Positioner Instruction Manual PST1000E

PST1000E
POSITIONER WITH RATED CAPACITY OF 1000 KG

K-Positioner
Kawasaki Robotics Positioner Instruction Manual
Contents:
1. Introduction ............................................................................................................................... 2
2. Technical parameters ................................................................................................................. 3
3. External dimensions .................................................................................................................. 4
4. Markings on the machine............................................................................................................5
5. Load charts ................................................................................................................................ 6
5.1. Maximum rated load distances .......................................................................................... 6
5.2. Chart of the load relative from the distance from the plate axis ......................................... 6
6. Basic units of the positioner ........................................................................................................ 7
6.1. Mechanical system.............................................................................................................. 7
6.2. Electrical system ................................................................................................................. 7
7. Assembly and start-up ............................................................................................................... 8
7.1. Assembly ........................................................................................................................... 8
7.2. Getting ready for operation ............................................................................................... 8
7.3. Emergency Stop connection .............................................................................................. 8
7.3.1. Cubic-S Option ........................................................................................................... 9
7.4. Start-up ............................................................................................................................. 9
7.5. Working and safe use conditions ....................................................................................... 10
7.6. Maintenance of the positioner .......................................................................................... 11
7.7. Maitenance schedule ........................................................................................................ 11
7.8. Complement to the copper paste in the ground transfer system....................................... 12
7.9. Adjustment of the clamping force of the ground transferring system ............................... 12
8. Storage and transport conditions ............................................................................................. 13
8.1. Storage ............................................................................................................................. 13
8.2. Transport .......................................................................................................................... 13
9. Safety information and residual risk ......................................................................................... 14
9.1. Danger due to mechanical construction: ........................................................................... 14
9.1.1. hing and cut-offs ....................................................................................................... 14
9.2. Dangers due to the electrical system ................................................................................ 14
10. Warranty conditions ............................................................................................................. 14
11. Notes .................................................................................................................................... 15
12. Manufacturer’s data .............................................................................................................. 17
Appendix 1 - Spare parts list
Copyright © 2018 Kawasaki Robotics GmbH All rights reserved by Astor
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K-Positioner
1. Introduction
One-axis (tilting) PST1000E positioner is an electrically driven positioner. It is equipped with

rotary axes controlled in a continuous manner. It is designed to work in a robotic welding station
and is used to rotate and tilt the welded parts. It is controlled from the KAWASAKI robot
controller as additional axes. Read and understand this manual thoroughly, and take
appropriate safety measures in using this product.
I. These instructions do not constitute a guarantee of the system in which the positioner
is installed. Accordingly, the Astor company is not liable for any accidents, damages
and/or problems related to industrial property rights arising as a result of using the
system.
II. It is recommended that all personnel assigned to operating, teaching, servicing or
maintaining the positioner attend the necessary courses when installing the system
before commencing the performance of their duties.
III. The Astor company reserves the right to alter, correct or update this manual without
prior notice.
IV. Keep the following instructions with care and in a place where they can always be
available for use. If the positioner is re-installed or relocated, please attach these
complete and unaltered instructions. In case the instructions are lost or damaged,
please contact the Astor company.
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K-Positioner
2. Technical parameters
Parameter PST1000E
Max. Payload 1000 kg
Nominal Torque 1225 Nm
Max. Torque 3062 Nm
Max. bending moment 3430Nm
Turning Range +/-360°*
Max. Rotating Speed 120°/s
Repeatability ±0.05 mm**
Max. Offset COG from Rotating Axis JT1 112 mm
Max. Mass moment of inertia 190 kgm2
Mass 70 kg
Default Height of Rotating Axis 185 mm
Installation Position Pedestal/table
Nominal weld current – 100% duty cycle 500 A
Environment cond. 0-40°C
Emitted acoustic pressure (adjusted by A) < 70 dB
Emitted acoustic pressure (adjusted by C) < 63 Pa
*possibility of setup range +/-36000
**on radius r=340mm from rotating axis
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3. External dimensions
Fig. 1 Basic dimensions of the positioner with spacing of fixing holes on the base and the plate
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K-Positioner
4. Markings on the machine
High voltage warning label
Rotating machine parts warning

label
Compression/crushing warning
label
Hot surface warning label
Information label
Fig. 2 Warning signs located on the positioner
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K-Positioner
5. Load charts
5.1. Maximum rated load distances
Fig. 3 Nominal rated load position
5.2. Chart of the load relative from the distance from the plate axis
Fig. 4 Drive torque of the axis
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K-Positioner
6. Basic units of the positioner

