.................................................................................................................................... 41
8 Grounding ............................................................................................................................ 42
9 Electric connections............................................................................................................ 43
9.1 Electrical interface ................................................................................................................. 43
9.2 Replacing the battery in the crossbox cables ........................................................................ 44
9.3 Dimensions for AC servo motor............................................................................................. 44
9.4 Description of the safety sensor ............................................................................................ 59
9.5 MOTOMAN delineation system ............................................................................................. 66
10 Technical data...................................................................................................................... 72
10.1 Type overview DK.................................................................................................................. 72
11 Overview positioner DK ...................................................................................................... 87
11.1 Schematic drawing ................................................................................................................ 87
12 Maintenance and Inspection............................................................................................... 89
12.1 General maintenance ............................................................................................................ 89
12.2 Handling problems................................................................................................................. 89
12.3 Lubrication and inspection schedule...................................................................................... 90
12.4 Maintenance DK-250 ............................................................................................................. 91
12.5 Maintenance DK-500 ............................................................................................................. 92
12.6 Maintenance DK-1000 ........................................................................................................... 93
12.7 Maintenance DK-1500 ........................................................................................................... 94
12.8 Maintenance DK-2500 ........................................................................................................... 95
12.9 General maintenance ............................................................................................................ 96
12.10 Checking and adjusting the toothed belt tension. .................................................................. 98
13 Replacement parts and consumables ............................................................................. 100
13.1 Replacement parts and consumables DK-250 .................................................................... 100
13.2 Replacement parts and consumables DK-500 .................................................................... 101
13.3 Replacement parts and consumables DK-1000 .................................................................. 102
MRD64092EN.5.I
TABLE OF CONTENS
MRD64092EN.5.I
1 Safety specifications
1.1 General
As this documentation refers to a special form, all illustrations must be regarded as
symbolical.
MOTOMAN robotec GmbH also reserves the right to make technical changes.
If you have any queries, please contact your MOTOMAN robotec GmbH sales partner.
All changes are subject to the written approval of MOTOMAN robotec GmbH.
Unauthorized modification to or operation of the DK positioners voids all warranty and
goodwill claims against MOTOMAN robotec GmbH with immediate effect.
The DK positioner has been built in accordance with the latest technological developments
and recognized safety requirements. In the event of incorrect operation or misuse, however,
there is a risk of danger to:
 the limb and life of the operator or of third parties,
 the machine and other property of the owner,
 the efficient working of the positioner and system.
The operating instructions must be kept permanently on hand at the location where the
system is used. In addition to the operating instructions, generally applicable and local
regulations for accident prevention and environmental protection must be made available and
observed.
1.2 Type overview

The types and the related data of the positioner DK are shown in the following table.
Type DK-250 DK-500 DK-1000 DK-1500 DK-2500

Total weight kg approx. 400 approx. 500 approx. 750 approx. 850 approx. 870
Gear
F2CFS-T455- F2CFS-T555- F2CFS-T555- F2CFS-T655-
basic drive (tilt F2CFS-T455-141
141 171 141 171
axis)
Motor
SGMDH- SGMDH- SGMRS-20A2A- SGMRS- SGMRS-
basic drive (tilt
22A2A-YR11 32A2A-YR11 YR11 30A2A-YR11 37A2A-YR11
axis)
Drive unit gear F2CFS-T355- F2CFS-T455-

F2CFS-C55-89 F2CFS-C65-89 F2CFS-C65-89
141 141
Motor SGMPH- SGMDH- SGMRS-30A2A- SGMRS- SGMRS-

drive arm 15A1A-YR11 22A2A-YR11 YR11 37A2A-YR11 37A2A-YR11
Toothed belt 800-8M-30 880-8M-30 880-8M-30
MRD64092EN.5.I 5
Type DK-250 DK-500 DK-1000 DK-1500 DK-2500
Welding earth Welding earth Welding earth Welding earth Welding earth Welding earth
transmission transmission transmission transmission transmission transmission
toothed quadrant Lubrication Lubrication

Lubrication fitting
fittingl DIN7142- fitting
DIN71412-M8x1
M8x1 DIN71412-M8x1
1.3 Symbols and marks on the system / component

There may be stickers and signs with important safety,
warning or general notes on the system/component.
 All notes on the device:
 must not be damaged,
 must not be removed,
 must not be covered, glued over or obliterated.
1.4 Danger and warning notes in this safety information

In this general safety information, danger and warning notes are used depending on the
potential risks.
1.4.1 Warning symbol and the signal word related to it
Consequences in the event of non-

Symbol and signal word
observance
Indicate an immediate, high-risk hazard that
DANGER
can cause death or serious
bodily injury if no precautions are taken.
Indicates a potential medium-risk hazard that
WARNING
can cause death or serious bodily injury if no
precautions are taken.
6 MRD64092EN.5.I
Consequences in the event of non-
Symbol and signal word
observance
Indicates a low-risk hazard that could cause
CAUTION
minor or moderate
bodily injury or property damage if no
DANGER Indicate an immediate, high-risk hazard that

can cause death or serious
bodily injury by electric current if no
due to electric current
1.4.2 Note symbol and the signal word related to it
Symbol and signal word Explanation
When this symbol appears, it refers to

important background information and
NOTE application tips.
MRD64092EN.5.I 7
2 Safety-related duties of the owner
The owner of the positioner/component is responsible for the safety of the operating
staff! This person must make sure that:
 the operating instructions and the related documentation have been read by the
operating staff (the manufacturer recommends having this confirmed in writing by the
operating staff).
 the operating instructions are kept on hand.
 the system/component is operated, maintained and serviced only by qualified, trained
and instructed personnel.
 unauthorised persons cannot have access to the system/component.
 the necessary, appropriate and possibly prescribed personal protective equipment is
available for the operating and service personnel and used by them.
 all existing necessary and prescribed safety equipment is
installed and working.
 function tests of the safety equipment are performed at prescribed or, if not prescribed,
at appropriate regular intervals.
 the system/component is operated only in accordance with its intended use.
If you have any questions or problems, contact the service department of MOTOMAN
robotec GmbH at tel. no.: (0049) (0) 180 5762683
2.1 Requirement for operating personnel
2.1.1 General
The operating staff must not be under the influence of alcohol, drugs or similar
substances. The operating staff must not have a restricted field of vision or be restricted in
any other way that could lead to risks. The operating staff must be in a suitable state of health
to operate the system/component (in particular, attention must be paid to medical aids, such
as cardiac pacemakers etc.)
2.1.2 Qualified personnel:

Persons involved in the commissioning, operation, maintenance and repair of the
system/component must be familiar with the system/component and trained accordingly.
They must have read the operating manuals and understood them. Furthermore, they must
be instructed and must be able to avoid possible residual risks to themselves and third
persons while working on the system/component or to reduce such risks as far as possible.
To maintain the qualification, the safety instruction must be repeated at least every year.
8 MRD64092EN.5.I
2.1.3 Qualified electrician:
Since work on electrical parts of the system/component is particularly dangerous, it may be
performed only by a certified electrician who can judge, recognise and avoid possible dangers
of the jobs assigned to him based on his training, knowledge and experience as well
as based on his knowledge of the relevant regulations.
2.2 Particular risks due to electric current
2.2.1 Working on electrical equipment

Before working on electrical equipment, the main switch of the system/component must be
switched OFF, or the mains supply must be disconnected. Then perform suitable
measurements to check if the system/component is deenergised.
The system/component must be safeguarded against being switched back ON accidentally
and against unauthorised access (e.g. padlock on main switch, warning signs or barriers).
MRD64092EN.5.I 9
DANGER due to electric current
If electrical current is not handled properly, this may result in a life-threatening situation.
Therefore, particular attention must be paid to the following:
 Only qualified electricians may perform jobs on electrical systems.
 When working on electrical systems and components, all relevant guidelines,
regulations and technical rules must be observed.
 All electrical systems, sub-assemblies and parts must be regularly checked for
sound state and proper functioning and replaced if necessary. The checks must be
performed in accordance with the valid guidelines and the manufacturer's
specifications.
 During wiring work the specifications of the manufacturer's electric circuit diagrams
(wiring diagrams) must be observed.
 Work and troubleshooting on an open control cabinet or on open devices are to be
performed with the necessary caution and care because the main power supply
terminals can be live, or there may be an external supply voltage.
 Even when the main switch is OFF, certain electrical circuits are still connected to the
power supply voltage!
 Persons with cardiac pacemakers or similar medical aids must not be in the vicinity of
large electric currents or voltages, strong magnetic fields or other sources of
disturbances that may affect the medical aid.
 All cables and lines must be fixed, undamaged, insulated, and have the adequate
dimensions. Loose connexions or cables and lines that are burnt, damaged or have
inadequate dimensions must be replaced immediately by an authorised electrician.
2.3 Safety instructions on electrical commissioning
DANGER due to electric

current
If electrical current is not handled properly, this may result in a life-
threatening situation.
Therefore, particular attention must be paid to the following:
 Only qualified electricians may perform jobs on electrical systems.
 For this, See “Particular risks due to electric current” on Page 9.
10 MRD64092EN.5.I
The documentation on the electrical system/component, circuit diagram and terminal diagram
etc. is prepared in compliance with the relevant standards and included in the scope of
delivery.
The structure and handling of these diagrams is explained in greater detail in the circuit
diagram.
DANGER due to electric

current
Observe the specifications of the terminal diagram and the circuit diagram
when wiring system parts.
 Failure to comply can cause the safety devices to start running
unexpectedly or render them ineffective and therefore put persons at
risk or cause damage to the electrical components of the system.
 Circuit diagram
The circuit diagram is the basis for the functional linking of all individual electrical and
electro-mechanical components for the complete system/component. The safety circuits and
electrical activation controls included in it as well as all other specifications are to be
maintained strictly. All changes to the electrical system are subject to the written approval of
MOTOMAN robotec GmbH and may be carried out by authorised specialist personnel
only after receipt of the modified circuit diagram.
 Terminal diagram
The terminal diagram is a logical version of the circuit diagram and reflects all terminals,
cables and connections. The terminal diagram is the guideline for clamping cable wires for
electrical installation.
2.3.1 Electrical connection of a positioner/component

