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QKM AH20 Maintenance Manual

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  • Page 2 Maintenance Manual AH20 Robot AH20-0850-0204-2000 AH20-0850-0204-4000 AH20-1050-0204-2000 AH20-1050-0204-4000 Document version V1.0.1 Issued on September 21, 2022 QKM Technology (Dongguan) Co., Ltd.

  • Page 3: Preface

    AH20 Robot, as well as the maintenance of mechanical and electrical components, so that users can better use AH20 Robot; this manual can serve as a reference for system integrators to design user workstation systems by using our AH20 Robot, and can also be used to guide system installation, commissioning and maintenance.
  • Page 4 AH20 Robot Maintenance Manual be sure to pay attention to the following signs when they appear in this document. The signs in this manual are described in the table below: Signs Description It indicates that a dangerous situation would occur and cause serious personal injury or death if it is not avoided.
  • Page 5 The contents of this document are subject to change any time due to product upgrade or other reasons. QKM reserves the right to change the contents of maintenance and operation in this manual without prior notice. For the recent information on this product, please download the latest manual from our official website.
  • Page 6 AH20 Robot Maintenance Manual QKM does not assume any direct, indirect, special or incidental loss or liability due to improper use of this product. QKM Technology (Dongguan) Co., Ltd. (Headquarters) Tower A, Building 17, Headquarters 1, No. 4 Xinzhu Road, Songshan Lake High-tech Industrial Development Zone, Dongguan City Tel.: +86 0769-27231381...

  • Page 7: Version History

    Version History Version History The version history contains the accumulated information on each update of the document, and the latest version of the document includes the updates in all previous versions of the document. Version Time Change Content The first version of the document was V1.0.0 June 10, 2022 released.

  • Page 8: Table Of Contents

    AH20 Robot Maintenance Manual Table of Contents Preface ........................... I Version History ........................V List of Figures ........................X List of Tables ........................XII Chapter 1 Safety Precautions ..................1 1.1 Precautions for operation ..................1 1.2 Precautions for electrical safety ................2 1.3 Warning sign ......................
  • Page 9 Table of Contents 3.2 Regular inspection....................10 3.3 Cleaning and maintenance ................... 10 3.4 Safety inspection ....................11 3.5 Handling of common exceptions ................. 12 Chapter 4 Maintenance of Mechanical Components ........... 14 4.1 Lubrication of spline screw shaft ................. 14 4.1.1 Standard type ....................
  • Page 10 AH20 Robot Maintenance Manual 4.4.3 Measuring steps and display ................. 41 4.4.4 Measuring results ................... 44 4.4.5 Precautions ..................... 45 Chapter 5 Maintenance of Electrical Components ............47 5.1 Replacement and maintenance of 1-axis motor fan ........... 48 5.1.1 Replacement of 1-axis motor fan ..............48 5.1.2 Maintenance of 1-axis motor fan ..............
  • Page 11 Table of Contents 5.11 Replacement and maintenance of the fan assembly of the mechanical arm 2 ............................77 5.12 Replacement and maintenance of brake PCBA ..........79 Chapter 6 Technical service ................... 83 6.1 Consulting and services ..................83 Document Version V1.0.1 (09-21-2022)

  • Page 12: List Of Figures

    AH20 Robot Maintenance Manual List of Figures Figure 1-1 Position of warning sign ................... 4 Figure 4-1 Special oil brush ..................... 15 Figure 4-2 Push down the spline screw shaft ..............16 Figure 4-3 Apply lubricating grease ................17 Figure 4-4 Push up the spline screw shaft ..............17 Figure 4-5 Diagram of robot covers ................
  • Page 13 List of Figures Figure 5-6 Diagram of encoder battery ................54 Figure 5-7 Position of encoder battery connector ............55 Figure 5-8 Controller assembly ..................56 Figure 5-9 Remove the controller assembly ..............57 Figure 5-10 IO-free-distribution PCBA ................59 Figure 5-11 Removal of IO-free-distribution PCBA ............
  • Page 14 AH20 Robot Maintenance Manual List of Tables Table 1-1 Warning signs ..................... 3 Table 3-1 Routine cleaning and maintenance schedule ..........10 Table 3-2 Handling of common exceptions ..............12 Table 4-1 Selection of lubricating grease ............... 15 Table 4-2 Accessories ....................... 21 Table 4-3 Accessories .......................