6.1. Mechanical system 1. Basic module– PST1000E
2. Servo Kawasaki 2.0kW
3. Rating plate
Fig.5 Basic units of the positioner
6.2. Electrical system
The power units consists of:

Axis 1 (Rotation of the plate -360o ÷ 360o) Kawasaki servo motor 2.0kW and cycloidal
transmission.
The axes are controlled as external axes from the robot control system. It is not possible to move
the positioner without connecting it to the KAWASAKI robot controller.
Standard length of electrical wires connecting the servo with the controller is 15m, but usable
length is 13m.
The ground is transferred to the rotating plate by means of a set of copper block located below
the bottom of the positioner gear.
Fig. 6 Ground transfer of the PST1000E positioner

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K-Positioner
7. Assembly and start-up

7.1. Assembly
The PST1000E is assembled, connected, and pre-commissioned by the personnel appropriately

prepared for this task. These persons are assigned by the manufacturer. These persons have the
knowledge and skills required to safely and correctly assemble the machine. Connection to the
mains must be carried out in accordance with the Polish Standards. It is not allowed to carry out
the assembly independently; this will result in loss of warranty. During the warranty period, the
user may not interfere in the electronic or mechanical components except as set forth in this
maintenance documentation. Failure to comply with the above will result in loss of warranty.
The positioner must be leveled and fixed to the pedestal/table using foundation bolts, M12 bolts
with a strength class of at least 10.9 and positioning pegs. The spacing of the mounting holes
fixing the positioner to the slab is shown in Figure 1.
7.2. Getting ready for operation
After completing the installation work on the positioner:
• Perform all the tasks on connecting the robotic station;

• Set up the tool for the positioner;
• Place the part in the tool.
The definition of the external axis is described in the documentation of the External Axis
(90210-1292DEC_External_Axis_Addition_Manual_(EOx-Series)).
7.3. Emergency Stop connection
Safety of the JT1 axis is ensured by the robot safety circuits and the circuits must be prepared in
accordance with Kawasaki technical documentation.
For proper safety of the JT1 axis of the positioner, two PN_CMD and PN_ON signals must be
connected to the robot inputs, the signals come from the safety curtain or the safety controller.
The signals in a high state after the axes control group (GROUP) change, cause power cut to the
servo which is located close to the operator.
Fig. 7 Ancillary axis off signal declaration
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K-Positioner
CAUTION!
When the positioner is supplied, the PN_CMD and PN_ON signals are declared as internal
signals. This should be changed when the positioner is integrated in the position.
7.3.1. Cubic-S Option
The Cubic-S option can further control the status of the Kawasaki exterior axis. In order to add
the axis monitoring, declare axis 7, 8 or 9 as DEVICE 1, 2 or 3.
Fig. 8 Stop Monitoring Declaration for ancillary axis in the Cubic-S option
The definition of the dedicated input for monitoring the status of the ancillary axis in CUBIC-S is
described in the documentation of the CUBIC-S option (90210-1272DED_Cubic-S_Instruction
Manual (E series)).
7.4. Start-up
To start the positioner, connect it to the robot control system.
Connect the 50979-0073L15 with the B marking to the B-JT8 MOTOR in the Kawasaki controller
Connect the 50979-3340L13 with the B marking to the B-JT8 SIGNAL in the Kawasaki controller
Connect the 50979-0073L15 with the C marking to the C-JT8 MOTOR in the Kawasaki controller
Connect the 50979-3340L13 with the C marking to the C-JT8 MOTOR in the Kawasaki controller
9
K-Positioner
* - connecting the second ancillary axis wires - a station with two ancillary Kawasaki axes,
**-only when controlling additional indexing servomotors.
Starting up the positioner starts up the robotic station and follows the positioning algorithm.
To move the axis JT7 or JT8 (drives Kawasaki), you should choose the appropriate group. Press the
"ALT" key on the TeachPendant off Monitors under (C) of the screen TP.JT7 or JT8.
GROUP -1 – no possibility
of moving additional axes,
GROUP 0 - the ability to

move axes without
cooperation,
GROUP 1 – moving the JT7

and JT8 axis in co-operative
mode.
Fig. 9 Revision Steering Group axes
Starting the positioner is synonymous with starting the robotic station and follows the algorithm
of the station's operation.
7.5. Working and safe use conditions
The PST1000E positioner is suitable for indoor use in the following environmental conditions:
• Air free from condensed stean, dust, corrosiver or explosive gases;