The electrical system is to be installed according to the specifications of the terminal diagram
of the respective positioner/component.
MRD64092EN.5.I 11
NOTE
Mains and external supply circuits (e.g. locking, interfaces) in the control
cabinets of the system/component are not included in the scope of the
product designed and supplied by MOTOMAN robotec GmbH. The user is
responsible for ensuring that the mains and external supply circuits
are connected in accordance with the guidelines and acknowledged
technical regulations at the installation site as well as with other regionally
applicable requirements. This includes taking into account the cable
dimensioning, fuses, earthing, shut-off and isolation. The necessary data
can be found in the circuit diagram and the technical data and specifications
of the respective system/component.
Before switching on the system/component for the first time, an electrical check must be
performed according to the manufacturer's specifications. All locally valid legal regulations
must be complied with when commissioning the system/component. The connection
conditions of the power supply company must also be taken into account.
2.4 Safety instructions on mechanical commissioning
DANGER
Faults and carelessness during transport and assembly of a system/
component can prove dangerous for persons.
 All set-up, assembly and commissioning work must be carried out by
instructed specialist personnel.
 During transport, make sure the means of transport and the lifting
equipment have sufficient carrying capacity! Nobody may stand
under suspended load.
 Assembly must be performed in accordance with the valid guidelines,
specifications and technical rules. The manufacturer's specifications
must be observed (e.g. transport instructions and operating
instructions).
 If necessary or prescribed, personal protective equipment must be
worn.
12 MRD64092EN.5.I
2.4.1 Setup and transport
The means of transport used must have sufficient carrying capacity. The system or
component weight is specified in the transport instructions or in the technical data.
If you have any questions, or if the transport instructions are missing or contradictory, contact
the manufacturer (shipper) of the components.
The load must not slip or tilt when it is lifted. Make sure the position of the centre
of gravity of the load is centred and balanced.
Individual system elements or components may not be stable in unassembled state. If
necessary, use locking or support devices until such elements and components have been
mounted according to their intended use. The locking or support devices must be removed
before the system elements or components are used.
2.4.2 Assembly and commissioning

During assembly observe any assembly instructions given in the manufacturer's operating
and maintenance instructions. If prescribed, comply with the order of assembly,
fastening materials, tightening torques etc.
If any transport safety devices were installed, remove them before commissioning.
If the manufacturer has provided any limit stops and/or proximity switches for limiting
movements, they must be fastened/installed and adjusted according to the manufacturer's
specifications. The limit values specified in the "Layout and Technical Data" must be
observed. They must be checked for proper functioning.
The system/component must not be altered or modified in any way. Every alteration or
modification must be discussed with the manufacturer.
NOTE
Unauthorised changes ordered by or performed by the user may result in
the cancellation of the EC manufacturer's declaration or the EC declaration
of conformity and the warranty and guarantee claims!
MRD64092EN.5.I 13
2.5 Safety instructions on maintenance and service
WARNING
Faults and carelessness during maintenance and servicing of a
system/component can prove dangerous for persons.
 All maintenance, cleaning and other servicing work must be carried out
by instructed specialist personnel.
 Press the emergency stop buttons before beginning with
maintenance work.
 In particular the safety instructions See “Particular risks due to electric
current” on Page 9. must be observed.
 If necessary or prescribed, personal protective equipment must be
worn.
 If there are any suspended axes (e.g. with gantries with X, Y, Z axes
and tilting axes due to eccentric shifting of the centre of gravity), they
must be moved to a safe, monitored position or safely supported
before beginning with work.
During maintenance, servicing and cleaning, take particular care to ensure that the
system/component is switched off and secured against unauthorised access and
being switched on again accidentally.
If there are any suspended axes (e.g. a robot arm that could be lowered) in the positioner/
component, they must be moved to a safe, monitored position or safely supported before
beginning with work. It is forbidden to stand under unsecured suspended axes.
The system/component must be maintained in accordance with the maintenance and
repair schedule.
Only genuine spare parts or spare parts and working materials approved by the manufacturer
may be used.
Do not use any highly inflammable or corrosive cleaning agents or cleaning agents that
are harmful to health or the environment.
 Environment
Pay attention to the safety data sheets of the cleaning materials and, if necessary, use the
recommended protective equipment. Pay particular attention to environmentally tenable
disposal of waste arising from cleaning, as well as to parts exchanged during maintenance
and upkeep. Likewise during disposal, observe local regulations and hazardous bylaws.
14 MRD64092EN.5.I
3 Installing protective devices
Safety devices are mandatory for the operation of the positioner/component. They have to be
designed according to the relevant guidelines, national regulations, the danger/risk involved
and the type of application.
They can consist of mechanical, optic or other safety devices and must surround the danger
zone completely. (ISO10218)
The machine/system manufacturer is responsible for adequate installation of safety
devices and for compliance with the appropriate standards.
We refer especially to the EC Machinery Directive and the following
standards: EN294, EN349, EN547-1, EN10218-1, EN10218-2, EN12100, EN60204-1
and further relevant standards.
If the positioner/component from MOTOMAN robotec GmbH is installed, appropriate safety
devices, such as optoelectronic protective equipment, isolating protective devices (safety
gates, enclosures,…..), are also installed depending on the design and the type of use of the
positioner/component.. Furthermore, safety functions, such as emergency stop linking, safe
switching off of axes, post-running time / movement of ext. axes, are checked. MOTOMAN
robotec GmbH recommends this to all other distributors of our products.
The safety devices mentioned above may not be changed!
NOTE
If the positioner/component is not integrated by MOTOMAN robotec GmbH,
the machine/system manufacturer must ensure that a superordinate
controller or a superordinate control element is implemented before the
machine/system is commissioned in order to control the processes (work
steps, logical linking, robot jobs) and the behaviour of the system in all
operating states, particularly in case of emergency stop, setup work,
maintenance etc.).
Should you have questions in this respect or require information, please contact your
MOTOMAN robotec GmbH sales partner.
MRD64092EN.5.I 15
4 Using the positioner/component
4.1 Proper use

The positioner/component may only be used for the purposes described by the manufacturer.
For this, pay attention to the product description provided by the manufacturer, e.g. in the
offer, the order confirmation, the functional specification, the operating instructions etc. The
technical data described in these documents, particularly for the load limits, must also be
complied with. Any other use, system modification or manipulation can result in loss of
warranty/guarantee and the CE conformity. Any retrofitting to enable alternative work
sequences and/or retrofitting with alternative components must be agreed upon with the
manufacturer.
4.2 Improper use

The positioner/component must not be used in areas with risk of explosion, in the foodstuff
industry or in the pharmaceutical industry unless it has been explicitly designed and approved
for this purpose by the manufacturer.
Safety devices must not be interfered with or rendered ineffective.
Pay attention to the improper use described by the manufacturer (refer to, for example, the
operating instructions and, if necessary, the functional specifications).
16 MRD64092EN.5.I
5 Transport instruction
Depending on the size and the type of positioner, it can also be transported with a forklift
or crane.
The general safety instructions must be observed during transport!
CAUTION
 Sling applications and crane or forklift operations must be
performed by authorized personnel only.
Failure to observe this caution may result in injury or damage.
 Avoid excessive vibration or shock during transporting.
As the system consists of precision components, faults during
transport and installation may adversely affect the performance
and life of the positioner.
NOTE
 All illustrations must be regarded as symbolical.
 Check that the eyebolts are securely fastened.
 Use lifting equipment strong enough to withstand the
weight.
 The attached transport devices, such as eye bolts, transport
screws, etc. must be removed after transport!
MRD64092EN.5.I 17
18
Company:
5.1

Order no.:
DK-250
Lifting jack
Lifting jack
DK-250 Transport with crane
Transport with crane or forklift
MRD64092EN.5.I
Points of attachment 3 x
Points of attachment 3x screwed
screwed
ACHTUNG - CAUTION
- Hebezeuge und Anschlagmittel mit
ausreichender Tragkraft verwenden HINWEIS - NOTE
- Kippgefahr! Auf den Schwerpunkt - Alle Abbildungen sind als sinnbildlich
achten! zu erachten!
- Use suitable lifting equipment with - All illustrations must be regarded as

sufficient carrying capacity! symbolical.
- Danger of tipping! Pay attention to the
centre of gravity! Date:
________
Company: 
Order no.:
forklift
DK-250
DK-250 Transport with Forklift
MRD64092EN.5.I
ACHTUNG - CAUTION

_______
19
20
ACHTUNG! ATTENTION! 
Gesamtgewicht/ gross weight:

Total weight DK-250
DK-250
MRD64092EN.5.I
ca./ approx.
approx. 400 kg
Order no:
Company: 
Order no.:
DK-500
Lifting jack
Lifting jack
screwed
MRD64092EN.5.I
Points of attachment 3 x Points of attachment 3 x
screwed screwed
ACHTUNG - CAUTION

________
21
22
Company:

Order no.:
forklift
DK-500
MRD64092EN.5.I
ACHTUNG - CAUTION

________

ACHTUNG! ATTENTION!

Total weight DK-500
DK-500
MRD64092EN.5.I
ca./ approx.
approx. 500 kg
Order no:
23
24
Company:

Order no.:
DK-1000
Lifting jack
Lifting jack
screwed
MRD64092EN.5.I
screwed
ACHTUNG - CAUTION

________
Company: 
Order no.:
forklift
DK-1000
MRD64092EN.5.I
forklift
ACHTUNG - CAUTION

________
25
26

Total weight DK-1000
DK-1000
MRD64092EN.5.I
ca./ approx.
approx. 750 kg
Order no:
Company: 
Order no.:
DK-1500 Lifting jack
Lifting jack
Lifting jack
MRD64092EN.5.I
screwed
ACHTUNG - CAUTION

________
27
28
Company:

Order no.:
forklift
DK-1500
MRD64092EN.5.I
forklift
ACHTUNG - CAUTION

________

ACHTUNG! ATTENTION!

