How to Install the NexBot Drives AC111-002 AC Servo Motor

Related Products

Tools Required

• Torque wrench (0-25 Nm range)
• Metric hex key set
• Safety glasses
• Lockout/Tagout (LOTO) kit
• Digital Multimeter
• Lint-free cloths

Article

This document outlines the standard procedure for installing the NexBot Drives AC111-002 AC Servo Motor. This high-performance component is used on the wrist axes (J4, J5, and J6) of several NexBot robot models, including the C-5, C-10, and S-5 series. Following these instructions carefully is critical to ensure personnel safety, proper motor function, and the longevity of the robotic system.

ATTENTION: This procedure should only be performed by qualified technicians familiar with industrial robotics and electrical safety protocols.

Prerequisites

Before beginning the installation, ensure you have gathered all necessary tools and parts and have prepared a safe work environment.

Safety

• Lockout/Tagout (LOTO): The robot controller and any related machinery must be fully de-energized and placed under a certified LOTO procedure before any work commences.
• Personal Protective Equipment (PPE): Safety glasses and appropriate gloves are mandatory.
• Mechanical Support: Ensure any robot arm linkages that will be unsupported after motor removal are securely blocked or braced to prevent unexpected movement or dropping.

Tools & Equipment

• Torque Wrench with a range covering at least 5-15 Nm
• Metric Hex Key Set (sizes 4mm - 8mm)
• Socket Set (as required by robot model)
• Digital Multimeter
• Lint-free cloths
• Isopropyl alcohol for cleaning mounting surfaces
• Lockout/Tagout (LOTO) kit

Parts

• 1x NXB-SRV-AC111-002 Ac Servo Motor
• Replacement motor mounting bolts (recommended)
• Replacement O-ring/gasket for motor flange (recommended to maintain IP65 rating)

Step-by-Step Instructions

This procedure assumes you are replacing an existing motor. If this is a first-time installation, skip the removal steps.

Phase 1: Preparation and Removal of Old Motor

1. Power Down: Power down the robot controller using the standard shutdown procedure.
2. Apply LOTO: At the main disconnect, apply your personal lock and tag to isolate all electrical energy sources from the robot cell.
3. Position Arm: If possible, move the robot to a safe and accessible position for maintenance before shutdown.
4. Disconnect Cables: Carefully disconnect the power and PROFINET/encoder cables from the servo motor. Cap the connectors to protect them from debris.
5. Remove Old Motor: Loosen the mounting bolts in a star pattern. While supporting the motor's weight, remove the bolts completely and carefully pull the motor away from the robot arm's mounting flange. Be mindful of the motor shaft's engagement with the gearbox.

Phase 2: Mechanical Installation

1. Inspect New Motor: Unbox the new NXB-SRV-AC111-002 motor. Visually inspect the housing, connectors, and shaft for any signs of shipping damage. Do not install a damaged motor.
2. Clean Surfaces: Thoroughly clean the mounting flange on the robot arm and the flange on the new motor using a lint-free cloth and isopropyl alcohol. Ensure both surfaces are free of oil, grease, and old gasket material.
3. Install Seal: Place the new O-ring or gasket onto the motor flange, ensuring it is seated correctly in its groove.
4. Align and Mount: Carefully align the motor shaft with the input coupling of the robot's gearbox. Slide the motor into place, ensuring the mounting holes are aligned. The motor should sit flush against the flange without being forced.
5. Secure Fasteners: Insert the mounting bolts and hand-tighten them to secure the motor's position.
6. Torque Bolts: Using a calibrated torque wrench, tighten the mounting bolts to 11 Nm in a star or crisscross pattern. This ensures even pressure and a proper seal. Re-check the torque on the first bolt after tightening the last one.

Phase 3: Electrical Connection

1. Connect Power Cable: Align the keyway on the motor power connector with the cable connector. Push firmly until it clicks into place. Secure the locking ring by turning it clockwise until it is fully seated. This is critical for maintaining the IP65 rating.
2. Connect Encoder/PROFINET Cable: Connect the signal cable using the same method. Ensure the connector is properly aligned and the locking mechanism is fully engaged.
3. Cable Management: Secure the cables along the robot arm using the existing cable management clips. Ensure there is enough slack for full axis motion without straining the cables or connectors.

Verification

1. Final Inspection: Perform a final visual inspection of the installed motor, checking that all bolts are tight and cables are securely connected and routed.
2. Remove LOTO: Once the work area is clear of tools and personnel, remove your Lockout/Tagout device according to your facility's safety procedures.
3. Power On: Power on the robot controller. Watch for any immediate faults on the teach pendant or HMI.
4. Check for Errors: Navigate to the controller's alarm or diagnostics screen. Verify there are no errors related to the axis where the motor was replaced (e.g., J4, J5, or J6 communication error, encoder fault).
5. Jog Axis: In manual mode and at a very low speed (10% or less), carefully jog the affected axis in both positive and negative directions. Listen for any unusual noises (grinding, binding) and watch for smooth motion.
6. Perform Mastering/Calibration: The replacement of a servo motor requires the axis position to be re-mastered or calibrated. Follow the specific procedure for your robot model to update the revolution counter and ensure positional accuracy. This step is mandatory for correct robot operation.

Keywords