  • Page 15: Chapter 1 Safety Precautions

    Chapter 1 Safety Precautions Chapter 1 Safety Precautions Before starting maintenance on the robot, please read all the following precautions: 1.1 Precautions for operation The maintenance of the robot system must be performed by safety-trained personnel. Safety-trained personnel are those who have received safety training (on knowledge, operation, teaching, etc.

  • Page 16: Precautions For Electrical Safety

    AH20 Robot Maintenance Manual 1.2 Precautions for electrical safety The discontinuation, storage and waste disposal of the robot and related parts must be handled in accordance with relevant laws, regulations and standards to protect the environment.  Be sure to unplug the power cable and lock the power supply when the robot is not used.

  • Page 17: Warning Sign

    Chapter 1 Safety Precautions 1.3 Warning sign There are corresponding dangers and warnings near the location where the signs are labeled, so take sufficient care when operating. In order to operate and maintain the robot system safely, be sure to observe the cautions and contents on the warning signs.

  • Page 18: Figure 1-1 Position Of Warning Sign

    AH20 Robot Maintenance Manual Non-professionals are not allowed to open it. A sign for protection from residual voltage Warning! Hot surface. Beware of collisions Figure 1-1 Position of warning sign Document Version V1.0.1 (09-21-2022)

  • Page 19: Chapter 2 Safety Maintenance

    2.1 Use of robot in accordance with regulations Do not use the robot illegally. QKM will not be liable for any losses due to illegal use by users. To ensure the service life of the robot, please regularly maintain it in accordance with the contents of this manual.

  • Page 20: E-Stop Device

    AH20 Robot Maintenance Manual The work area refers to the range of working area of the robot determined by its motion trajectories and guaranteed by protective devices.  Protective area  The protective area must be larger than the work area, inside which protective devices need to be placed for warning and safe use.

  • Page 21: Precautions For General Safety

    Chapter 2 Safety Maintenance 2.4 Precautions for general safety The robot may be damaged in the case of incomplete safety functions and protective devices. Do not use the robot when safety functions are disabled or protective devices are removed.  Operational changes ...
  • Page 22 AH20 Robot Maintenance Manual or putting back into operation:  Check whether all protective devices have been properly installed and functioned well.  Check whether the electrical cables are properly connected. If compressed air is used, check whether the corresponding air pipes are connected properly.

  • Page 23: Chapter 3 Routine Maintenance And Safety Inspection

    Chapter 3 Routine Maintenance and Safety Inspection Chapter 3 Routine maintenance and safety inspection 3.1 Routine inspection 1. Inspection of preparations for robot startup Confirm whether the external supporting facilities of the robot are normal before use.  Inspection of compressed air: ...

  • Page 24: Regular Inspection

    The cycle for routine inspection is based on the normal working conditions. For the normal working environment, please refer to the section of environment requirements in "AH20 Robot User Manual". The actual maintenance cycle depends on the operating frequency of the robot.

  • Page 25: Safety Inspection

    Chapter 3 Routine Maintenance and Safety Inspection Maintenance item Maintenance cycle Recommended maintenance method Robot body 1 month Wipe dust off the surface with a clean cloth. Spline shaft 3 ~ 6 months Add lubricating grease. The protection class of standard robot is IP20. It can be cleaned with a damp cloth rather than water.

  • Page 26: Handling Of Common Exceptions

    AH20 Robot Maintenance Manual  Manual-automatic switch on the manual control pendant (if user is provided with a manual control pendant).  Servo enable switch on the manual control pendant (if user is provided with a manual control pendant). 3.5 Handling of common exceptions...
  • Page 27 Chapter 3 Routine Maintenance and Safety Inspection Connector is damaged or  Replace the damaged connector. RS-232 communication plug inserted  Properly connect the plug. connector fails properly. communication Improper parameter Reconfigure parameters of communication configuration. connector. communication Check whether the I/O line is properly I/O plug is damaged.