DK-1500
MRD64092EN.5.I
ca./ approx.
approx. 850 kg
Order no:
29
30
Company:

Order no.:
Lifting jack DK-2500 Lifting jack
MRD64092EN.5.I
screwed
ACHTUNG - CAUTION

________
Company: 
Order no.:
forklift
DK-2500
MRD64092EN.5.I
forklift
ACHTUNG - CAUTION

________
31
32

DK-2500
MRD64092EN.5.I
ca./ approx.
approx. 870 kg
Order no:
CAUTION
 Use suitable lifting equipment with sufficient carrying
capacity!
 Use a forklift with sufficient carrying capacity!
 Danger of tipping! Pay attention to the centre of gravity!
NOTE
If you have any queries or problems related to positioner
transportation or if there is any damage, please contact the
service department of MOTOMAN robotec GmbH
at tel. no.: (0049) (0) 180 576 268 3.
MRD64092EN.5.I 33
6 Setup instructions
6.1 Structure and attachment
6.1.1 Base plate for positionierers DK

 Base plate DK-250, DK-500
DK-250, DK-500
420
M16 (8x) 26 (10x)

60
610 0,2
580
320
600
420
295
30
20 H7 (2x)
340
420
580
600
Base plate
34 MRD64092EN.5.I

Base plate
10 946,5 395 118,5
1051,5 ±0,50 350

185 75 25 X 45°
60 80
5,
5(
10 X 45° 4x 25 28
)
100
0
R1
6x M6
122,75
5
R2
230
150
420
320
260 + 0,50
200
330
300
500 + 2
260 + 0,50
Base plate DK-1000, DK-1500, DK-2500
MRD64092EN.5.I
148
122,75
250
2x M20
20 tief
2x M20
DK-1000, DK-1500, DK-2500
100
40 202,5
4x M6
50 50 50 100
6x M16 6x 22
1020 400
860 580
1600
35
6.2 Assembly instruction for the base of the positioner
The Positioner must be mounted on a base plate and foundation. That is strong enough to
permanently carry the weight of the positioner and to absorb all occurring acceleration and
deceleration forces.
CAUTION
Uneven surfaces on the mounting area can cause deformations.
 This may affect the functioning of the positioner/component!
6.2.1 Ambient conditions at the place of use:
Temperature: 0° to + 45° Celsius
Humidity: 20% - 80% rel. humidity
Vibrations less than 0.5 G (5 m/s2)
Miscellaneous: No corrosive gases, liquids. No water, oil,

aggressive dust. No electrical
faults (plasma, magnetic tables etc.....).
6.2.2 Requirements related to the hall floor / floor characteristics:

MOTOMAN robotec GmbH strongly recommends using the floor anchor:
Type: fischer Highbond-Anker dynamic FHB dyn or FHB dynV
Designation: FHB dyn 20x170
or an equivalent product of a comparable manufacturer.
If the type FHB dyn 20x170 is used, the following conditions must be fulfilled
(differences must be discussed with the manufacturer of the floor anchor and/or a structural
engineer):
 unreinforced or reinforced concrete.
 cracked or non-cracked.
36 MRD64092EN.5.I
 Strength classes according to DIN EN 206-1:2001-07 min: C20/25 max: C50/60.
 Strength classes according to DIN 1045:1988-07: min: B25 max: B55.
 Edge distance: min. 150 mm (from each anchor to each edge of the concrete slab).
 Base plate thickness: min. 25 mm.
 Concrete thickness: min. 340 mm.
6.2.3 Evenness / height offset:

The concrete floor must be absolutely even in the area of the base plates!
If not, an even compensating layer must be used.
The thickness of the compensating layer must not exceed half of the shaft diameter
(max.: 0.39 in).
When mounting the positioner type with turn unit – counter bearing (WD, WH, G also
positioners of the type WL with counter bearing), the max. horizontal height offset of 10 mm
must not be exceeded.
Background: max. compensation with adjusting screws.
NOTE
The centric position of the centre axes of turn unit – counter
bearing must have a length of 10 m within +/- 0.2 mm
(in horizontal and vertical position). Also, all positioners must be
horizontally and vertically aligned with an even surface
using a machine spirit level.
 The foundation of the positioner must be able to withstand the maximum loads
in accordance with the ”maximum acceleration and brake forces of the positioner
in an emergency-off situation” and the ”maximum torques during
normal operation”.
MRD64092EN.5.I 37
6.2.4 Maximum acceleration and brake forces of the positioner in an emergency-off situation:
 DK-250 = 4.600 Nm
 DK-500 = 7.900 Nm
 DK-1000 = 5.000 Nm
 DK-1500 = 7.100 Nm
 DK-2500 = 11.000 Nm
6.2.5 Maximum moments during normal operation:

 DK-250 = 3.020 Nm
 DK-500 = 5.240 Nm
 DK-1000 = 3.200 Nm
 DK-1500 = 4.700 Nm
 DK-2500 = 7.300 Nm
6.3 Overtravel measurement log
6.3.1 Overtravel measurement DK250 turning
Measured values type DK250:

Overtravel distance mm 0120
Overtravel time ms 0421
6.3.2 Overtravel measurement DK250 tilting

38 MRD64092EN.5.I
6.3.3 Overtravel measurement DK2500 turning

6.3.4 Overtravel measurement DK2500 tilting

6.4 Mounting and fastening with compensating plates for exact

leveling.
 Installation of mortar cartridge and anchor rod
Setting time:
Floor temperature Setting time
(min)
(°C)
>20 10
+10 to +20 20
0 to +10 60
Note: The same setting times apply to a moist drill hole
MRD64092EN.5.I 39
Use a concrete drill (d = 25 mm) to drill holes approximately 170 mm deep in all the through
holes (d = 26 mm) into the base plate and clean them.
Note:
- Please pay attention to the information on the packaging for the floor attachment plugs.
- The floor attachment plugs are not contained in the scope of supply!
6.4.1 Structure of the fastening with adjustment plate

Next use a spirit level to align the positioner so that it will be exactly level vertically and
horizontally. Use M16 screw bolts for this purpose.
Anchor bolt
M16 jack screw
Locking nut
Base plate
Press plate
NOTE
After aligning and fastening the positioner, remove the attached
transport aids (e.g. attachment points, stacker supports, etc.)!
40 MRD64092EN.5.I
7 Wiring
WARNING
 Ground resistance must be 0.1 Ohm 0,1  or less.
 Failure to observe these warnings can lead to fire or
electrical shock.
 Before you connect, be sure to turn the main power supply
OFF, and put up a warning sign. (ex. DO NOT TURN THE
POWER ON.)
electrical shock.
CAUTION
 Wiring must be performed by authorized or certified
personnel.
 The control unit input supply voltage without is 3 x 200V at
50/60Hz.
 Connections to other power supply systems must be made
using an appropriate adapter transformer.
 When the systems are being connected, the corresponding
safety precautions, especially VDE 0100 and EN 60204, as
well as the requirements of the local power company must
be observed.
 A connection to the wrong power supply system could cause
considerable damage to the control unit. Any earth wire
connection to a component must be properly installed and
safe according to industry standards.
(The contact points must not be insulated.)
electrical shock.
MRD64092EN.5.I 41
8 Grounding
Observe the local regulations for the wire cross-section.

The cable cross-section must be 16.0 mm2 or more.
NOTE
 Never use the ground point and ground cable together with
other ground cables.
Never connect an additional ground cable of another
provider!
 Where metal ducts, metallic conduits, or distributing racks
are used for cable laying, ground in accordance with
Electric Equipment Technical Standards.
 Ensure that no paint or other insulating material is on the
earthing or connection point of the earthing cable
42 MRD64092EN.5.I
9 Electric connections
9.1 Electrical interface

The electrical interfaces in the positioner depend on the positioner
model.
Mastic
Plug for battery

Plug for battery
backup
backup
Plug for encoder

Plug for motor,
brake
Plug for motor,
brake
Cable for
safety sensor
Connections in the
base
Battery at the
crossbox cables
Mastic
MRD64092EN.5.I 43
9.2 Replacing the battery in the crossbox cables
NOTE
The battery for the crossbox cables should be replaced every two
years by trained and instructed specialist staff in order to prevent
loss of set data
Replace the battery of standard positioners as described below:

 An error message appears on the programming pendant, indicating that the battery
must be replaced.
CAUTION:To avoid loss of data, do not switch off the control before replacing the battery
!
 Replace the battery at the crossbox cables.
9.3 Dimensions for AC servo motor
9.3.1 Typ SGMDH-32A2A-YR11

275
70 204
44 MRD64092EN.5.I
NOTE
 All dimensions in mm!
 Absolute encoder is used as detector, 17 bit.
 Vibration: 15 µm or less.
 Connector and cable gland are optional.
 Electrical specifications: BE9401716
 This motor corresponds to the IP67 degree of protection.
(except for the cable plug)
 Motors with oil seal should be operated under the following
conditions.
• The optimal oil level is below the oil sealing lip.
• Oil should splash on the oil seal.
 For designation (**) see cable diameter (reference:
BE9372785).
Attach the battery connecting terminal

(NICHIFU)
A Battery (+)
B Battery (-)
MRD64092EN.5.I 45
 Encoder connecting terminal
Receptacle: 97F3102E20-29P
Options:
Plug: JL08A-20-29S-J1-EB
Cable gland:
JL04-2022CKE (**)
A ----------- K ----------
B ----------- L ----------
C DATA + M -----------
D DATA- N ----------
E ---------- P ----------
F ---------- R ----------
G 0V S Battery -
H + 5V DC T Battery +
Housing earth
J
connection
 Motor, brake connection
Receptacle: JL04V-2E24-10PE-B
Options:
Plug: JL04V-8A24-10SE-EB
Cable gland:
JL04-2428CK (**)
A phase U
B phase V
C phase W
D Housing earth connection
E Brake
F Brake
G ---------------------
46 MRD64092EN.5.I
9.3.2 Typ SGMDH-22A2A-YR11
NOTE
 Connector and cable gland are optional.
 Electrical specifications: BE9401714
(except for the cable plug)
conditions.
 For designation (**) see cable diameter (reference:
BE9372785).

