EFORT EC2-S User manual

EC2-S Control Cabinet Operation and
Maintenance Manual for Industrial Robot
Apply to ER7-700 ER7-900 ER3-600 ER10-3-900
EFORT Intelligent Equipment Co., Ltd
Service Hotline（Tel）：400-0528877

Electrical Operation and Maintenance Manual for Control Cabinet of EC2-S Industrial Robot
Statement
Thank you for purchasing EFORT Robot products. To ensure proper set-up
of products, please read this manual carefully before operation. The content
mentioned in this statement and manual involves your personal and property
safety. Not following the instructions and warnings of the manual may cause
injury to you and EFORT robots, as well as loss of surrounding properties. This
statement and manual are the latest version until this batch of products leave the
factory. Please visit the official website, www.efort.com.cn, to obtain up-to-date
information in the future.
This manual is only used as a normal operation guide. EFORT company
will not be liable for personal injury and property loss caused by other reasons
except product defects. Therefore, EFORT Company solemnly advise people
involved in robot operation, teaching, maintenance, repair, equipment check, and
other relevant activities complete the training courses offered by EFORT, before
being authorized to do so.
Version：V 1.3

Electrical Operation and Maintenance Manual for Control Cabinet of EC2-S Industrial Robot
I
Contents
Chapter One Safety....................................................................................................................1
1.1 Safety Instructions............................................................................................................... 1
1.2 Safety Criteria...................................................................................................................... 1
1.3 Safety Precautions during Work.......................................................................................... 3
1.3.1 Safety in Robot Installation and Connection.................................................................... 3
1.3.2 Safety Before Starting Robot............................................................................................4
1.3.3 Safety of Starting Robot....................................................................................................5
1.3.4 Safety in Robot Test Run.................................................................................................. 6
1.3.5 Safety in Teaching.............................................................................................................6
1.3.6 Safety in Automatic Operation..........................................................................................8
1.3.7 Safety in Repair.................................................................................................................8
1.3.8 Safety in Equipment Check and Maintenance................................................................10
Chapter Two Transportation and Installation...........................................................................13
2.1 Generals............................................................................................................................. 13
2.2 Basics................................................................................................................................. 13
2.2.1 List of Parts and Accessories.......................................................................................... 13
2.2.2 Preparation before Installation........................................................................................14
2.2.3 Storage Environment for Robot......................................................................................14
2.2.4 Operation Environment for Robot.................................................................................. 14
2.2.5 Start Robot in Cold Environment................................................................................... 14
2.2.6 Placement of Control Cabinet.........................................................................................15

EFORT Intelligent Equipment Co., Ltd
II
2.3 Installation on Site............................................................................................................. 17
2.3.1 Transporting Precautions................................................................................................ 17
2.3.2 Transporting of Control Cabinet..................................................................................... 18
2.4 Electrical Connection.........................................................................................................18
2.4.1 Power.............................................................................................................................. 19
2.4.2 Power Cable, Signal Cable, and Ground Wire................................................................19
2.4.3 Emergency Stop..............................................................................................................20
Chapter Three Composition of Robot Control Cabinet System.............................................. 23
3.1 Composition of Robot Control Cabinet............................................................................. 23
3.1.1 Basic Parameters.............................................................................................................23
3.1.2 Distribution of Components............................................................................................23
3.2 Motion Control Unit.......................................................................................................... 26
3.2.1 Motion Controller........................................................................................................... 26
3.2.3 Definition and Extension of Local IO.............................................................................30
3.2.3 Motion Control Card.......................................................................................................34
3.3 Servo Drive Unit................................................................................................................36
3.4 Safety Function Unit..........................................................................................................39
3.5 Human-Computer Interaction Unit....................................................................................43
3.5.1 Button Operation Panel...................................................................................................43
3.5.2 Teach Pendant (Enable/Hand Press)............................................................................... 45
3.6 Power Distribution Management Unit...............................................................................48
3.7 Brake Release Unit............................................................................................................ 48
3.7.1 Overview.........................................................................................................................48

Electrical Operation and Maintenance Manual for Control Cabinet of EC2-S Industrial Robot
III
3.7.2 Brake Release Unit Position........................................................................................... 48
3.7.3 Manual Brake Release.................................................................................................... 49
3.8 Teach Pendant Hot Swap Unit (Optional)..........................................................................51
3.8.1 Teach Pendant Hot Unplug............................................................................................. 51
3.8.2 Teach Pendant Hot Insertion...........................................................................................51
3.8.3 Common Problems..........................................................................................................51
Chapter Four Maintenance.......................................................................................................53
4.1 Introduction........................................................................................................................53
4.2 Maintenance Plan...............................................................................................................53
4.3 Check Activity................................................................................................................... 54
4.3.1 Check the Control Cabinet Seal......................................................................................54
4.3.2 Check the Information Label.......................................................................................... 55
4.3.3 Check the Wiring Harness.............................................................................................. 56
4.3.4 Check the Working Condition of Main Electrical Components..................................... 57
4.3.5 Check the Emergency Stop Switch.................................................................................57
4.4 Change/Replacement Activities.........................................................................................57
4.4.1 Replace the Controller.................................................................................................... 58
4.4.2 Replace Safety Relay...................................................................................................... 59
4.4.3 Replace the Servo Drive................................................................................................. 60
4.4.4 Replace the Switching Power Supply.............................................................................61
4.4.5 Replace the Fuses, Fuse Cores, and Fuse Gears............................................................. 61
4.4.6 Replace the Fan...............................................................................................................62
4.5 Cleaning............................................................................................................................. 63

EFORT Intelligent Equipment Co., Ltd
IV
4.5.1 Overview.........................................................................................................................63
4.5.2 Precautions......................................................................................................................63
Chapter Five Troubleshooting..................................................................................................64
5.1 Overview............................................................................................................................64
5.2 Common Hardware Faults................................................................................................. 64
5.3 Controller Fault Handling..................................................................................................65
5.3.1 View Event Log.............................................................................................................. 66
5.3.2 Fault Light Display on the Controller.............................................................................67
5.3.3 Controller Fault Handling...............................................................................................69
5.4 Drive Fault Handling......................................................................................................... 69
5.5 Program Running Fault Handling......................................................................................70
Chapter Six Deactivation......................................................................................................... 71
6.1 Overview............................................................................................................................71
6.2 Environmental Information................................................................................................71
6.3 Discard the Robot.............................................................................................................. 71
Chapter Seven Circuit Diagram...............................................................................................73
Appendix 1 Spare Parts List.................................................................................................... 83
Appendix 2 Controller Alarms and Warnings......................................................................... 85
1.1 Controller Alarms...............................................................................................................85
1.1.1 System Alarms (1-999)................................................................................................... 85
1.2 User Alarms and Warnings................................................................................................ 88
1.2.1 MajorAlarms (1800-1999)..............................................................................................88
1.2.2 Minor Alarms (3900-3999).............................................................................................90

Electrical Operation and Maintenance Manual for Control Cabinet of EC2-S Industrial Robot
V
1.2.3 Warnings（4900-4999）................................................................................................92
Appendix 3 Drive Alarms and Warnings.................................................................................96
1.3 EC2-A Drive (Alarm:1000-1199，Warning:4050-4099)..................................................96
1.3.1 Alarms.............................................................................................................................96