  • Page 28: Chapter 4 Maintenance Of Mechanical Components

    AH20 Robot Maintenance Manual Chapter 4 Maintenance of Mechanical Components 4.1 Lubrication of spline screw shaft 4.1.1 Standard robot  Grease usage: Check whether there is grease in the groove of the spline screw shaft; or wipe the surface of the shaft with dust-free paper and observe whether the dust-free paper is reflective on its surface.

  • Page 29: Figure 4-1 Special Oil Brush

    Accessories: special oil brush, AFC grease or AZ food machinery grease and disposable protective gloves. Figure 4-1 Special oil brush  QKM offers special oil brush and YAMABALA KY1106 grease.  Keep special oil brush back in the bottle when it is not...

  • Page 30: Figure 4-2 Push Down The Spline Screw Shaft

    AH20 Robot Maintenance Manual in use. Step 1 Confirm that the robot is powered on and in servo-off state. After confirmation, wear disposable gloves and hold the end of the screw, then press the brake button and do not release it until the spline screw shaft is pushed down to the lowest end, as shown in Figure 4-2.

  • Page 31: Figure 4-3 Apply Lubricating Grease

    Chapter 4 Maintenance of Mechanical Components Figure 4-3 Apply lubricating grease Step 3 Hold the end of the screw, then press the brake button and push the spline screw shaft up to the top, as shown in Figure 4-4. Figure 4-4 Push up the spline screw shaft Document Version V1.0.1 (09-21-2022)
  • Page 32 AH20 Robot Maintenance Manual Step 4 Wipe the old grease off the screw with dust-free paper, and then use the special oil brush to evenly apply appropriate amount of grease on the screw. Step 5 Hold the end of the screw, then press the brake button, and push the screw up and down more than 5 times.

  • Page 33: Protective Type

    Chapter 4 Maintenance of Mechanical Components skin: 4.1.2 Protective robot Remove the protective cover from the robot before replenishing grease onto the screw. Accessories: Allen wrench, special oil brush, AFC grease or AZ food machinery grease and disposable protective gloves. Removal of protective cover Step 1 Refer to Section 4.2.1 ( ) to remove the...

  • Page 34: Removal Of Protective Cover

    AH20 Robot Maintenance Manual Telescopic protective cover Deep groove ball bearing Fixed cover Jackscrew Connecting fastener Deep groove ball bearing Bearing fixing ring Accessories of screw lower protective cover Circlip for hole Telescopic protective cover Coupling 4.2.1 Removal of protective cover Material preparation before installation: Document Version V1.0.1 (09-21-2022)

  • Page 35: Table 4-2 Accessories

    Chapter 4 Maintenance of Mechanical Components Table 4-2 Accessories Tools Allen wrench Straight screwdriver Protective gloves The installation steps are as follows: Step 1 Check whether the robot is equipped with a protective cover. Step 2 Remove the protective cover at the upper end of the screw. ①...
  • Page 36 AH20 Robot Maintenance Manual ③ Use the straight screwdriver to remove the fastening screws from the coupling at the bottom of the protective cover at the upper end of the screw; remove the protective cover and the coupling in upward direction and place them properly, as shown in the figure below.
  • Page 37 Chapter 4 Maintenance of Mechanical Components ② Use 4 mm Allen wrench to loosen the 2*M5 fastening screws of the flange at the end of the screw, remove the end flange in downward direction and properly place it, as shown in the figure below. ③...
  • Page 38 AH20 Robot Maintenance Manual coupling at the top of the protective cover at the upper end of the screw, as shown in the figure below; remove the protective cover and the coupling in upward direction and place them properly. Step 4 Reinstall the end flange.
  • Page 39 Chapter 4 Maintenance of Mechanical Components To tighten the fastening screws of the flange, pre-tighten the screws on one side, and then tighten the screws on the other side, alternately perform the operation for 2 ~ 3 times until all the screws are tightened firmly;...