(NICHIFU)
A Battery (+)
MRD64092EN.5.I 47
(NICHIFU)
B Battery (-)
Receptacle: 97F3102F20-29P
Options:
Plug: JL08A-20-29S-J1-EB
Cable gland:
JL04-2022CKE (**)
A ----------- K ----------
B ----------- L ----------
C DATA + M -----------
D DATA- N ----------
E ---------- P ----------
F ---------- R ----------
G 0V S Battery -
H + 5V DC T Battery +
Housing earth
J
connection
Receptacle: JL04V-2E24-10PE-B
Options:
Plug: JL04V-8A24-10SE-EB
Cable gland:
JL04-2428CK (**)
A phase U
B phase V
C phase W
E Brake
F Brake
G ---------------------
48 MRD64092EN.5.I
9.3.3 Typ SGMPH-15A1A-YR11
NOTE
 Motor specification: DP9492297
 Encoder specifications: DP9494166
 The magnetic brake is only for the self-holding position.
 This motor corresponds to the IP55 degree of protection
(except for the connector and drive at the rear).
• When connectors needs IP55 attach waterproof connector.
• When drive end side needs IP55 mount an oilseal.

(NICHIFU)
PC-2005M Battery (+)
PC-2005F Battery (-)
MRD64092EN.5.I 49
1 DATA + Blue
2 DATE - blue/black
3 3.6 V (Battery) yellow + red
4 0 V (Battery) yellow/black + black
5 +5V (PG) Red
6 0V (PG) gray
7 FG Orange
8 ---------- ----------
9 ---------- -----------
1 phase U Red
2 phase V White
3 phase W Blue
4 F G green/yellow
5 Brake Black
6 Brake Black
50 MRD64092EN.5.I
9.3.4 Typ SGMRS-20A2A-YR11
NOTE
 Electrical specifications: 900-010-752.
• If this motor is used for conformity protection,
IP67 is applicable; select the plugs and cables in
accordance with this drawing.
conditions.
 Permissible radial load: 980N
(At the end of the shaft) Permissible thrust load: 490N
 Maximum speed: 4600min-1
 The bearings include a plastic cast cage and urea grease.
 If you apply the emergency brake, also use the dynamic
brake!
• Emergency brake energy: 2800 J or less.
• Emergency brake interval: 30 minutes or more.
MRD64092EN.5.I 51
(NICHIFU)
 Encoder connecting terminal (JAE)
Receptacle: JN2AS10ML1
1 3
4 7 Options:
Plug: JN2FS10SL
8 10
stay bolt: JN1-22-**S-10000
1 DATA + 6 Battery (+)
Housing earth
2 DATA- 7
connection
3 ------------ 8 -----------
4 +5V DC 9 0V
5 Battery (-) 10 ----------
 Motor connecting terminal (JAE)
A phase U
B phase V
E C phase W
D F
CG A
B E Housing earth connection
F Housing earth connection
Connection socket: JL04V-2E20-10PE-B
Options:
PLUG: JL04V-8A24-10SE-EB
Cable clamp: JL04-2428CK(**)
52 MRD64092EN.5.I
305
242
0,04 A
46 196 63
18 3,2 Ø 0,04 A
-0,013
0
Ø28
174
-0,025
0
Ø 114,3
0,02
113
224
NOTE
conditions.
MRD64092EN.5.I 53
(NICHIFU)
1 3
4 7 Options:
Plug: JN2FS10SL
8 10
Housing earth
2 DATA- 7
connection
3 ------------ 8 -----------
4 +5V DC 9 0V
5 Battery (-) 10 ----------
A phase U
B phase V
E C phase W
D F
CG A
B E Brake connection
F Brake connection
Options:
54 MRD64092EN.5.I
326
263
0,04 A
46 217 63
18 3,2
Ø 28 -0,013
Ø 0,04 A
0
17 4
Ø 114,3-0,025
0
0,02
134
245
NOTE
conditions.
MRD64092EN.5.I 55
(NICHIFU)
1 3
4 7 Options:
Plug: JN2FS10SL*
8 10
Housing earth
2 DATA- 7
connection
3 ------------ 8 -----------
4 +5V DC 9 0V
5 Battery (-) 10 ----------
A phase U
B phase V
E C phase W
D F
CG A
B E Brake connection
F Brake connection
Options:
56 MRD64092EN.5.I
9.3.7 Connection at the positioner
The electric connections are on the bottom on the stand.
Up to 4 connections are available, which can be optionally assigned

(refer to the positioner model):
 Connection 1:
 Connection 2:
 Connection 3:
 Connection 4:
9.3.8 Connection at the control

 Check the numbers before you connect the connection cable to the control (NX100)
 With the help of the circuit diagram provided, connect the connections of the positioner
in the switch cabinet.
 With the help of the circuit diagram of the positioner, connect the welding earth
connection.
 The safety sensor must be integrated in the safety device by trained and instructed
specialist staff!
 The servo control must be connected by instructed specialist staff! If you have any
queries or problems, please contact the service department of MOTOMAN robotec
GmbH at tel. no.: (0049) (0) 180 5762683.
 Before operating the positioner, check whether all connections, such as the welding
earth connection, have been made properly.
NOTE
Due to the special hazards posed, work on electric parts of the
switch cabinet must only be carried out by qualified electricians.
A qualified electrician can assess the work to be carried out and
recognize and avert possible dangers because of his training,
knowledge and experience as well as his knowledge of applicable
regulations.
MRD64092EN.5.I 57
Connections at the positioner Reverse side of the control cabinet
2X
Connection OverRun Interior of the control cabinet
Servo control
NOTE
 The number of servo controls depends on the
type of positioner.
 Depending on the construction of the positioner, additional
connections can be installed as an option for special safety
features, for example.
 In addition, the electric connection can also be installed in an
access box as a separate terminal block.
58 MRD64092EN.5.I
9.4 Description of the safety sensor
9.4.1 Inductive safety sensor BES M13MI-POC40B-S04G

The BALLUFF safety sensor (BES M12MI-POC40B-S04G) may be installed depending on
the positioner type.
NOTE
For further technical data of the safety sensor, please refer to the
documentation from BALLUFF.
Electrical data
Connection Connector
Rated operational voltage, DC 24 V DC
Rated operational current (le) 200 mA
Maximum delay in readiness (tv) 30 ms
Electrical design DC, d.c. voltage
Usage category DC 13
Maximum hysteresis (H) 15 %
Off-load current, energized = 15 mA
Off-load current, de-energized = 15 mA
Maximum residual current (lr) 20 µA
Maximum residual ripple from Ue = 15%
Switching output PNP
MRD64092EN.5.I 59
Electrical data
Switching function Break contact (NC)
Switching frequency (f) 300 Hz
Maximum static voltage drop 2.5 V
Maximum operating voltage, DC (UB) 30 V
Minimum operating voltage, DC (UB) 12 V
Mechanical data
Number of conductors 3-wire
Tightening torque 15 Nm
Nominal switching distance (sn) 4 mm
Diameter M12x1 mm
Safe switching distance (Sa) 0...3.2 mm
Mechanical installation conditions Flush installation

possible
Maximum ambient temperature +70 °C
Minimum ambient temperature -250°C
Degree of contamination 3
Material of the active surface LCP
Material, housing CuZn, nickel-plated
Repetition accuracy (R) = 5%
General data
Function display yes
Short-circuit protection yes
Brand GlobalProx
Safety class 2
With reverse polarity protection yes
Approval CE,c_ul_us
Connection diagram Pinout
60 MRD64092EN.5.I
9.4.2 Row position switch BNS 813-B..-L12-61-12-...
The BALLUFF row position switch (BNS 813-B..-L12-61-12-...) may be installed
and preset depending on the positioner type. The station at the positioner/track can be determined
with the row position switch.
If you have any queries related to checking and setting the row position switch, please contact the
service department of MOTOMAN robotec GmbH at telephone no.: (0049) (0) 180 5762683.
NOTE
For further technical data of the row position switch,
please refer to the documentation from BALLUFF.
Characteristic Value
Construction Row position switch
Design 61
Active principle mechanical
Shaped as plunger Anti-friction bearing
Plunger diameter 10 mm
Switch element BSE 61
Feedthrough for cable gland 2 thread outputs, M20x1.5
Plug None
Plunger distance, 1st switching point 12 mm
Pitch (T) 12 mm
Width 120 mm
Height (H) 36...84 mm
Depth 74 mm
Protection type IP IP67
MRD64092EN.5.I 61
 Assembly
Cam Cam bar
NOTE
To ensure the switching function, the dimension 3 -0.5 must be
particularly observed!
9.4.3 Positioning switch

The Siemens position switch (ID: G_NSC0_XX_90013) may be installed depending on the
positioner type. The position switch prevents the rotary axis from being turned beyond a
preset value.
After the presetting by MOTOMAN robotec GmbH, the rotary axis can be rotated through
maximum + 190° and - 190° without any damage, e.g. cable damage etc., to the positioner.
NOTE
For information on modifying the positioner for endless
rotation of the rotary axis, please contact
MOTOMAN robotec GmbH.
If you have any queries related to checking and setting the position switch, please contact the
service department of MOTOMAN robotec GmbH at telephone no.: (0049) (0) 180 5762683.
MLFB/code no.:
3SE2120, 3SE2120-0GW, 3SE2120-0GW00-0AA3, 3SE2120-0GW00-0AG2,
3SE2120-0GW00-0AK0, 3SE2120-1GW, 3SE2120-1GW00-0AA3, 3SE2120-1GW00-0AC1,
3SE2120-1GW00-0AE0, 3SE2120-1GW00-0AG1, 3SE2120-1GW00-0AG2,
3SE2120-1GW00-0AK0, 3SE2120-1GW00-0AK1, 3SE2120-3GW, 3SE2120-3GW00-0AA3,
62 MRD64092EN.5.I
3SE2120-6GW, 3SE2120-6GW00-0AA3, 3SE2120-6GW00-0AG1, 3SE2120-6GW00-0AG2,
3SE2120-6GW00-0AK1, 3SE2120-7GW, 3SE2120-7GW00-0AA3, 3SE2120-8GW00,
3SE2120-8GW00-0AA3, 3SE2120-8GW00-0AK1.
19 60
54
30
56
26
Ø5,3 16
60
75
30
M20x1,5
40 39
7,3x5,3
NOTE
For further technical details of the position switch with rocker,
please refer to the documentation from Siemens.
9.4.4 Inductive safety sensor GG712S

