CMA Dishmachines GR Series User manual

GR Painting Robot Series
Electrical Operation and Maintenance Manual
Version No.：ZL-GR6150-003-V1
Issue Date: January, 2020
The copyright is reserved for CMA (WUHU) Robotics Company Limited
For customer use only and any unauthorized use of this manual is strictly prohibited
CMA (WUHU) Robotics Company Limited
No.96, East Wanchun Road, Jiujiang Economic Development District, Wuhu, Anhui Province
TEL：[phone]
CMA
CMA (WUHU) Robotics Company Limited
Supplier of Intelligent Painting Robots

ZL-GR6150-003-V1 Electrical Operation and Maintenance Manual
CMA (WUHU) Robotics Company Limited
Statement
Thank you for purchasing the painting robots designed by CMA (WUHU) Robotics Company Limited
(CMA, in short). The contents stated in the manual are directly related to your safety, lawful rights and
responsibilities. Please ensure to read through the manual and correctly set the operation parameters before
use. Any operation that does not strictly follow the instructions or the warnings of the manual might lead to
physical injury or property damage. All rights for explanation are reserved by CMA.
This manual is intended for technical reference only which makes no warranty to the entire application
of the robot system. Therefore, CMA accepts no responsibility for any accident, damage or industrial
copyright dispute that follows the use of the application system. It is strongly recommended that all the
professionals involved in operation, teaching, maintenance, and inspection should take CMA special training
before being authorized to use the robots.
Copyright and Brand Name
The copyright of the manual is fully reserved by CMA and is intended for CMA users only. Neither can
the manual be reproduced nor should it be revealed to a third party without the written consent of CMA.
The manual should be well kept during the life circle of the robot. An optional copy can be ordered from
CMA if the original one is damaged or lost. The address of the new owner is required to be reported to CMA
if the robot is resold or transferred.
This manual is an indispensable part of the whole manual collection and all the professionals involved
in operation, teaching, maintenance, and inspection are required take CMA special training on the knowledge
instructed by the following manuals:
ZL-GR-001-V1：Safety Manual for GR Painting Robot Series.
ZL-GR-002-V1：Maintenance Manual for GR Painting Robot Series.
ZL-GR-003-V1：Explosion Protection Manual for GR Painting Robot Series.
ZL-GR-004-V1：Remote Assistance Manual for GR Painting Robot Series.
ZL-GR-005-V1：IO Communication Instruction Manual GR Painting Robot Series.
ZL-GR-006-V1：Program Editor Instruction Manual for GR Painting Robot Series
ZL-GR6150-001-V1 Installation and Connection Instruction Manual for GR6150 Painting Robot.
ZL-GR6150-002-V1 Mechanical Operation and Maintenance Manual for GR6150 Painting Robot.
ZL-GR6150-003-V1 Electrical Operation and Maintenance Manual for GR6150 Painting Robot.
ZL-GR6150-004-V1：Electrical Schematic Diagram for GR6150 Painting Robot.
All rights reserved by CMA. The manual and the relevant manuals are subject to change without prior
notice for the purpose of product improvement, specification change and instruction update. Please visit the
following website for the latest updates: www.cmarobot.com.cn

ZL-GR6150-003-V1 Electrical Operation and Maintenance Manual
CMA (WUHU) Robotics Company Limited
About the Manual
The target readers of the manual include professionals involved in robot operation, maintenance and
technical service.
This manual intends to explain the electrical maintenance instructions of the GR6150 painting robot and
the matters needing attention during maintenance. It is applicable to the GR6150 painting robot of CMA
company.
In order to effectively draw the attention of the users of the manual to a specific subject or aspect, the
following symbols will be used, each with the following meanings.
The safety precautions in this manual are classified into four categories: "Danger", "Warning",
"Caution", and "Important".
In addition, even the content recorded in the “Attention” will lead to serious consequences due to
different circumstances. Therefore, any one of the precautions is extremely important, so please be sure to
strictly observe it.
Please read the manual and the files attached carefully and master all the required knowledge
about the robot and the safety instructions before use.
The illustrations in the manual are drawn by removing the cover or safety shield to illustrate
the details. Please ensure to restore the cover or safety shield according to the regulations before any
operation.
The pictures and photos in this manual are representative examples and may be different from
the purchased product.
The manual is subject to change without prior notice for the purpose of product improvements,
specification changes and more convenient use for the manual itself .
The manual will be reissued and a new version number will be specified if the contents are
renewed.
Contact the nearest sales office on the back cover to purchase a new manual if the present one
is damaged or lost, and order according to the data number on the cover.
Danger! Fatal accidents may occur if operated improperly.
Attention! Minor injuries or property damage accidents
may occur if operated improperly.
Special attention should be paid to certain important operation.
Danger! Fatal accidents or serious injury may occur if
operated improperly.
Danger
Warning
Attention
Important

ZL-GR6150-003-V1 Electrical Operation and Maintenance Manual
CMA (WUHU) Robotics Company Limited
CMA is not responsible for any consequence caused by unauthorized modification of the
robot which is not within the scope of the company’s warranty.