  • Page 40: Installation Of Protective Cover

    AH20 Robot Maintenance Manual 4.2.2 Installation of protective cover Preparation of accessories: Table 4-3 Accessories Tools Spare parts 1 set Allen wrench Straight screwdriver Protective gloves Step 1 Install the protective cover at the lower end of the screw. ① Use 4 mm Allen wrench to loosen the fastening screws of the end flange, remove the flange in downward direction;...
  • Page 41 Chapter 4 Maintenance of Mechanical Components ② Install the protective cover and the coupling, and tighten the fastening screws of the coupling after completely applying it to the top of the protective cover, as shown in the figure below. ③ Install the bearing fixing ring and the connecting fastener, loosen the fastening screws of the bearing fixing ring, apply it into the middle and upper part of the screw by placing its boss downward, and pre-tighten the screws;...
  • Page 42 AH20 Robot Maintenance Manual into the connecting fastener by placing the boss of the connecting fastener upward, as shown in the figure below. The downward-facing boss of the bearing fixing ring The upward-facing boss of the connecting fastener ④ Install the end flange.
  • Page 43 Chapter 4 Maintenance of Mechanical Components connecting fastener, then tighten the fastening screws of the bearing fixing ring. ⑤ Use 2.5 mm Allen key to install the protective cover and the connecting fastener. Do not screw in the bolt at one time when fixing.
  • Page 44 AH20 Robot Maintenance Manual Install the protective cover. Step 2 Install the protective cover at the upper end of the screw. ① Install the coupling and the protective cover, and tighten the fastening screws of the coupling after completely applying it to the bottom of the protective cover.
  • Page 45 Chapter 4 Maintenance of Mechanical Components ② Use 5 mm Allen wrench to install the extension rod assembly of the protective cover, as shown in the figure below. ③ Lock the protective cover in the protective cover extension rod assembly, and use 2.5 mm Allen wrench to install the protective cover and the protective Document Version V1.0.1 (09-21-2022)
  • Page 46 AH20 Robot Maintenance Manual cover extension rod assembly, as shown in the figure below. The robot equipped with the protective cover is shown in the figure below. The Z-axis stroke of the robot equipped with the protective cover is reduced by 30 mm.

  • Page 47: Cover

    Chapter 4 Maintenance of Mechanical Components 4.3 Cover Be sure to make replacement after powering off the controller and related devices and unplugging the power plug, otherwise safety accidents and robot failures may occur. Robot cover Base connector panel Base side door Figure 4-5 Diagram of robot covers 4.3.1 Robot cover Tools: a set of Allen wrench, a straight screwdriver...

  • Page 48: Figure 4-6 Removal Of Fastening Screws

    AH20 Robot Maintenance Manual Step 1 Lower the spline screw shaft to the lowest point. Step 2 Use 2.5 mm Allen wrench to remove the fastening screws from the robot cover, as shown in Figure 4-6. Figure 4-6 Removal of fastening screws Step 3 Lift the robot cover as shown in Figure 4-7.

  • Page 49: Base Side Door

    Chapter 4 Maintenance of Mechanical Components Figure 4-7 Lift the cover 4.3.2 Base side door Tool: Allen wrench Step 1 Use 2.5 mm Allen wrench to loosen the anti-off screws from the side door of the base, as shown in the figure. Document Version V1.0.1 (09-21-2022)

  • Page 50: Figure 4-8 Removal Of Fastening Screws

    AH20 Robot Maintenance Manual Figure 4-8 Removal of fastening screws Step 2 Take out the side door of the base, as shown in Figure 4-9. Document Version V1.0.1 (09-21-2022)

  • Page 51: Connector Panel

    Chapter 4 Maintenance of Mechanical Components Figure 4-9 Take out the side door of the base 4.3.3 Connector panel Tool: Allen wrench Step 1 Use 2.5 mm Allen wrench to remove the fastening screws from the connector panel, as shown in Figure 4-10. Document Version V1.0.1 (09-21-2022)

  • Page 52: Figure 4-10 Remove The Fastening Screws From The Connector Panel

    AH20 Robot Maintenance Manual Figure 4-10 Remove the fastening screws from the connector panel Step 2 Gently take the connector panel out by holding its upper end. Be careful not to break off the cables when taking it out, as shown in Figure 4-11.

