EFORT ER15-1400 User manual

1
EFORT INTELLIGENT EQUIPMENT CO., LTD
Hotline (Tel): [phone]
ER15-1400 Mechanical Operation and
Maintenance Manual for Industrial Robot

Statement
Thank you for purchasing EFORT robot products. The contents mentioned
in this manual are related to your safety, legal rights and responsibilities. Before
using this product, please read this manual carefully to ensure that the product
has been set up correctly. Failure to follow the instructions and warnings in this
manual may cause injury to you and the people around you, and damage to the
EFORT Robot or other surrounding objects. The final interpretation right of this
document and all related documents of EFORT robot belongs to EFORT. Subject
to update without prior notice. Please visit www.efort.com.cn the latest product
information.
Once you use this product, you are deemed to have carefully read the
disclaimer and warning, understand, recognize and accept all terms and contents
of this statement. You promise to take full responsibility for the use of this
product and the possible consequences. You promise to use this product only for
legitimate purposes, and agree on these terms and any relevant regulations,
policies and guidelines formulated by EFORT.
EFORT is not responsible for the losses, injuries and any legal liabilities caused
by the direct or indirect use of this product. Users should follow but not limited
to the safety guidelines mentioned in this manual.
Version: V 1.1

Content
Chapter One Safety............................................................................................................................................1
1.1 Instructions for Safe Use of Robots.....................................................................................................1
1.1.1 Safety Precautions during Adjustment, Operation, Maintenance, etc..................................... 1
1.1.2 Safety Countermeasures of Robot Body.................................................................................. 3
1.2 Robot Body Label Description............................................................................................................7
1.3 Shift, Transfer, and Sale of Robots......................................................................................................7
1.4 Abandonment of Robots...................................................................................................................... 8
Chapter Two Basic Description....................................................................................................................... 10
2.1 Robot system composition.................................................................................................................10
2.2 Unpacking Check...............................................................................................................................10
2.3 Machine Body Nameplate................................................................................................................. 11
2.4 Body Part Composition and Direction Identification of Each Axis..................................................12
2.5 Robot Axis Range Limit and Home Position.................................................................................... 12
2.6 Robot Performance Parameters......................................................................................................... 13
2.7 Allowable Value of Wrist Payload.....................................................................................................15
2.7.1 Allowable Weight................................................................................................................... 15
2.7.2 Allowable Maximum of Static Payload Torque..................................................................... 15
2.7.3 Allowable Maximum of Moment of Inertia........................................................................... 15
2.7.4 Allowable Payload Curve Diagram........................................................................................15
Chapter Three Handling and Installation.........................................................................................................16
3.1 Robot Handling..................................................................................................................................16
3.1.1 Handling Precautions..............................................................................................................16
3.1.2 Auxiliary Handling Tooling....................................................................................................16
3.1.3 Handling Method....................................................................................................................17
3.2 Robot Installation...............................................................................................................................20
3.2.1 Setting of Safety Fence...........................................................................................................20
3.2.2 Robot Installation Method......................................................................................................20
3.2.3 Ground Mounting................................................................................................................... 21
3.2.4 Supporter Installation............................................................................................................. 22
3.2.5 Suspended Installation............................................................................................................23
3.3 Installation Site and Environment..................................................................................................... 23
3.4 Integrated Application Installation Interface.....................................................................................24
3.4.1 End Flange Installation Interface........................................................................................... 24
3.4.2 external installation Interface................................................................................................. 25
3.4.3 Definition of Wrist I/O Single Cable Connector....................................................................25
3.4.4 Location of Pneumatic and Signal Line Interface..................................................................26
Chapter Four Overhaul and Maintenance........................................................................................................28
4.1 Preventive Maintenance.................................................................................................................... 28
4.1.1 Daily Inspection......................................................................................................................28
4.1.2 Quarterly Inspection............................................................................................................... 28