Depending on the positioner type, the positioner may have a built-in safety sensor from ifm
(GG712S).
NOTE
For further technical data of the safety sensor, please refer to the
documentation from ifm.
MRD64092EN.5.I 63
LEDs
1 Safety sensor
2 Close-up zone
3 Enabling zone
4 Safe switch-off distance
5 Damping element
Yellow signal LED: Switching state
Green power LED: Operating voltage
 Enabling zone
The outputs (OSSDs) are enabled only if there is damping in the enabling zone. The outputs
remain switched off outside this enabling zone.
With damping with a standard plate of 18 x 18 x 1 mm made of FE360 (= ST37K) and with
flush installation according to IEC 60947-5-2, the enabling zone is in the range = 1 ... = 5 mm.
The safe switch-off distance is > 7 mm.
If you use damping elements whose material, shape and size differ from those of the standard
plate, the enabling zone is different. Enabling zone for other
materials*:
Material Enabling zone

Stainless steel 1.4301 0.5...3.5 mm
(V2A)
AIMg3G22 0..0.20.00 in
CuZn37 0..0.20.00 in
Cu 0..0.1.5 mm
* Typical values with damping with a reference measuring plate of 18 x 18 x 1 mm and flush
installation according to IEC 60947-5-2
64 MRD64092EN.5.I
NOTE
Depending on the properties of the damping element, there may
not be any close-up zone.
 Assembly
Flush installation of the device is possible according to IEC 60947-5-2, type I1A18SP2.
- Secure the device against being detached. Maximum tightening torque: 30 Nm
- Comply with the installation requirements shown in figures 1 to 3:
- Deenergise the electrical connection of the system. If necessary, also switch off
relay load circuits to which power is supplied independently.
- Supply voltage: connect L+ at connection 1 and L– at connection 3 of the plug
.
NOTE
The nominal voltage is 24 V DC. This voltage may fluctuate
between 19.2 V and 30 V incl. 5 % residual ripple
according to EN 61131-2.
 Operation as four wire system
Evaluation unit or PLC
MRD64092EN.5.I 65
9.4.5 Operation of the safety sensor
 Safe state
The safe state is the switched off state (currentless state: logical "0") of at least one of the
outputs A1 and A2 (OSSDs). If one of the outputs A1 and A2 is switched off, the downstream
safety-oriented logical unit must bring the complete system to the state defined as safe.
 Switched state
If the damping element is in the enabling zone and there is no sensor error, both outputs A1
and A2 (OSSDs) are enabled (logical "1").
 Cross connections
- A cross connection between the two outputs (A1 and A2) is detected by the safety sensor
and results in switching off of the outputs (OSSDs) when the next safety request is made.
Outputs A1 and A2 remain switched off until the error has been eliminated.
- A cross connection between one of the two outputs (A1 or A2) and the supply voltage results
in switching off of the other output (A2 or A1) when a safety request is made.
The output characteristics, overview tables and response times can be found in the
documentation from ifm (GG712S).
9.5 MOTOMAN delineation system

The MOTOMAN delineation system is used to check the position if there are problems, or
to determine the exact position (for example, after disconnecting the encoder cable,
when replacing the motor, when replacing the gear, or if the battery at the crossbox cables is
empty).
66 MRD64092EN.5.I
NOTE
 Other delineation systems may be installed on the positioner DK-
250 and DK-500 as an option.
- If you have any queries or problems related to the installed

delineation, please contact the service department of
MOTOMAN robotec GmbH at tel. no.: (0049) (0) 180 5762683.
 The delineation system may be set only by trained and
instructed specialist staff!
 The auxiliary tool with the pins to be used is not included in
the scope of delivery and must either be ordered separately
(article number 118573) or created with the help of the
drawing shown below.
 Alternatively, the delineation can also en attached to the
drive of the main arm!
MRD64092EN.5.I 67
 Drawing of auxiliary tool
118573
Complete auxiliary tool
A A
102353
DIN7979-6x50
137193
102346
DIN6325-4x40
A-A
M4x25-8.8 DIN 912
68 MRD64092EN.5.I
137193
Centre part of auxiliary tool
25
5
A 5 4,4
10
6 H7
3.2
8
25
4,5
5
A A-A
5
4 H7
3.2
10
9.5.1 Checking the delineation

For example, after disconnecting the encoder cable, when the motor or gear is replaced, or if
the battery at the crossbox cables is empty, the following points must be observed to restore
the absolute data with the delineation.
 The error message appears on the programming pendant after the control
is switched on. It must be confirmed with "RESET".
MRD64092EN.5.I 69
 In the main menu, press "SYSTEM INFO".
Then select the point "SAFETY" in the submenu.
 Enter the password under "MODE".
NOTE
 If you have any queries or problems related to the password,
please contact the service department of
MOTOMAN robotec GmbH at tel. no.: (0049) (0) 180 5762683
 In the main menu, press "ROBOT".

Then select the point "ZERO POSITION" in the submenu.
 With the "PAGE" button on the programming pendant, scroll through the individual
pages with the zero position.
NOTE: All absolute data marked with " * " must be reset.
 Press the "SERVO" button and the hold-to-run button.
An error message will appear that must be confirmed with "RESET".
Then the servo motors of the positioner are started.
 Now press the direction keys (+/-) on the programming pendant to move the positioner
to the delineation position (0 position).
This position is reached when the delineation pin fits in the socket.
70 MRD64092EN.5.I
NOTE: When approaching the delineation position, select a low
speed (using the "SLOW" button on the programming pendant).
LAYOUT GO BACK
DIRECT
OPEN
COORD
Multi PAGE AREA
MAIN SHORT
SERVO SELECT
ON !? CANCEL
MENU CUT
READY ASSIST
SERVO ON
X- X+
S- S+ X- X+
HIGH R- R+
SPEED
Y-. Y+
L- L+ Y- Y+
.
B- B+
FAST
MANUAL SPEED
Z- Z+
U- U+ Z- Z+
SLOW T- T+
INTER 7 8 9 TEST
SHIFT LOCK START SHIFT
ROBOT INFORM 4 5. 6 BWD FWD

LIST
EX.AXIS 1 2 3 DELETE INSERT
BACK MOTION 0 . -
SPACE MODIFY ENTER
TYPE
MOTOMAN
 Now select the axis for which the absolute data is missing and press the button
"SELECT" and "YES" to set the approached zero position.
NOTE
 Note down the absolute data of the respective zero positions
and keep it with your documentation.
 When positioning with several delineation units, you must
repeat this procedure for each delineation!
MRD64092EN.5.I 71
10 Technical data
10.1 Type overview DK

The DK positioner comprises two servo axes (tilt axis and rotational axis).
The tilt axis on the positioner can be swivelled through +/- 90°. The rotation axis has an
endless rotation. (for the types DK-250 and DK-500 this is only possible without media!)
The positioners of type DK-250 and DK-500 designed in such a way that, depending on the
specified load, no counter bearing is used.
For the positioner type DK-1000 or higher an additional counter bearing is mounted on
the tilt axis.
The positioner of the DK series is fitted with the following components:
Safety sensors, zeroing function for axes on both sides and a welding current collector.
The positioner can also be fitted with additional options such as electric,
pneumatic and hydraulic duct at the counter bearing.
DK-250, DK-500
Z
Y d
X
DK-1000, DK-1500, DK-2500
Z
H
72 MRD64092EN.5.I
Type DK-250 DK-500 DK-1000 DK-1500 DK-2500
Payload kg 250 500 1.000 1.500 2.500
Height of the tilt axis "H" mm 500 500 620 620 620
Height of the positioner "Z" mm 767 767 800 800 800
Diameter of the
mm 500 500 600 600 600
aceplate „d“
Floor space X x Y mm x mm 650 x 650 650x 650 663 x 1,600 679 x 1,600 680 x 1,600
Tilt axis:
Torque, static Nm 1.290 2.350 4.700 7.720 11.750
Speed rpm 31,1 22,5 8,0 7,2 5,3
Rotation axis:
Torque, static Nm 370 740 2.050 3.300 3.300
Speed rpm 25,5 27,1 22,5 18,3 18,3
10.1.1 Additional functions for DK
Description DK-250, DK-500 òDK-1000

Slip ring component, 16 signal, pneumatic hoses - o
Slip ring component, 16 signal, 2x pneumatic hoses - o
Slip ring component, 16 signal, 4x hydraulic lines - o
Slip ring component, ASI BUS, pneumatic hoses - o
Slip ring component, ASI BUS, 2x pneumatic hoses - o
Slip ring component, ASI BUS, 4x hydraulic lines - o
Slip ring component, Profibus, pneumatic hoses - o
Slip ring component, Profibus, 2x pneumatic hoses - o
Slip ring component, Profibus, 4x hydraulic lines - o
Fastening and installation kit for 30x40 mm support bar,

o o
faceplate

o o
fastener.

o o
faceplate
MRD64092EN.5.I 73
Description DK-250, DK-500 òDK-1000
o o
fastener
- = not available
o = option
10.1.2 Specified load of DK positioners
3000
DK 250
DK 500
DK 2500
DK 1000
2000 DK 1500
maximum load [kg]
DK 2500
DK 1500
1000
DK 1000
DK 500
DK 250
0
0 200 400 600 800 1000
Distance from centre of gravity to faceplate [mm]
*Nominal Values, for real application please contact MOTOMAN robotec GmbH (Sales@motoman.de).
74 MRD64092EN.5.I
10.1.3 Type list of the basic drives
Type Graphics
DD
DH
DG
Drive unit Type rated