  • Page 53: Timing Belt Tension Measurement

    Chapter 4 Maintenance of Mechanical Components  Do not pull the connector panel by force. Failure to do so may result in cable damage, disconnection or poor contact, abnormal system operation or power outage.  When installing the connector panel, do not clasp the cables or forcibly bend them to press in.

  • Page 54: Figure 4-13 Introduction Of The Screen

    AH20 Robot Maintenance Manual 1-Mass, Belt Unit Mass 2-Width, Belt Width 3-Span, Tangent Length 4-No., Storage Code 5-Frequency Setting Figure 4-13 Introduction of the screen 6-Battery capacity In low-light conditions, the LCD backlight automatically turns on, and the screen shows the data used at the previous shutdown.

  • Page 55: Parameter Setting

    Chapter 4 Maintenance of Mechanical Components Range (key combination, 00, 01, RANGE 02, etc. are optional) Selection key (available to select SELECT set width) Numeric key  USB connector The meter is equipped with a USB connector to connect to PC. The upper and lower limits of the measurements can be set via PC, and the data will be displayed directly on the PC screen upon measurement.
  • Page 56 AH20 Robot Maintenance Manual Step 3 Select the proper range (such as 00, 01, 02, etc.) via key combination according to the width, mass and span of the belt. If the measurement is conducted for the first time, measure the width, mass and span of the belt first.
  • Page 57 Chapter 4 Maintenance of Mechanical Components of either tension or frequency may be incorrect. Tension display · T= □□□□ Kgf/lbf/N The measurement output values can be displayed in kilograms, pounds or newtons by following steps below: When the power is off, press "0" and "9" buttons and the "POWER"...

  • Page 58: Measuring Results

    AH20 Robot Maintenance Manual As auto-trigger function is available, it is not necessary to press the "MEASURE" button again. After obtaining tension or frequency values, compare at least two additional data. If multiple measurement results are close to each other, it means that the measurements are correct.

  • Page 59: Precautions

    Chapter 4 Maintenance of Mechanical Components J3-axis drive belt J4-axis primary drive belt J4-axis secondary drive belt Characteristics Before measuring the installing tension of a new belt, turn it back and forth several • times. Abnormal drive shaft or irregular belt teeth will affect the tension of the belt when it is running.
  • Page 60 AH20 Robot Maintenance Manual Do not use this product in areas with potential for sparks, as this may cause • explosions. Do not use this product outdoors during thunderstorms. Turn off the power and use • it in a safe place, or you may be struck by lightning.

  • Page 61: Chapter 5 Maintenance Of Electrical Components

    Chapter 5 Maintenance of Electrical Components Chapter 5 Maintenance of Electrical Components At the time of replacement, keep the removed components properly. To ensure that the appearance of the robot is not damaged, do not scratch the surface of the robot. ...

  • Page 62: Replacement And Maintenance Of 1-Axis Motor Fan

    AH20 Robot Maintenance Manual operation to prevent them from damage, disconnection or poor contact. 5.1 Replacement and maintenance of 1-axis motor fan 5.1.1 Replacement of 1-axis motor fan The position of the 1-axis motor fan is shown in the figure.

  • Page 63: Figure 5-2 Tear Off The Warning Sign

    Chapter 5 Maintenance of Electrical Components Figure 5-2 Tear off the warning sign Step 2 Use the Allen wrench to remove the fastening screws from the protective cover and take out the protective cover, as shown in the figure. Figure 5-3 Take out the protective cover Step 3 Use the Allen wrench to remove the fastening screws from the 1-axis fan assembly, as shown in the figure.

  • Page 64: Figure 5-4 Remove The Fan Assembly

    AH20 Robot Maintenance Manual Figure 5-4 Remove the fan assembly Step 4 Slightly lift the fan assembly and then pull it out, unscrew the waterproof connecting plug from the fan cable; then take out the fan assembly to be replaced, as shown in the figure.