ZL-GR6150-003-V1 Electrical Operation and Maintenance Manual
CMA (WUHU) Robotics Company Limited
Contents
CHAPTER ONE SAFETY .................................................................... 1
1.1 SAFETY INSTRUCTIONS ...............................................................................................................................1
1.2 ABOUT SAFETY SIGNS ..............................................................................................................................1
1.3 SAFETY REGULATIONS ................................................................................................................................3
1.3.1 THE SAFETY REGULATIONS FOLLOWED BY THE ROBOT SYSTEM: .....................................................3
1.3.2 SAFETY REGULATIONS THE SAFETY MODULE COMPLIES WITH .......................................................3
1.4 SAFETY PRECAUTIONS DURING EACH WORK PROCESS ...........................................................................4
1.4.1 SAFETY IN ROBOT INSTALLATION AND CONNECTION ...................................................................... 4
1.4.2 SAFETY BEFORE STARTING THE ROBOTS ..........................................................................................5
1.4.3 SAFETY OF STARTING ROBOT ........................................................................................................... 5
1.4.4 SAFETY IN ROBOT TEST RUN ............................................................................................................6
1.4.5 SAFETY IN TEACHING ....................................................................................................................... 7
1.4.6 Safety in Automatic Operation ........................................................................................................8
1.4.7 SAFETY IN REPAIR .............................................................................................................................9
1.4.8 SAFETY IN EQUIPMENT CHECK AND MAINTENANCE ..................................................................... 10
CHAPTER TWO INSTALLATION AND CONNECTION ......................................... 12
2.1 OVERVIEW .............................................................................................................................................. 12
2.2 BASICS DESCRIPTION ............................................................................................................................. 12

ZL-GR6150-003-V1 Electrical Operation and Maintenance Manual
CMA (WUHU) Robotics Company Limited
2.2.1 UNPACKING AND INSPECTION ........................................................................................................... 12
2.2.2 Preparation Before Installation ........................................................................................................ 14
2.2.3 STORAGE ENVIRONMENT FOR ROBOT ............................................................................................ 14
2.2.4 Operation Environment for Robot ................................................................................................... 15
2.2.5 Start Robot in Cold Environment .................................................................................................... 15
2.3 CONNECTION ............................................................................................................................................ 15
2.3.1 TRANSPORTATION .............................................................................................................................. 17
2.3.2 INSTALLATION ................................................................................................................................. 18
2.3.3 SET UP A SAFETY FENCE .................................................................................................................20
2.3.4 CONNECTION OF GROUND WIRE ...................................................................................................... 21
2.3.5 CONNECTION OF POWER CORD ........................................................................................................ 22
2.3.6 CONNECTION OF TEACH PENDANT ...................................................................................................25
2.3.7 CONNECTION OF THE ROBOT ..........................................................................................................26
2.3.8 CONNECTION OF SAFETY SIGNAL (SAFETY DOOR) .......................................................................... 27
2.3.9 CONNECTION OF SAFETY SIGNAL (SAFETY LIGHT CURTAIN) .......................................................... 29
2.3.10 CONNECTION OF SAFETY SIGNAL (EXTERNAL EMERGENCY STOP) ...............................................32
2.3.11 INPUT SIGNALS AVAILABLE .......................................................................................................... 34
2.3.12 OUTPUT SIGNALS AVAILABLE .......................................................................................................36

ZL-GR6150-003-V1 Electrical Operation and Maintenance Manual
CMA (WUHU) Robotics Company Limited
2.3.13 ETHERNET CONNECTION (STANDARD) ...........................................................................................39
2.3.14 CONNECTION OF PROFIBUS BUS MODULE (PROFI ACCESSORIES) ............................................. 40
CHAPTER THREE CONTROL CABINET ......................................................43
3.1 DESCRIPTION OF ELECTRIC CABINET .......................................................................................................43
3.1.1 Basic Parameters .............................................................................................................................. 45
3.1.2 LAYOUT OF CONTROL CABINET ..................................................................................................... 46
3.1.3 BUTTONS ......................................................................................................................................... 47
3.2 TEACH PENDANT ......................................................................................................................................48
3.2.1 PARAMETERS OF TEACH PENDANT ................................................................................................. 48
3.2.2 BUTTONS ON THE TEACH PENDANT ............................................................................................... 48
3.2.3 HOW TO HOLD THE TEACH PENDANT .............................................................................................. 52
3.2.4 OPERATION AND CLEANING ............................................................................................................53
3.3 MOTION CONTROLLER ............................................................................................................................. 54
3.3.1 CONTROLLER X20CP3584 ................................................................................................................54
3.3.2 INDUSTRIAL COMPUTER APC2100 ..................................................................................................58
3.4 DRIVE POWER MODULE AND SERVO DRIVE ............................................................................................59
3.4.1 MAIN POWER MODULE ...................................................................................................................59
3.4.2 AUXILIARY POWER MODULE ..........................................................................................................62

