How to Install the NexBot Drives INC142-014 Incremental Encoder

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Tools Required

• Hex key set (metric)
• Torque wrench (0-10 Nm)
• Lint-free cloths
• Isopropyl alcohol
• Safety glasses
• LOTO kit (lock and tag)

Article

This document outlines the standard procedure for installing the NexBot Drives INC142-014 Incremental Encoder. Proper installation is critical for ensuring accurate position and velocity feedback, which is essential for the safe and precise operation of NexBot articulated and SCARA robot systems. Following these steps will help maintain system integrity and performance.

Prerequisites

Before beginning the installation, ensure the following conditions are met and the necessary tools and parts are available.

Safety Precautions:

• The robot system must be completely powered down.
• All hazardous energy sources (electrical, pneumatic, hydraulic) must be isolated and de-energized according to your facility's Lockout/Tagout (LOTO) procedures.
• The robot arm must be secured in a stable position, using mechanical brakes or external supports if necessary.
• Always wear appropriate Personal Protective Equipment (PPE), including safety glasses.

Parts and Tools:

• One (1) NexBot Drives INC142-014 Incremental Encoder (P/N: NXB-SNS-INC142-014)
• Mounting hardware (typically M4 screws, provided with the robot or joint assembly)
• Appropriate PROFINET M12 connector cable
• Torque wrench with a range covering 2-5 Nm
• Metric hex key set
• Lint-free cloths
• Isopropyl alcohol (99%)
• LOTO kit (lock and tag)

Step-by-Step Instructions

This procedure is divided into two main sections: mechanical installation and electrical connection.

1. Mechanical Installation

1. Power Down and Apply LOTO: Confirm the robot controller is off and apply your LOTO device to the main electrical disconnect. Verify that all stored energy has been dissipated.
2. Access the Mounting Location: Remove the necessary access panels or covers on the robot joint (J1-J6) to expose the motor's rear shaft or the designated encoder mounting flange. Refer to the specific service manual for your robot model (e.g., R-20, S-5 Series) for detailed disassembly instructions.
3. Prepare the Motor Shaft: Inspect the motor shaft where the encoder will be mounted. It must be clean and free of grease, oil, or debris. Gently clean the shaft with a lint-free cloth and isopropyl alcohol. Ensure there are no burrs or damage that could prevent the encoder from seating properly.
4. Mount the Encoder:

• Carefully align the encoder's hollow shaft with the motor shaft. Slide the encoder onto the shaft until its mounting flange is flush with the motor's mounting surface.
• Do not force the encoder onto the shaft. If it does not slide on smoothly, remove it and re-inspect both shafts for obstructions or damage.
• Align the mounting holes on the encoder's flange with the threaded holes on the motor housing.

1. Secure the Encoder Housing:

• Insert the M4 mounting screws through the flange into the motor housing. Lightly tighten them in a star pattern to ensure the encoder is seated evenly.
• Using a calibrated torque wrench, tighten the M4 screws to 2.5 Nm. Do not overtighten, as this can damage the encoder housing or bearings.

1. Secure the Shaft Clamp: Tighten the set screw on the encoder's shaft collar to secure it to the motor shaft. Refer to the encoder's data sheet for the specific torque value, typically around 1.5 Nm.

2. Electrical Connection

1. Route the PROFINET Cable: Route the PROFINET cable from the robot's axis control module to the newly installed encoder. Ensure the cable is protected from sharp edges, pinch points, and abrasive surfaces. Leave sufficient slack to allow for full joint articulation without straining the cable or connector.
2. Connect to Encoder: Align the key on the M12 cable connector with the slot on the NXB-SNS-INC142-014 encoder's socket. Push the connector in and screw the collar on until it is hand-tight. This ensures a secure connection and maintains the IP65 rating against dust and moisture ingress.
3. Connect to Controller: Connect the other end of the cable to the corresponding PROFINET port on the axis drive or control module inside the robot's controller cabinet.

Verification

After installation, it is crucial to verify that the encoder is functioning correctly before returning the robot to service.

1. Reassemble and Power On: Reinstall any access panels or covers that were removed. Following safety protocols, remove your LOTO device and power on the robot controller.
2. Check for Errors: Observe the teach pendant or HMI for any encoder-related fault codes. Navigate to the system diagnostics or PROFINET device status screen and confirm that the controller has established communication with the NXB-SNS-INC142-014 encoder.
3. Test Axis Movement: In a low-speed manual mode (e.g., T1), carefully jog the axis where the new encoder was installed. Move the joint a small amount in both directions.
4. Verify Position Feedback: Watch the live joint position data on the teach pendant. Confirm that the values change smoothly, correspond to the direction of movement, and are free from jitter or dropouts. The reported position should accurately reflect the robot's physical movement.
5. Perform Axis Mastering/Calibration: A new encoder installation requires the robot's position to be re-mastered. Follow the procedure in your robot's service manual to perform a full axis calibration. This step is mandatory to ensure positional accuracy.

Once the verification and calibration are complete, the robot can be returned to operational mode.

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