  • Page 65: Maintenance Of 1-Axis Motor Fan

    In order to reduce fan alarms and failures caused by dust accumulation and extend its service life, the 1-axis motor fan of AH20 Series Robot needs to be cleaned and maintained regularly. Tools and accessories: Allen wrench, diagonal pliers, anti-static gloves.
  • Page 66 AH20 Robot Maintenance Manual  In the power-on state, visually check whether the fan rotates normally and aurally check whether there is any abnormal noise. In case of any abnormality, find out the cause and solve the fault.  In the power-on state, connect the upper computer...

  • Page 67: Replacement And Maintenance Of Encoder Battery

    Chapter 5 Maintenance of Electrical Components  Make a fan inspection and maintenance record table and perform regular maintenance (as shown in the table below). Table 5-1 Fan inspection and maintenance record Inspection content Notes Inspection Inspected by time Replacement Cleaning 5.2 Replacement and maintenance of encoder battery The encoder is equipped with a 3.6 V disposable Li-SOCl2 battery with a normal voltage of not less than 3.6 V.

  • Page 68: Figure 5-6 Diagram Of Encoder Battery

    AH20 Robot Maintenance Manual robot; replace the battery once a year under non-continuous operation condition of the robot. (Continuous operation: the robot runs 20h a day and 300 days a year)  Replacement of the battery after it is depleted will affect production operation. It is recommended to make a preventive replacement.

  • Page 69: Figure 5-7 Position Of Encoder Battery Connector

    Chapter 5 Maintenance of Electrical Components Encoder battery connector Figure 5-7 Position of encoder battery connector Step 4 Use the diagonal pliers to cut off the cable tie of the encoder battery, install a new encoder battery, and fix it with a cable tie. Step 5 Remove the cable tie along the cable, and pull out the connector of the old encoder battery.

  • Page 70: Replacement And Maintenance Of Controller Assembly

    AH20 Robot Maintenance Manual battery is fully connected.  Remove the old cable ties from the electric control cabinet. Do not leave sundries in the electric control cabinet. Removed old batteries must be recycled at designated locations. 5.3 Replacement and maintenance of controller assembly The controller is located in the robot base.

  • Page 71: Figure 5-9 Remove The Controller Assembly

    Chapter 5 Maintenance of Electrical Components calibrate the zero point of the robot. (In case of any problems which cannot be solved by yourself, contact QKM.) Tools and accessories: Allen wrench, cable tie, diagonal pliers, controller assembly, anti-static gloves. Base side door Step 1 Refer to Section 4.3.2 (...

  • Page 72: Replacement And Maintenance Of Io-Free-Distribution Pcba

    AH20 Robot Maintenance Manual Step 4 After removing the old control assembly, install a new controller assembly in the base and tighten the screws. Reconnect all the cables to the corresponding connectors of the new controller assembly. At the time of installation, users shall check whether the connectors match the line labels, as shown in the figure below.

  • Page 73: Figure 5-10 Io-Free-Distribution Pcba

    Chapter 5 Maintenance of Electrical Components IO-free-distribution PCBA Figure 5-10 IO-free-distribution PCBA Tools and accessories: Allen wrench, special assembly and disassembly tool for aviation plug, cable tie, diagonal pliers, anti-static gloves. Connector panel Step 1 Refer to Section 4.3.3 ( ) to remove the connector panel from the robot.

  • Page 74: Figure 5-12 Removal Of Io-Free-Distribution Pcba

    AH20 Robot Maintenance Manual Step 4 Use the special tool to loosen the nut and remove the IO-free- distribution PCBA. The position of the screw is shown in Figure 5-12. Figure 5-12 Removal of IO-free-distribution PCBA Step 5 Install a new IO-free-distribution PCBA on the base connector panel and tighten the screws.

  • Page 75: Replacement And Maintenance Of Surge Suppressor

    Chapter 5 Maintenance of Electrical Components Step 6 Refer to Section 4.3.3 to reinstall the base panel on the robot. 5.5 Replacement and maintenance of surge suppressor The surge suppressor is located on the connector panel of the robot. To replace it, it’s required to remove the connector panel.