Load
Overha
ng COG
rated
Torque
Peak
Torque
rated
Speed
max.
Speed
max.
Inertia
Load  Acc./
Dec.
at rated Angle
mm Load
kg N*m N*m rpm rpm kg*m2 degree
mm
DD-150 Direct Drive 150 400 160 375 24,7 37,0 20 1.000 30
DD-250 Direct Drive 250 300 500 1.150 16,9 25,3 130 1.500 30
DD-500 Direct Drive 500 190 940 2.130 10,6 28,4 200 1.700 30
DD-750 Direct Drive 750 175 1.400 3.200 10,6 28,4 280 2.000 30
DD-1000 Direct Drive 1000 205 2.070 4.700 10,6 28,4 420 2.200 30
DD-1500 Direct Drive 1500 180 3.240 7.300 8,8 21,1 1.300 2.700 30
MRD64092EN.5.I 75
Drive unit Type rated
Load
Overha
ng COG
rated
Torque
Peak
Torque
rated
Speed
max.
Speed
max.
Inertia
Load  Acc./
Dec.
at rated Angle
mm Load
kg N*m N*m rpm rpm kg*m2 degree
mm
DH-150 Hollow Shaft 150 800 225 650 11,3 19,8 40 1.000 30
Drive
DH-250 Hollow Shaft 250 450 370 800 17,0 25,4 80 1.500 30
Drive
DH-500 Hollow Shaft 500 320 740 1.930 10,2 27,1 160 1.700 30
Drive
DH-750 Hollow Shaft 750 320 1.240 3.020 10,2 27,1 240 2.000 30
Drive
DH-1000 Hollow Shaft 1000 350 2.050 5.240 8,4 22,5 700 2.500 30
Drive
DH-1500 Hollow Shaft 1500 350 3.300 8.160 7,0 16,9 1.800 3.200 30
Drive
DH-3000 Hollow Shaft 3000 650 4.440 10.550 5,97 14,1 3.500 4.000 30
Drive
DG-150 Gear Drive 700 165 400 93,8 250 1,8
DG-250 Gear Drive 1200 245 550 68,2 182 3,1 for rack
& pinion
DG-300 Gear Drive 1800 290 700 93,8 225 7,3 drives
DG-500 Gear Drive 3300 460 1.030 68,2 164 13,4
DG-1500 Gear Drive 1.400 3.200 10,6 28,4
DG-2000 Gear Drive 2.070 4.700 10,6 28,4
DG-3000 Gear Drive 3.240 7.300 8,8 21,1
76 MRD64092EN.5.I
Type R-250 R-500 R-750 R-1000 R-1500 R-2000 R-3000 R-4000 R-5000 R-6000
Typical load kg 250 500 750 1.000 1.500 2.000 3.000 4.000 5.000 6.000
Maximum kg 500 800 1.200 1.500 2.000 4.500 7.500 12.500 15.000 25.000
load
Maximum kg*m2 80 160 240 700 1.800 3.500 7.500 15.000 26.000 40.000
moment of
inertia
Workpiece  mm 1.500 1.500 1.500 2.200 3.000 3.000 4.500 5.500 6.500 7.500
at
nominal load
Drive DH-250 DH-500 DH-750 DH- DH- DH- DG- DG- DG- DG-
1000 1500 3000 1500 2000 2000 3000
unit
Type Hollow Shaft Drive Gear Drive
Nominal Nm 370 740 1.240 2.050 3.300 4.440 3.980 7.400 9.850 13.900
torque
Acceleration Nm 800 1.930 3.020 5.240 8.160 10.550 9.100 16.900 22.500 31.500
torque
Acceleration ° 30 30 30 30 30 30 25 20 15 10
angle
Maximum °/S 153 163 163 108 97 85 57 45 34 28

rotational
speed
Swivel time sec 2,0 2,0 2,0 2,5 2,8 3,0 4,5 5,2 6,5 7,5
for 180°
(approx.)
Drive unit Motor Toothed Motor Toothe Toothed Gear Gear Total Nomin Maximu
belt toothed d belt ratio ratio al m speed
wheel washer tension torque
of the
drive.
Hz N*m U/min
DD-150 81 81 160 37,0
DD-250 118,5 118,5 500 25,3

Refer to See
DD-500 mechanical Mechanical 141 141 940 28,4
parts list parts list
DD-750 141 141 1.400 28,4
DD-1000 141 141 2.070 28,4
DD-1500 171 171 3.240 21,1
MRD64092EN.5.I 77
Drive unit Motor Toothed Motor Toothe Toothed Gear Gear Total Nomin Maximu
belt toothed d belt ratio ratio al m speed
wheel washer tension torque
of the
drive.
DH-150 L-5M- 24 72 116 59 177,0 225 19,8

15-CXP
III
DH-250 L-5M- 36 72 145 59 118,0 370 25,4

15-CXP
III
DH-500 L-8M- 24 60 109 59 147,5 740 27,1

Refer to 20-Extr. Refer to
mechanical mechanical
DH-750 parts list L-8M- 24 60 110 parts list 59 147,5 1.240 27,1
20-Extr.
DH-1000 L-8M- 30 60 114 89 178,0 2.050 22,5

20-Extr.
DH-1500 L-8M- 30 72 134 89 213,6 3.300 16,9

20-Extr.
DH-3000 255 255 4.440 14,1
DG-150 16 16 166 250
DG-250 22 22 245 182
DG-300 16 16 287 225

Refer to Refer to
DG-500 mechanical mechanical 22 22 458 164
parts list parts list
DG-1500 141 141 1.400 28,4
DG-2000 141 141 2.070 28,4
DG-3000 171 171 3.240 21,1
NOTE
 No indexation is attached to the basic drive types "DD" and
"DH"!
10.1.4 DD-xxx
These drives offer extremely high torque capacities and very good precision together
with excellent dynamics. In addition, they are robust, maintenance-free and
the cheaper versions our drive systems.
The drives consist of a Cyclo drive with a Yaskawa AC-servo motor attached to it by means of
a intermediate flange.
The output side of the drive is supported in large-scale bevel roller bearings. Input and output
78 MRD64092EN.5.I
sides are sealed with the help of shaft sealing rings.
The output flange must be assembled together with a sealing agent.
When fastening the drive and the output flange, all fastening bores must be used and the
high-strength screws must be tightened with the prescribed torques.
Depending on the fitting position, the
output flange must be provided with either a lubricant filler and opening. For this, the
intermediate flange is fitted with two 180° offset threads R1/4". Once the output flange has
been fitted, the drive is to be filled with oil in accordance with the manufacture's guidelines.
The lubricant must be replaced after 5 years. We recommend an inspection of the drive by the
manufacturer after 10 years.
Information for maintenance (See 12.1)
10.1.5 Permissible torsion forces of drive without sleeve shaft (DD-150 to DD-
1500)
4.500
4.000
3.500
DD-1500
3.000
maximum load [kg]
2.500
DD-1000
2.000
DD-750
1.500
DD-500
1.000
DD-250
500
DD-150
0
0 100 200 300 400 500
Distance from centre of gravity to rotary axis
MRD64092EN.5.I 79
10.1.6 Permissible torsion forces of drives without sleeve shafts (DD-150 to
DD-1500)
1500
DD-1500
DD-1000
1000
maximum load [kg]
DD-750
DD-500
500
DD-250
DD-150
0
0 200 400 600 800 1000
80 MRD64092EN.5.I
10.1.7 Permissible moment of inertia for drive without sleeve shaft (DD-150
to DD-1500)
4.500
4.000
3.500
DD-1500
3.000
maximum load [kg]
2.500
DD-1000
2.000
DD-750
1.500
DD-500
1.000
DD-250
500
DD-150
0
0 1000 2000 3000 4000
Diameter of the workpiece [mm]
10.1.8 DH-xxx
These drives, with their central sleeve shafts, allow for media to be performed at the output
end. The drive has an extended central drive sleeve shaft, which is powered by a drive motor
over a cam belt (in the case of DH-3000 it is a gear wheel) The drives are fitted with seals on
both the input and output end. The output side of the drive is supported in large-scale bevel
roller bearings (DH-3000 has crossed roller bearing). When fastening the drive and the output
flange, all fastening bores must be used and the high-strength screws must be tightened with
the prescribed torques. The lubricant of the drive must be replaced after 5 years. We
recommend an inspection of the drive by the manufacturer after 10 years.
The cam belt must be checked yearly for wear and be replaced after 5 years.
Information for maintenance (See 12.1).
MRD64092EN.5.I 81
10.1.9 Permissible rotational load of drive with sleeve shaft (DH-250 to DH-
3000)
4.500
DH-3000
4.000
3.500
DH-1500
3.000
maximum load [kg]
2.500
DH-1000
2.000
1.500
DH-750
1.000
DH-500
DH-250
500
0
0 100 200 300 400 500
Distance from centre of gravity to rotary axis
82 MRD64092EN.5.I
10.1.10 Permissible tilt loads of drives with sleeve shafts (DH-250 to DH-3000)
DH-3000
4.000
3.000
maximum load [kg]
DH-1500
2.000
DH-1000
DH-750
1.000
DH-500
DH-250
0
0 00 400 600 800 1000
MRD64092EN.5.I 83
10.1.11 Permissible mass moment of inertia for drives with sleeve shafts (DH-
250 to DH-3000)
4.500
DH-3000
4.000
3.500
DH-1500
3.000
maximum load [kg]
2.500
DH-1000
2.000
DH-750
1.500
DH-500
1.000
DH-250
500
0
0 1000 2000 3000 4000
10.1.12 DG-xxx
These drives are fitted with gear pinions on the drive output end. The sizes DG-150 and DG-
500 are used for linear drive systems, the sizes DG-1500 to DG-3000 serve as driving
mechanisms for toothed rotary connectors. The latter sizes consist of the drive types DD-xxx
with flanged gear pinions at the far side.
Just the same as with the other drive systems, this drive requires all fastening bores to be
used together with high-strength screws and the prescribed torques. The lubricant of the drive
must be replaced after 5 years.
We recommend an inspection of the drive by the manufacturer after 10 years.
Information for maintenance (See 12.1)
84 MRD64092EN.5.I
10.1.13 Technical data for R-3000 to R-6000
Technical data R-3000 R-4000 R-5000 R-6000

Typical load kg 3.000 4.000 5.000 6.000
Maximum load kg 7.500 12.500 15.000 25.000
Maximum moment of inertia kg*m2 7.500 15.000 26.000 40.000
Workpiece  at nominal load mm 4.500 5.500 6.500 7.500
Drive unit DG-1500 DG-2000 DG-2000 DG-3000