4.1.3 Annual Inspection................................................................................................................... 29
4.1.4 Inspect Every Three Years......................................................................................................29
4.2 Overhaul of Main Bolts..................................................................................................................... 29
4.3 Change the Lubricant.........................................................................................................................30
4.3.1 The Oil Supply Quantity of Lubricant................................................................................... 30
4.3.2 Space Orientation of Lubrication........................................................................................... 30
4.3.3 Lubricant Replacement Steps for J1~J4 Axis Reducer and Wrist Parts................................ 31
4.3.4 Release the Residual Pressure in the Lubricating Oil Cavity................................................ 32
4.4 Timng Belt Maintenance................................................................................................................... 32
4.4.1 Timing Belt Tension............................................................................................................... 33
4.4.2 Timing Belt Replacement....................................................................................................... 33
4.5 Robot Maintenance and Use Area..................................................................................................... 34
4.5.1 The use area must have the following safety conditions........................................................34
4.5.2 Qualification requirements and precautions for maintenance personnel...............................34
4.6 Home Position Calibration................................................................................................................ 34
4.6.1 Home Position Calibration Method........................................................................................35
4.6.2 Mechanical Home Position Calibration of Each Axis........................................................... 35
4.7 Battery Replacement..........................................................................................................................36
Chapter Five Common Faults and Treatment Measures................................................................................. 37
Appendix..........................................................................................................................................................42
A Screw Tightening Torque Table........................................................................................................... 42
B Backup List.......................................................................................................................................... 42

ER15-1400 Mechanical Operation and Maintenance Manual for Industrial Robot
1
Chapter One Safety
1.1 Instructions for Safe Use of Robots
Before performing installation, operation, maintenance, and overhaul operations, please be sure to
read this manual and other attached documents thoroughly and use this product correctly. Please fully grasp
the equipment knowledge, safety information and all precautions before using this product. This manual
uses the following symbols to indicate their importance.
Danger
It means that if the handling is wrong, it will cause the user's death or serious
injury, and the situation is very dangerous.
Warning
It indicates a situation that will cause death or serious injury to the user if the
handling is incorrect.
Attention
It indicates a situation that will cause minor injuries or property damage to
the user if the handling is incorrect.
1.1.1 Safety Precautions during Adjustment, Operation, Maintenance, etc.
1）Operators must wear work clothes, safety helmets, safety shoes, etc.
2）When turning on the power, make sure that there are no workers within the robot's operating range.
3）The power must be cut off before entering the robot's range of motion for work.
4）When overhaul, maintenance and other operations must be carried out under the power-on state, two
persons should work in a team at this time. One person maintains a posture that can immediately press
the emergency stop button, while the other person is within the robot's range of motion, staying
vigilant and working quickly. In addition, you should confirm the retreat path before proceeding.
5）The load on the wrist and the robot arm must be controlled within the allowable carrying weight and
torque. If the allowable carrying weight and torque regulations are not observed, it will lead to
abnormal action or premature damage of mechanical components.
6）It is forbidden to disassemble and work on parts not covered in the maintenance manual.
The robot is equipped with various self-diagnostic functions and abnormality detection functions, so
that it can stop safely even if an abnormality occurs. Even so, accidents caused by robots still occur
from time to time.

ER15-1400 Mechanical Operation and Maintenance Manual for Industrial Robot
2
Danger
Danger! Most robot accidents are as follows:
1、The automatic operation was performed without confirming whether there is
anyone in the robot's motion range.
2、It enters the robot's motion range in the automatic operation state, and the robot
starts suddenly during the operation.
3、You just notice the robot in front of you, ignoring the others.
The above-mentioned accidents were all caused by the same reasons as "ignorance of safety operation
procedures" and "no idea that the robot would move suddenly". In other words, they are all accidents
caused by man-made unsafe behaviors such as "temporary negligence" and "failure to follow the prescribed
steps."
"Emergency situations" make it too late for operators to implement "emergency stop", "flee" and other
behaviors to avoid the accident, which may lead to major accidents. "Emergency situations" generally have
the following types.
1）Low-speed action suddenly becomes high-speed action.
2）Other operators performed the operation.
3）A different program was started due to an abnormality or program error in the peripheral equipment.
4）Abnormal operation due to noise, malfunction, defect, etc.
5）Misoperation.
6）Originally planned to regenerate at low speed to perform the action, but it performed the high-speed
action.
7）The work pieces transported by the robot fall and scatter.
8）When the work piece is in the stopped state of clamping and interlocking standby, it suddenly loses
control.
9）The next or behind robot performed the action.
The above are only some examples, and there are many forms of "emergency situations". In most
cases, it is impossible to "stop" or "escape" a robot that moves suddenly, so the following best
countermeasures should be implemented to avoid such accidents.
Danger
Be careful and approach the robot cautiously.
Danger
When the robot is not in use, measures such as "press the emergency stop button"
and "cut off the power" should be taken to prevent the robot from moving.