  • Page 76: Figure 5-13 Surge Suppressor

    AH20 Robot Maintenance Manual Surge suppressor Figure 5-13 Surge suppressor Step 1 Refer to Section 4.3.3 to remove the connector panel from the robot. Step 2 Unplug all cables from the surge suppressor. Step 3 Use the cross screwdriver to remove the screws from the surge suppressor, as shown in Figure 5-14.

  • Page 77: Figure 5-14 Removal Of Fastening Screws

    Chapter 5 Maintenance of Electrical Components Figure 5-14 Removal of fastening screws Step 4 Install a new surge suppressor on the part in the base and tighten the screws, then connect all the cables to the new surge suppressor. At the time of installation, users shall check whether the connectors match the line labels and avoid damage to the controller due to wrong connection.

  • Page 78: Replacement And Maintenance Of Filter

    AH20 Robot Maintenance Manual Step 5 Refer to Section 5.3, 4.3.2 and 4.3.3 to restore the controller, side door and connector panel of the robot. 5.6 Replacement and maintenance of filter The filter is located on the connector panel of the robot. To replace it, it’s required to remove the connector panel of the robot.

  • Page 79: Figure 5-15 Filter

    Chapter 5 Maintenance of Electrical Components Filter Figure 5-15 Filter Step 1 Refer to Section 4.3.3 to remove the connector panel from the robot. Step 2 Unplug all cables connected to the filter. Step 3 Use the cross screwdriver to unscrew the fastening screws from the filter and remove them, as shown in Figure 5-16.

  • Page 80: Figure 5-16 Removal Of Fastening Screws

    AH20 Robot Maintenance Manual Figure 5-16 Removal of fastening screws Step 4 Install a new filter on the connector panel and tighten the screws. Connect all cables to the new filter. At the time of installation, users shall check whether the connectors match the line labels and avoid damage to the controller due to wrong connection.

  • Page 81: Replacement And Maintenance Of Qbus Module

    Chapter 5 Maintenance of Electrical Components Step 5 Refer to Section 4.3.3 to restore the connector panel on the robot. 5.7 Replacement and maintenance of QBUS module The QBUS module is located in the base of the robot. To replace it, the connector panel and side door of the robot need to be pulled out.

  • Page 82: Figure 5-17 Qbus Module

    AH20 Robot Maintenance Manual Figure 5-17 QBUS module Step 1 Refer to Section 4.3.2 and 4.3.3 to remove the side door and connector panel from the robot. Step 2 Refer to Section 5.3 to remove the controller assembly. Step 3 Use the straight screwdriver to remove the terminals from the connector.

  • Page 83: Figure 5-18 Removal Of Qbus Module

    Chapter 5 Maintenance of Electrical Components Figure 5-18 Removal of QBUS module Step 5 Install a new QBUS module and connect to the connection terminals. Step 6 Refer to Section 5.3, 4.3.2 and 4.3.3 to restore the controller, side door and connector panel of the robot.

  • Page 84: Replacement And Maintenance Of Qbus Fuse

    AH20 Robot Maintenance Manual At the time of installation, users shall check whether the connectors match the line labels and avoid damage to the controller due to wrong connection. The line labels corresponding to each connector are shown below: grounding (PE-5) 5.8 Replacement and maintenance of QBUS fuse...

  • Page 85: Figure 5-19 Qbus Fuse

    Chapter 5 Maintenance of Electrical Components QBUS fuse Figure 5-19 QBUS fuse Step 1 Refer to Section 4.3.2 to remove the side door from the robot. Step 2 Find the QBUS module, use the straight screwdriver to turn counterclockwise the fuse cover on the QBUS module, and take out the fuse. Step 3 After installing a new fuse, tighten the cover and restore the robot after replacement.

  • Page 86: Replacement And Maintenance Of 24 V Switching Power Supply

    AH20 Robot Maintenance Manual a short circuit, replace the QBUS, and replace the drive Cell at the same time when possible. A careful troubleshooting is required before further operation. Do not power on after replacing the fuse separately without troubleshooting, as this may cause secondary damage.