• Permissible ambient temperature: +5oC ÷ +40oC;
• Maximum temperature of the positioner’s plate: 90oC.
When operating the positioner:
• Observe all the safety rules for safe work at a robotic station;
• Get acquainted with possible health or life hazards due to improper operation of the
device;
• An employee handling the robotic station with the PST1000E positioner must be familiar
with the contents of this Operation and Maintenance Manual and the Operation and
Maintenance Manual for the industrial robot;
• It is not permitted to carry out maintenance work during the operation of the station
• It is forbidden to leave tools on the housing and servo drives of the positioner.
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K-Positioner
Detailed health and safety regulations should be developed by the user at the workplace. Observe
general health and safety regulations for electrical and mechanical equipment when connecting,
starting-up and operating the positioner.
It is not permitted for persons to be present in the operating area of the positioner during the work
of the machine (within range of the tilt and working rotation position of the positioner including
the tooling) as well as for unauthorized persons to carry out repairs and maintenance.
In addition, the operating crew must know how to attach the tools to the positioner plate and how
to place the parts in this equipment.
Secure the robot in the positioner workstation area using fencing and light barriers in accordance
with Polish safety standards.
7.6. Maintenance of the positioner
Maintenance procedures include measures aiming at reducing wear on parts and components of
the mechanical system and ensuring correct positioner operation. Maintenance should be
carried out by trained personnel. The service technician authorized to carry out repairs is the
manufacturer or a person designated by the manufacturer. The warranty does not cover
mechanical damage resulting from improper use of the station.
Before performing any maintenance work, make sure the equipment is

disconnected from the mains
7.7. Maitenance schedule
Period of time Daily Monthly 2500 5000 hours or

Action inspection inspection hours 1 year
Physical damage ☑ ☑
Gear blacklash and abnormal sounds during
operation ☑ ☑
* Complement to the copper paste in the
ground transfer system ☑ ☑
Replenish gear lubrication and bearings
Check the positioner brakes ☑
Refresh transmission lubricants ☑
Check the internal wires of the positioner ☑
Battery change ☑
Check the welding mass clamps ☑
** Replacement of welding mass clamps ☑
Checking the tightening torque of the
assembly screws ☑
Review made by authorized service
K-Positioners ☑
* instruction on performing the activity in item 7.8.
** In case of excessive wear and tear.
11
K-Positioner
7.8. Complement to the copper paste in the ground transfer system
Fig. 10 Place of restoration of copper paste
The recommended measure is the grease or copper paste (WÜRTH CU 800), which as a means of
seperating, protects the surface against seizing. In order to be completed, clean the old grease
and apply a new one on the back of the rotating plate (in the basie nad support unit)- the device
must be disconnected from the power supply.
The action should be performed once a month.
7.9. Adjustment of the clamping force of the ground transferring system
The ground clamps
Fig. 11 Tightening place of the ground clamps
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K-Positioner
8. Storage and transport conditions