Type Gear Drive
Nominal torque Nm 3.980 7.400 9.850 13.900
Acceleration torque Nm 9.100 16.900 22.500 31.500
Acceleration angle ° 25 20 15 10
Maximum rotational speed °/s 57 45 34 28
Swivel time for 180° (approx.) sec 4,5 5,2 6,5 7,5
The positioners are fitted with pluggable connectors for all kinds of connections.
Other options are:
 Bushings for electrical, compressed air and hydraulics for endlessly turning positioners.
 Separate welding mass transfer for a defined assignment of welding machines to
stations.
 Frames for fixture mounting.
The fastening must only be carried out on a load-bearing undersurface. If down pins are to be
used, only those which can withstand dynamic loads and have been approved by the building
standards control can be used in the sizes and numbers determined by us.
MRD64092EN.5.I 85
10.1.14 Permissible mass moment of inertia for basic drives (R-2000 to R-
6000)
40.000
R -6000
35.000
maximum load [kg]
R -5000
30.000
25.000
R -4000
20.000
15.000
R -3000
10.000
R -2000
5.000
0
0 1000 2000 3000 4000 5000 6000 7000 8000
10.1.15 Admissible load for basic drives for 2-station operation (R-2000 to R-
6000)
6.000
R -6000
5.000 R -5000
4.000 R -4000
Maximum load per station [kg]
R -3000
3.000
2.000
R -2000
1.000
0
0 1000 2000 3000 4000 5000
Length of the workpiece [mm]
86 MRD64092EN.5.I
11 Overview positioner DK
11.1 Schematic drawing

11 7 5 8 2 3 7 8 11 4 11 8 5 3 13 14
4 3 5 1 9 10 1 9 3 2 6 9 12 9 1 4 6 2 9 3 10
Figure 1: Schematic drawing positioner
Number Designation Number Remarks
1 Floor panel with base 1 Can be fitted optionally.
Tilt axis
2 1
(Motor + gear)
3 Safety sensor 2
Rotation axis
4 1
(Motor + gear)
Different delineation systems (x2) may be

5 Delineation system 1
installed for type DK-250 and DK-500!
Rack segment Only installed for type DK-1000, DK-1500 and

6 1
(pinion + gear) DK-2500.
2 x welding earths are installed for type DK-

7 Welding earthing 1 250 and DK-500"
8 Faceplate 1
4 x swivel eye bolt for type DK-250 and DK-

500.
9 Borehole for swivel eye bolt 6 Optionally, up to 2x swivel eye bolts can be
screwed in at the face plate. This depends on
the size of the face plate!
10 Electric connections
11 Welding earth transmission 1
Only installed for type DK-1000, DK-1500 and

12 Pedestal bearing 2
DK-2500.

13 Jumper ring for overrun 1
DK-2500.
MRD64092EN.5.I 87
Number Designation Number Remarks

14 Overrun switch 1
DK-2500.
88 MRD64092EN.5.I
12 Maintenance and Inspection
12.1 General maintenance
General maintenance:
Inspection Interval Procedure
For vapours Check daily During operation
General condition as required Clean with a cloth or brush; remove weld spatter with a
scraper
The grounding may only be Annually must be greater than 10 MOhm measured with 500 V
carried out by trained personnel. test voltage after disconnecting the motor
Shafts Every 5000 hrs. Check for play, etc. Replace if necessary.
Overhaul Every 20000 hrs. or Please contact MOTOMAN robotec GmbH

every 5 years
12.2 Handling problems

*Caution: Prior to maintenance work, make sure that the system or positioner is disconnected
from the electric power.
The master switch must be locked in order to prevent restarting.
Handling problems
Problem Possible cause Remedy
Motor does not start Bad connection* Tighten connection*

faulty wiring* connect correctly*
Unstable connection Incorrect or faulty wiring* Check terminals L1, L2, L3 and PE, or
BC cable connector*
Motor overheating Ambient temperature too Reduce the temperature to below +40°C, clean the
high; motor / cooling fans cooling fins, reduce weight
heavily soiled; overload
Unusual noises Motor not correctly mounted; Tighten the fastening screws of the motor/gear to the
gear not correctly mounted; required torque.
machine vibrations Please contact MOTOMAN robotec GmbH
MRD64092EN.5.I 89
12.3 Lubrication and inspection schedule
Only a properly maintained positioner will give the required performance over its entire
lifetime. Failure to comply with the maintenance schedule or "overgreasing" of the gears will
reduce the product life drastically.
Lubrication and inspection schedule:

Interval Item Method Notes
1x after 1000 hour of operation Fastening screws Check for correct fitting and
tighten with torque spanner if
necessary
Annually Industrial bronze carbon Check and replace if Not installed in type SI
brushes necessary
4-6 years complete overhaul, Please contact

based on run time and condition MOTOMAN robotec GmbH
90 MRD64092EN.5.I
12.4 Maintenance DK-250
1 3
2 4 5
Figure 2: Maintenance DK-250
Maintenance: DK-250
Item Designation Number Remarks
1 Gear basic drive (tilt axis) 1

F2CFS-T455-141
2 Motor basic drive (tilt axis) 1

SGMDH-22A2A-YR11
3 Drive unit gear 1

F2CFS-T355-141
4 Motor drive arm 1

SGMPH-15A1A-YR11
MRD64092EN.5.I 91
1 3
2 4 5
Maintenance: DK-500

F2CFS-T555-171

SGMDH-32A2A-YR11
3 Drive unit gear 1

F2CFS-T455-141
4 Motor drive arm 1

SGMDH-22A2A-YR11
92 MRD64092EN.5.I
8 5 6
2 1 3 4 7
Maintenance: DK-1000

F2CFS-T455-141

SGMRS-20A2A-YR11
3 toothed quadrant 1
Lubrication fitting DIN71412-M8x1
5 Drive unit gear 1

F2CFS-C55-89
6 Motor drive arm 1

SGMRS-30A2A-YR11
7 Toothed belt 1
800-8M-30
MRD64092EN.5.I 93
8 5 6
2 1 3 4 7

F2CFS-T555-141

SGMRS-30A2A-YR11
Lubrication fittingl DIN7142-M8x1
5 Drive unit gear 1

F2CFS-C65-89
6 Motor drive arm 1

SGMRS-37A2A-YR11
7 Toothed belt 1
880-8M-30
94 MRD64092EN.5.I
8 5 6
2 1 3 4 7

F2CFS-T655-171

SGMRS-37A2A-YR11
5 Drive arm gear 1

F2CFS-C65-89
6 Motor drive arm 1

SGMRS-37A2A-YR11
7 Toothed belt 1
880-8M-30
MRD64092EN.5.I 95
12.9 General maintenance
All installed parts of the positioner requiring maintenance are listed below together with the
corresponding maintenance intervals.
12.9.1 Maintenance FINE CYCLO gear

 The F2C-T or F2C-C gear kit is lubricated for life with Optimol longtime PDO grease
or, alternatively with Shell Alvania EP RO grease.
The product life of the gear kit can be extended by inspection and relubrication in the
plant after 5 years (see the documentation provided by FINE CYCLO).
12.9.2 Maintenance of the tooth segment/pinion (tilt axis)

The rack segment/pinion is lubricated once per year with OPTIMOL Longtime 2 grease,
with 5 pump strokes at each of the two lubrication nipples.
12.9.3 Maintenance of SKF Groove ball bearing

The groove ball bearing from SKF has a lifetime grease packing and requires no
maintenance. Please contact SKF for further details about re-lubrication and calculating the
groove ball bearing's service life.
12.9.4 Maintenance of the ifm safety sensor (GG712S)

If operated properly, maintenance and repair are not required.
 The device may be repaired only by the manufacturer.
 Dispose of the device in an environmentally friendly manner according to the valid
national regulations.
(refer to the ifm documentation).
12.9.5 Maintenance Yaskawa Motor

If operated properly, maintenance and repair are not required.
12.9.6 Maintenance toothed belt

The toothed belts require no maintenance. For checking and setting the toothed belts'
tension, see Chapter „ 12.10. Checking and adjusting the toothed belt tension.“.
However, there is a risk that the very easy to put together toothed belts are bent or folded too
96 MRD64092EN.5.I
tightly. This can result in damage to the inserts and weakening of their load transfer capability.
We recommend that the toothed belts are protected during storage from excessive
temperature influences and high humidity, as well as UV irradiation (in this connection see
Dokumentation von Firma WALTHER FLENDER GmbH).
12.9.7 Maintenance slip ring

The friction paths should be lubricated every 100,000 revolutions or semi-yearly with
"Top Pin" contact oil (See Morgen Rekofa GmbH documentation).
12.9.8 Maintenance of slip ring from the Schleifring company.