ZL-GR6150-003-V1 Electrical Operation and Maintenance Manual
CMA (WUHU) Robotics Company Limited
3.4.3 SERVO DRIVE .................................................................................................................................. 64
3.4.4 BUS MODULE .................................................................................................................................. 69
3.5 SAFETY PLC .............................................................................................................................................70
CHAPTER FOUR MAINTENANCE ...........................................................72
4.1 INTRODUCTION ......................................................................................................................................... 72
4.2 MAINTENANCE PLANS ..............................................................................................................................72
4.2.1 CLEAN THE INTERIOR OF THE ELECTRICAL CABINET .................................................................... 73
4.3.2 CHECK THE VENTILATION OF THE OPERATION CABINET (FORCED VENTILATION VERSION) ........ 74
4.3.3 CHECK THE OPERATION OF THE DRIVE AND RADIATOR FAN .........................................................75
4.3.4 CHECK WHETHER THE SAFETY DEVICE IS WORKING PROPERLY .................................................. 76
4.3.5 CHECK THE SEALING OF THE ELECTRICAL CABINET ..................................................................... 77
4.3.6 CHECK THE WIRING HARNESS ........................................................................................................77
4.3.7 CHECK THE WORKING CONDITION OF MAIN ELECTRICAL COMPONENTS ..................................... 78
4.3.8 CHECK THE EMERGENCY STOP SWITCH ......................................................................................... 78
4.3 TEMPORARY WORK ................................................................................................................................ 79
4.4 NON-ROUTINE MAINTENANCE ............................................................................................................... 79
4.4.1 REPLACE THE FUSE .........................................................................................................................80
4.4.2 REPLACE THE DRIVE .......................................................................................................................81

ZL-GR6150-003-V1 Electrical Operation and Maintenance Manual
CMA (WUHU) Robotics Company Limited
4.4.3 REPLACE THE RADIATOR COOLING FAN ........................................................................................ 84
4.4.4 REPLACE THE COOLING FAN OF THE DRIVE .................................................................................... 85
CHAPTER FIVE TROUBLESHOOTING ....................................................... 86
5.1 TROUBLESHOOTING METHODS ................................................................................................................ 86

ZL-GR6150-003-V1 Electrical Operation and Maintenance Manual
CMA (WUHU) Robotics Company Limited
1
Chapter One Safety
1.1 Safety Instructions
According to relevant national and local laws, regulations, and ordinances, safety instructions are the
most basic focus in operating industrial systems including robots.
The factory using robots are liable for personal injury and property damage led by the operation of robot.
Therefore, this manual and relevant materials together with regulations and standards concerning health and
safety must be understood and abide by.
For safety concerns, complying with the requirements in other manuals offered by CMA is also strongly
advised. Safety information recorded in this manual is general and does not include all the aspects of the
operating system of robots. Therefore, necessary safety measures should be taken and strictly abide by
according to the real operation situations.
1.2 About Safety Signs
When operating the robot in accordance with the contents of this manual, you may encounter dangerous
situations of different degrees. Therefore, in the attachments of the operating instructions that may cause
danger, there will be a special safety mark prompt box to remind the user to pay attention to precautions. The
content of the prompt box includes:
An icon indicating the safety level and the corresponding name, such as warning, danger, reminder, etc.;
A brief description to explain the possible consequences if the operator does not eliminate the danger;
Instructions on how to eliminate dangerous operations;
Icon
Name
Description
Danger
Danger
If the content with this logo is not operated in accordance with the
regulations, it will cause serious or even fatal injury to personnel, and
will/may cause serious damage to the robot. Operations related to such
hazards include contacting high-voltage devices in the control cabinet,
entering the work area of the robot while it is running, and so on.
Warning
Warning
If the content with this logo is not operated in accordance with the
regulations, it may cause serious injury to personnel, or even fatal, and
cause great damage to the robot.