  • Page 87: Figure 5-20 Diagram Of 24 V Switching Power Supply

    Chapter 5 Maintenance of Electrical Components 24 V switching power supply 220 V connector 24 V connector Figure 5-20 24 V switching power supply Step 1 Refer to Section 4.3.2 and 4.3.3 to remove the side door and connector panel from the robot. Step 2 Unplug the 24 V power plug and 220 V power plug from the switching power supply.

  • Page 88: Replacement And Maintenance Of 24 V Switching Power Module Cooling

    AH20 Robot Maintenance Manual switching power supply and take out the switching power supply, as shown in Figure 5-21. Figure 5-21 Removal of power module Step 4 Install a new switching power supply on the bracket and tighten the screws. Connect the 24 V power plug and 220 V power plug to the new switching power supply.

  • Page 89: Figure 5-22 Switching Power Supply Fan Assembly

    Chapter 5 Maintenance of Electrical Components Switching power supply fan assembly Figure 5-22 Switching power supply fan assembly Step 1 Refer to Section 4.3.2 and 4.3.3 to remove the side door and connector panel from the robot. Step 2 Use diagonal pliers to remove the cable tie along the fan cable. Step 3 Refer to Section 5.4 Definition of pins on IO-free-distribution PCBA to locate the "Fan # 2"...

  • Page 90: Figure 5-23 Remove The Power Module Cooling Fan

    AH20 Robot Maintenance Manual Figure 5-23 Remove the power module cooling fan Step 5 Install a new fan assembly, plug in the fan connector, fix the fan cable with a cable tie. Connect the connector of the new fan assembly to the connector of the switch fan.
  • Page 91 Chapter 5 Maintenance of Electrical Components touch other connectors when removing the cable ties. Remove the old cable ties from the control cabinet. Do not leave sundries in the control cabinet.  Do not forcibly pull the cables in the control cabinet to prevent them from damage, disconnection or poor contact.

  • Page 92: Figure 5-24 Fan Assembly Of The Mechanical Arm 2

    AH20 Robot Maintenance Manual Fan assembly of the mechanical arm 2 Figure 5-24 Fan assembly of the mechanical arm 2 Step 1 Refer to Section 4.5 to remove the screws from the mechanical arm 2 shell of the robot and gently pull out the second mechanical arm shell.

  • Page 93: Figure 5-25 Removal Of The Fan From The Mechanical Arm 2

    Chapter 5 Maintenance of Electrical Components Figure 5-25 Removal of the fan from the mechanical arm 2 Step 4 Install a new fan in the original position and tighten the screws, then connect the fan cables. 5.12 Replacement and maintenance of brake PCBA The brake PCBA is located in the mechanical arm 2 of the robot.

  • Page 94: Figure 5-26 Brake Pcba Of The Mechanical Arm 2

    AH20 Robot Maintenance Manual Brake PCBA Figure 5-26 Brake PCBA of the mechanical arm 2 Step 1 Refer to Section 4.3.1 to remove the screws from the mechanical arm 2 shell of the robot and gently pull out the mechanical arm 2 shell.

  • Page 95: Figure 5-27 Removal Of The Brake Pcba From The Mechanical Arm 2

    Chapter 5 Maintenance of Electrical Components Figure 5-27 Removal of the brake PCBA from the mechanical arm 2 Step 4 Install a new brake PCBA in the original position and tighten the screws, then connect all the cables to the new brake PCBA. At the time of installation, users shall check whether the connectors match the line labels and avoid damage to the controller due to wrong connection.
  • Page 96 AH20 Robot Maintenance Manual (J6) Brake button (J5) Brake button (J8) 24V power supply (J3) 3-axis controller power (J15) 3-axis motor modification (J4) 4-axis controller power (J14) 4-axis motor modification Step 5 Reinstall the mechanical arm 2 shell of the robot.
  • Page 97 Chapter 6 Technical service 6.1 Consulting and services QKM is committed to providing you with technical information on machine motion and operation to help you remove faults and reply to your inquiry in detail. If your robot or equipment fails during use, you can contact our service department and provide information below as much as possible: ...
  • Page 98 AH20 Robot Maintenance Manual Document Version V1.0.1 (09-21-2022)

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