Unless otherwise indicated in the data sheet from the manufacturer (Schleifring),
inspection and maintenance work must be performed after 14.5 x 106 rotations or every 5
years respectively, whichever is reached first. No maintenance is required between the
intervals given.
The equipment must be sent to the manufacturer for maintenance. If you wish to perform
simple maintenance jobs on the equipment yourself, please consult the manufacturer,
Schleifring, first (see documentation from Schleifring).
12.9.9 Maintenance welding earth transmission

1 x weekly visual inspection with:
 remove abrasion residue.
 if applicable: if damages are visible, the welding earth transmission must be replaced.
MRD64092EN.5.I 97
12.10 Checking and adjusting the toothed belt tension.
The deflection of toothed belt d must be between 3 and 6 mm. For example, this is measured
with a test load of Fp=12 N for a 4.5 kW motor.
In both cases the side length s (distance between the centres of the toothed belts) is
approximately 250 mm. If wear can be detected in the toothed belt (e.g., abrasion, cracks,
etc., the belt must be replaced and the correct tension adjusted.
 Deflection d = s / 50 (mm)
 with test load of Fp in [N]
 Side length s in mm
 s = distance of axis
98 MRD64092EN.5.I
12.10.1 Tightening the toothed belt
1.) To adjust the toothed belt the 4 fastening screws (A) must be unscrewed and the lock nut
(C) loosened.
2.) To increase the tension of the toothed belt, turn the adjusting screw (B) clockwise.
3.) To reduce the tension of the toothed belt, turn the adjusting screw (B) in the
counterclockwise direction.
4.) When the correct belt tension has been set, the adjusting screw (B)
must be tightened with the lock nut (C).
5.) Then the 4 fastening screws (A) must be tightened with a torque of 120 Nm.
Toothed belt
Screw (C)
Screw (B)
Screw (C) Screw (A)
MRD64092EN.5.I 99
13 Replacement parts and consumables
It is recommended to keep a stock of special replacement and wearing parts for the
positioner. You will find a list of the most commonly used parts below.
NOTE
Use replacement and wearing parts from the product range of
MOTOMAN robotec GmbH to
 ensure longer product life of the replacement and wearing
parts of the positioner.
CAUTION
Use of alternative replacement and wearing parts must be agreed
upon with MOTOMAN robotec GmbH.
 Non-compliance with this rule may void the
warranty/guarantee and the CE conformity.
If you require replacement and wearing parts, please make sure you have the following data
ready:
 Type of the positioner
 Order number, e.g. 30025000
 The part number of the part to be replaced
 Part name
 Number
13.1 Replacement parts and consumables DK-250
Replacement parts and consumables: DK-250

Numb Replacem
Designation Number Wearing part Remarks
er ent part
Gear basic drive (tilt axis) 110326 1 X

F2CFS-T455-141
100 MRD64092EN.5.I
Numb Replacem
er ent part
Motor basic drive (tilt axis) 112246 1 X

SGMDH-22A2A-YR11
Drive unit gear 110302 1 X

F2CFS-T355-141
Motor drive arm 112245 1 X

SGMPH-15A1A-YR11
Welding earth transmission 1 X
Bronze carbon 104988 1 X

M195 without radius
Battery at the crossbox cables 107562 1 X
Auxiliary tool for delineation pin 118573 1 X Option
Jumper ring 129536 1 X

DKE tilt axis
Delineation system 129557 1 X Option

Pin DKE K axis (base axis)

Pin DKE D axis (drive unit)

Numb Replacem
er ent part

F2CFS-T555-171

SGMDH-32A2A-YR11

F2CFS-T455-141

SGMDH-22A2A-YR11
Welding earth transmission 127407 1 X
Bronze carbon 104988 1 X

M195 without radius
Auxiliary tool for delineation pin 118573 1 X Option

Clock DKE 32/22 K axis (base axis)

Pin DKE D axis (drive unit)
MRD64092EN.5.I 101

Numb Replacem
er ent part

F2CFS-T455-141

SGMRS-20A2A-YR11

F2CFS-C55-89

SGMRS-30A2A-YR11
Toothed belt 110861 1 X

800-8M-30
Safety sensor 139160 2 X
Carbon tip 127349 1 X

HS9381711
Auxiliary tool for delineation pin 118573 1 X
Delineation 141094 1 X
Pin/sensor holder
Counterpart for face plate
Jumper ring for overrun tilt axis 141430 2 X
Toothed wheel standstill monitoring 127591 2 X
Switch cam range limitation 240° 127571 1 X
Self-aligning ball bearing 110370 2 X X

1217
Groove ball bearing 110562 1 X X

6312-2RSR
Lubrication terminal 130089 2 X


Numb Replacem
er ent part

F2CFS-T555-141

SGMRS-30A2A-YR11

F2CFS-C65-89
102 MRD64092EN.5.I
Numb Replacem
er ent part

SGMRS-37A2A-YR11

880-8M-30

HS9381711
Pin/sensor holder

1217


Numb Replacem
er ent part

F2CFS-T655-171

SGMRS-37A2A-YR11

F2CFS-C65-89

SGMRS-37A2A-YR11

880-8M-30

HS9381711
Pin/sensor holder
MRD64092EN.5.I 103
Numb Replacem
er ent part

1217

104 MRD64092EN.5.I
Notes
MRD64092EN.5.I 105
MOTOMAN offices and representatives near you
YASKAWA Electric Corporation
JP 2-1, Kurosaki-shiroishi
Yahatanishi-ku Kitakyushu -shi 806-0004
+093-645-8801
MOTOMAN Gruppe Distributors

A MOTOMAN robotec GmbH Wien BG Kammarton Bulgaria Ltd.
+43-1-707-9324-15 Sofia +359-02-926-6060
CZ MOTOMAN robotec s.r.o. CH Messer Eutectic Castolin Switzerland S.A.
Prag +420-251-618-430 Dällikon +41-44-847-17-17
D MOTOMAN robotec GmbHAller- CZ Hadyna International spol s.r.o.
shausen +49-8166-90-0 MOTO- Ostrava-Marianske Hory +420-596-622-636
MAN robotec GmbHFrankfurt Sp-Tech s.r.o.
+49-6196-77725-025 Nymburk +420-325-515105
DK MOTOMAN Robotics Europe AB H Fiexman Robotics Kft
LØsning +45-7022-2477 Budapest +36-30-9510065
E MOTOMAN Robotics Iberica S.L. Rehm Hegesztéstechnika Kft
Barcelona +34-93-6303478 Budapest +36-53-380-078
F MOTOMAN Robotics S.A. IL KNT Engineering Ltd
Nantes +33-2-40131919 Beit Shemesh +972-2-9905882
FIN MOTOMAN Robotics Finland Oy Uniweid Ltd.
Turku +358-403000600 Yavne +972-8-9328080
GB MOTOMAN Robotics UK Ltd N Optimove AS
Banbury +44-1295-272755 Lierstranda +47-32240600
I MOTOMAN Robotics Italia SRL- PL Integrator RHC Sp. z.o.o.
Modena +39-059-280496 Torun +48-56-6519710
Turin +39-011-9005833 RUSWeber Comechanics
NL MOTOMAN benelux B.V. Torun +7-495-105-8887
Breda +31-76-5302305 TR Teknodrom Robotik
P MOTOMAN Robotics Iberica S.L. Otomasyon San. Tic. Ltd. pti
Aveiro +351-234-943 900 Gebze/Kocaeli +90-262-678-88-18
SE MOTOMAN Robotics Europe AB ZA Robotic Systems SA PTY Ltd
Kalmar +46-480-417800 Johannesburg +27-11-6083182
MOTOMAN Robotics Europe AB
Torsas +46-480-417800
SI MOTOMAN robotic d.o.o.
Ribnica +386-1-8372-410
RISTRO d.o.o.
Ribnica +386-1-8372-410
Schulung & Vertriebsbüro Frankfurt/

Zentrale / Headquarter
MOTOMAN robotec GmbH Training centre and sales office Frankfurt
Kammerfeldstraße 1 MOTOMAN robotec GmbH
D-85391 Allershausen, Deutschland Hauptstraße 185
Telefon / Fon 0049-8166-90-0 D-65760 Eschborn
Telefax / Fax 0049-8166-90-103 Telefon /Fon 0049-6196-777 25-0
Telefax / Fax 0049-6196-777 25-39
www.motoman.de e-Mail: info@motoman.de
Änderungen, welche den technischen Fortschritt dienen, vorbehalten.

Alterations in the course of technical progress, are reserved, without separate information.

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Operating and

TYPE: DK-250, DK-500, DK-1000, DK-1500,

Document no. MRD64092EN.5.I

1 Safety specifications ............................................................................................................. 5

13.5 Replacement parts and consumables DK-2500 .................................................................. 103

1.2 Type overview

Type DK-250 DK-500 DK-1000 DK-1500 DK-2500

Drive unit gear F2CFS-T355- F2CFS-T455-

Motor SGMPH- SGMDH- SGMRS-30A2A- SGMRS- SGMRS-

Toothed belt 800-8M-30 880-8M-30 880-8M-30

toothed quadrant Lubrication Lubrication

1.3 Symbols and marks on the system / component

1.4 Danger and warning notes in this safety information

1.4.1 Warning symbol and the signal word related to it

Consequences in the event of non-

Indicate an immediate, high-risk hazard that

Indicates a potential medium-risk hazard that

Indicates a low-risk hazard that could cause

DANGER Indicate an immediate, high-risk hazard that

1.4.2 Note symbol and the signal word related to it

Symbol and signal word Explanation

When this symbol appears, it refers to

2.1 Requirement for operating personnel

2.1.2 Qualified personnel:

2.2 Particular risks due to electric current

2.2.1 Working on electrical equipment

2.3 Safety instructions on electrical commissioning

DANGER due to electric

DANGER due to electric

2.3.1 Electrical connection of a positioner/component

2.4 Safety instructions on mechanical commissioning

2.4.2 Assembly and commissioning

The safety devices mentioned above may not be changed!

4.1 Proper use

4.2 Improper use

- Use suitable lifting equipment with - All illustrations must be regarded as

- Use suitable lifting equipment with - All illustrations must be regarded as

Gesamtgewicht/ gross weight:

- Use suitable lifting equipment with - All illustrations must be regarded as

- Use suitable lifting equipment with - All illustrations must be regarded as

Gesamtgewicht/ gross weight:

- Use suitable lifting equipment with - All illustrations must be regarded as

- Use suitable lifting equipment with - All illustrations must be regarded as

Gesamtgewicht/ gross weight:

- Use suitable lifting equipment with - All illustrations must be regarded as

- Use suitable lifting equipment with - All illustrations must be regarded as

Gesamtgewicht/ gross weight:

- Use suitable lifting equipment with - All illustrations must be regarded as

- Use suitable lifting equipment with - All illustrations must be regarded as

Gesamtgewicht/ gross weight:

6.1 Structure and attachment

6.1.1 Base plate for positionierers DK

M16 (8x) 26 (10x)

1051,5 ±0,50 350

6.2.1 Ambient conditions at the place of use:

Temperature: 0° to + 45° Celsius

Humidity: 20% - 80% rel. humidity

Vibrations less than 0.5 G (5 m/s2)

Miscellaneous: No corrosive gases, liquids. No water, oil,

6.2.2 Requirements related to the hall floor / floor characteristics:

Type: fischer Highbond-Anker dynamic FHB dyn or FHB dynV

Designation: FHB dyn 20x170

or an equivalent product of a comparable manufacturer.