ER15-1400 Mechanical Operation and Maintenance Manual for Industrial Robot
3
3
Danger
During the operation of the robot, please configure a monitor (the third party) who
can immediately press the emergency stop button to monitor the safety status.
Danger
During the operation of the robot, the operation should be carried out in a state
where the emergency stop button can be pressed immediately.
In order to comply with these principles, it is necessary to fully understand the following precautions
and follow them.
1.1.2 Safety Countermeasures of Robot Body
Attention
The design of the robot should remove unnecessary protrusions or sharp parts, use
materials that adapt to the working environment, and adopt a fail-safe protection
structure that is not prone to damage or accidents during operation. In addition, it
should be equipped with misoperation detection stop function and emergency stop
function when the robot is in use, as well as interlocking function to prevent the
danger of the robot when the peripheral equipment is abnormal, so as to ensure
safe operation.
Attention
The main body of the robot is a multi-joint manipulator structure, and the angle of
each joint in the movement is constantly changing.
When you must approach the robot for teaching and other tasks, be careful not to
get caught by the joints. Each joint action end is equipped with a mechanical stop,
which has a high risk of being clamped, so special attention should be paid to it.
In addition, if the servo motor is removed or the brake is released, the robot arm
may fall due to its own weight or move in an uncertain direction. Therefore,
measures to prevent falling must be implemented, and the surrounding safety
conditions must be confirmed before operation.
Attention
When installing the attached machine on the end effector and the mechanical arm,
the size and quantity of screws specified in this book should be strictly observed,
and the torque wrench should be used to tighten according to the specified torque.
In addition, do not use rusty or dirty screws.
Unspecified tightening and imperfect methods will loosen the screws and cause
major accidents.

ER15-1400 Mechanical Operation and Maintenance Manual for Industrial Robot
4
4
Attention
When designing and manufacturing the end effector, it is controlled within the
allowable load range of the robot wrist.
Attention
The fail-safe protection structure should be adopted, even if the power supply or
compressed air supply of the end effector is cut off, the installation object will not
be released or fly out, and the corner or protruding part should be treated to
prevent damage to people and objects.
Attention
It is strictly forbidden to supply power, compressed air, and welding cooling water
outside the specifications, which will affect the performance of the robot and cause
abnormal operations, malfunctions, damage and other dangerous situations.
Attention
Although electromagnetic interference is related to its type or intensity, there is no
perfect countermeasure with current technology.
When the robot is in operation or when the power is on, the operation precautions
and regulations should be followed. Due to electromagnetic waves, other noises, and
substrate defects, the recorded data will be lost.
Therefore, please back up programs or frequently used data to an external storage
medium such as a Compact flash card.
Attention
In a large-scale system, multiple operators are involved in the work. When it is
necessary to talk at a distance, the intention should be correctly conveyed by means
of gestures, etc.
Factors such as noise in the environment can make it impossible to convey the
meaning correctly and cause accidents.

ER15-1400 Mechanical Operation and Maintenance Manual for Industrial Robot
5
5
Attention
Industrial robot gesture method (example)
1. Connect: Do the work
related to the connection
2. No way! Disconnect:
Raise your right hand and
wave vigorously left and
right
3. Is that OK? (to
confirm): Raise your right
hand up high forward
4. OK: Raise your right
hand up high forward
Use your thumb and index
finger to form a circle
5. Wait a moment: The
right hand is facing the
opponent
Straight up arms
horizontally
6. Leave: Stretch your
right arm horizontally and
weave to the left
Attention
Operators should also maintain awareness of escape at all times during operations.
It must be ensured that in an emergency, you can escape immediately.
Attention
Always pay attention to the actions of the robot, and do not work with your back to the
robot.
Slow response to robot movements can also lead to accidents.
Attention
When an abnormality is found, the emergency stop button should be pressed
immediately.
This requirement must be thoroughly implemented.

ER15-1400 Mechanical Operation and Maintenance Manual for Industrial Robot
6
6
Attention
According to the setting place and operating content, the relevant operation regulations
and checklists such as starting method, operation method, solution in case of
abnormality, etc. of the robot should be compiled. And carry out the operation
according to the operating regulations. Operation only based on the memory and
knowledge of the operator can cause accidents due to forgetting and mistakes.
Attention
For the completed program, use the storage protection function to prevent accidental
editing.
Attention
When teaching, confirm the program number or step number before proceeding.
Editing procedures and steps incorrectly can cause accidents.
Attention
When it is not necessary to make the robot move and operate, please turn off the power
before performing the work.
Attention
After the teaching operation is completed, the robot movement should be manually
checked at a low speed.
If you run at 100% speed in automatic mode immediately, accidents will occur due to
program errors and other factors.
Attention
After the teaching work is over, clean up and check if you have forgotten to take the
tool. The work area is contaminated by oil, and tools are forgotten, etc., which can cause
accidents such as falls.
Ensuring safety starts with tidying up.