8.1. Storage
The PST1000E one-axis positioner should be stored indoors, in rooms free from aggressive
corrosive agents. Ambient temperature should range between + 5 ° C ÷ + 40 ° C and humidity
should not exceed 80%. The positioner should also be protected against shocks and vibrations.
8.2. Transport
Transport of the positioner should be carried out by clean, dry and covered means of transport,
protected against penetration of precipitation into the interior and against exceeding the
temperatures of + 50 ° C and -25 ° C. At the same time the positioner must be protected against
sliding.
13
K-Positioner
9. Safety information and residual risk
The PST1000E has been designed and built for precise positioning of objects attached to it in one
axis, depending on the used version of the device. It is a prerequisite for the safe use of the device
described above that the maximum permissible load shown in this manual is not exceeded.
9.1. Danger due to mechanical construction:
9.1.1. hing and cut-offs
Fig. 12 Areas with the risk of crushing
There is a risk of crushing, cutting fingers or other parts of the body in the marked areas. Do not
leave or put any tools or parts of the body or animals in these areas.
It is forbidden to stay in the work zone while the positioner is in operation.
9.2. Dangers due to the electrical system
After connecting the positioner to the mains, it is forbidden to connect and/or disconnect the
wiring of the device; these actions may result in an electric shock.
10. Warranty conditions
Warranty covers only defects arising from causes inherent in the sold product. The
manufacturer's warranty covers 12 months. The basic principle of the maintenance of warranty
is to use a table with the timing of the steps preservatives (p. 11) and use the device as intended
and technical parameters.
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K-Positioner
11. Notes
15
K-Positioner
Appendix 1.
Parts of the positioner must be ordered from the ASTOR company. List of branches available
at: http://www.astor.com.pl/kontakt.html. In order to improve order handling, please specify
the positioner model and the part name along with the code.
Spare Parts List:
Name Product code Quantity [pcs]
Servo drive
Kawasaki 50601-1461A 1
2.0 kW
Cycloidal
transmission RH-125N 1
JT1
Plate of the
positioner PST1000E-PLATE 1
JT1
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K-Positioner
12. Manufacturer’s data
Astor Sp. z o.o.
Ul. Smoleńsk 29, 31-112 Kraków
Phone number: +48 (12) 428 63 00
Fax: +48 (12) 428 63 09
e-mail: [email protected]
NIP: 676 01 05 127
17

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PST1000E

POSITIONER WITH RATED CAPACITY OF 1000 KG

Appendix 1 - Spare parts list

Copyright © 2018 Kawasaki Robotics GmbH All rights reserved by Astor

One-axis (tilting) PST1000E positioner is an electrically driven positioner. It is equipped with

Copyright © 2018 Kawasaki Robotics GmbH All rights reserved by Astor

Copyright © 2018 Kawasaki Robotics GmbH All rights reserved by Astor

Copyright © 2018 Kawasaki Robotics GmbH All rights reserved by Astor

4. Markings on the machine

High voltage warning label

Rotating machine parts warning

Hot surface warning label

Fig. 2 Warning signs located on the positioner

Copyright © 2018 Kawasaki Robotics GmbH All rights reserved by Astor

Fig. 3 Nominal rated load position

Fig. 4 Drive torque of the axis

Copyright © 2018 Kawasaki Robotics GmbH All rights reserved by Astor

6. Basic units of the positioner

Fig.5 Basic units of the positioner

6.2. Electrical system

The power units consists of:

Fig. 6 Ground transfer of the PST1000E positioner

7. Assembly and start-up

The PST1000E is assembled, connected, and pre-commissioned by the personnel appropriately

7.2. Getting ready for operation

After completing the installation work on the positioner:

• Perform all the tasks on connecting the robotic station;

7.3. Emergency Stop connection

Fig. 7 Ancillary axis off signal declaration

Copyright © 2018 Kawasaki Robotics GmbH All rights reserved by Astor

7.3.1. Cubic-S Option

To start the positioner, connect it to the robot control system.

Copyright © 2018 Kawasaki Robotics GmbH All rights reserved by Astor

**-only when controlling additional indexing servomotors.

GROUP 0 - the ability to

GROUP 1 – moving the JT7

Fig. 9 Revision Steering Group axes

7.5. Working and safe use conditions

• Air free from condensed stean, dust, corrosiver or explosive gases;

When operating the positioner:

Copyright © 2018 Kawasaki Robotics GmbH All rights reserved by Astor

7.6. Maintenance of the positioner

Before performing any maintenance work, make sure the equipment is

Period of time Daily Monthly 2500 5000 hours or

* instruction on performing the activity in item 7.8.

** In case of excessive wear and tear.

Copyright © 2018 Kawasaki Robotics GmbH All rights reserved by Astor

7.8. Complement to the copper paste in the ground transfer system

Fig. 10 Place of restoration of copper paste

7.9. Adjustment of the clamping force of the ground transferring system

The ground clamps

Fig. 11 Tightening place of the ground clamps

Copyright © 2018 Kawasaki Robotics GmbH All rights reserved by Astor

8. Storage and transport conditions

Copyright © 2018 Kawasaki Robotics GmbH All rights reserved by Astor

9. Safety information and residual risk

9.1. Danger due to mechanical construction:

9.1.1. hing and cut-offs

Fig. 12 Areas with the risk of crushing