EFORT ER15-4-1600 User manual

ER15-4-1600 Electrical Operation and
Maintenance Manual for Industrial Robot
EFORT INTELLIGENT EQUIPMENT CO., LTD
HOT LINE（Tel）：[phone]

Statement
Thank you for purchasing EFORT Robot products. In order to ensure that the product has
been set up correctly, please read this operation manual carefully before using this product.
The contents mentioned in this statement and the manual relate to your personal and property
safety. If you do not follow or do not follow the instructions and warnings of the manual and
operate without permission, it may cause personal injury to you and the people around you or
give EFORT robot Or other objects around cause property damage. This statement and the
manual are the latest version as of this batch of products before leaving the factory. Please
follow the official website of www.efort.com.cn for the updated information.
This manual is only used as a guide for the normal operation of the product. During the
use of the product, EFORT will not be liable for personal injury and property damage caused
by reasons other than product defects. EFORT solemnly recommends that: personnel involved
in robot operation, teaching, maintenance, repair, inspection and other related activities should
not give them permission to operate the robot before completing the training courses prepared
by EFORT.
Version：V 1.1

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Content
Chapter 1 Safety Precautions...................................................................................................... 4
1.1. Safety instructions........................................................................................................4
1.2. General safety guidelines............................................................................................. 4
1.3. Safety precautions in each work process..................................................................... 6
1.3.1. Safety of robot installation and connection.......................................................7
1.3.2. Safety before starting the robot.........................................................................7
1.3.3. Robot startup safety.......................................................................................... 8
1.3.4. Trial run safety.................................................................................................. 9
1.3.5. Safety during teaching.....................................................................................10
1.3.6. Safety during automatic running.....................................................................12
1.3.7. Safety during fixing........................................................................................ 13
1.3.8. Safety during inspection and maintenance......................................................14
Chapter 2 Installation and Commissioning...............................................................................18
2.1. Overview....................................................................................................................18
2.2. Unpack....................................................................................................................... 18
2.2.1. Preparation before installation........................................................................ 18
2.2.2. Start the robot in a cold environment..............................................................19
2.2.3. Control cabinet working space........................................................................19
2.3. On-site installation..................................................................................................... 20
2.3.1. Robot transport considerations........................................................................20
2.3.2. Robot body Transport......................................................................................20
2.3.3. Control cabinet Transport................................................................................22
2.4. Electrical connections................................................................................................ 22
2.4.1. Robot power....................................................................................................23
2.4.2. Robot cable..................................................................................................... 23
2.5. Introduction to external emergency stop....................................................................25

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Chapter 3 Robot Electric Control Cabinet System................................................................... 27
3.1. Robot control cabinet................................................................................................. 27
3.2. Safety function unit....................................................................................................29
3.3. Human-computer interaction unit.............................................................................. 31
3.3.1. Button operation panel.................................................................................... 31
3.3.2. Teach Pendant (enable/hand press)................................................................. 31
3.4. Brake release unit.......................................................................................................34
3.4.1. Overview.........................................................................................................34
3.4.2. Position of brake release unit..........................................................................34
3.4.3. Manually release the motor holding brake......................................................35
3.5. Hot-swappable unit.................................................................................................... 36
3.5.1. Hot swap of teach pendant..............................................................................36
3.5.2. Hot-plug operation of teach pendant...............................................................36
3.5.3. FAQ.................................................................................................................38
3.6. Servo drive unit..........................................................................................................39
3.7. Motion control unit.................................................................................................... 41
3.7.1. Controller local IO definition..........................................................................41
3.7.2. Controller extension IO...................................................................................43
3.7.3. Motion control card.........................................................................................45
Chapter 4 Maintenance............................................................................................................. 47
4.1. Introduction................................................................................................................47
4.2. Specific safety rules................................................................................................... 47
4.3. Maintenance plan....................................................................................................... 48
4.4. Inspection activity...................................................................................................... 49
4.4.1. Check the control cabinet seal.........................................................................49
4.4.2. Check the information label............................................................................49
4.4.3. Check harness..................................................................................................50

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4.4.4. Check the working condition of main electrical components.........................50
4.4.5. Check the emergency stop switch...................................................................50
4.5. Battery pack replacement...........................................................................................51
4.6. Zero point quick recovery method............................................................................. 52
4.7. Cleaning activities......................................................................................................52
4.7.1. Overview.........................................................................................................52
4.7.2. Matters needing attention................................................................................53
Chapter 5 Repair and mending...............................................................................................54
5.1. Overview....................................................................................................................54
5.2. Replacement of core components.............................................................................. 54
5.2.1. Replacing the controller..................................................................................54
5.2.2. Replacing the safety relay...............................................................................55
5.2.3. Replace Servo Drive....................................................................................... 55
5.2.4. Replace the switching power supply...............................................................56
5.2.5. Replace fuses...................................................................................................56
5.2.6. Replace the fan................................................................................................57
5.3. Fault display...............................................................................................................58
5.4. View event log............................................................................................................60
5.5. Controller alarm fault light.........................................................................................61
5.6. Abnormal diagnosis and treatment suggestions.........................................................62
5.7. Faults and handling suggestions................................................................................ 62
Chapter 6 Deactivation...........................................................................................................73
6.1. Introduction................................................................................................................73
6.2. Environmental information........................................................................................ 73
6.3. Abandoned robot........................................................................................................ 73
Annex 1 Schematic diagram..................................................................................................... 74
Appendix2 Spare parts.............................................................................................................. 90

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Chapter 1 Safety Precautions
.1 Safety instructions
According to relevant national and local laws, regulations, and rules, safety precautions
are the most basic concern when using industrial systems including robots.
In the accidents of personal injury and property damage caused by the use of robots,
factories using robots are responsible. Therefore, in addition to understanding this manual and
related materials, you must understand all laws and standards related to health and safety, and
be sure to follow them.
For safety, compliance with the requirements of this manual and other EFORT manuals
is only a minimum requirement. As a general rule, the safety-related information recorded in
this manual does not fully cover all aspects of the robot application system. Therefore, when
using the robot, the necessary safety measures should be taken according to the actual
situation of the system and its application environment, and strictly observed.
The operator must read the following information carefully, paying special attention to
the safety measures listed in this chapter.
Users of EFORT industrial robots are responsible for ensuring compliance with the
applicable safety laws and regulations in the country where they are located, and that the
necessary safety equipment used to protect the robot system operator is reasonably designed
and installed correctly. Robot operators must be familiar with the operation and handling of
industrial robots such as those described in the following applicable documents:
ER series robot operation manual
ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual
ER15-4-1600 Industrial robot mechanical maintenance manual
This manual contains all safety instructions contained in the product manuals for robots and control
cabinets. The robot system should be well designed and manufactured to allow safe access to all areas
where intervention is necessary during operation, adjustment and maintenance. For situations where it is
necessary to work in a safety-protected space, it must be ensured that the work position can be safely and
fully entered.。
.2 General safety guidelines
Prohibited behavior
1. Do not delete or tamper with the protective devices and safety devices
installed in industrial robots.
2. If flooding occurs, do not touch the robot, you should first cut off all power
and drain the site.
3. The operation of industrial robots can only be carried out by professionals
who have received sufficient training and guidance (including those who have
read this manual).

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4. Make sure that the emergency stop equipment is unobstructed, and no debris
can be piled up in front of the emergency stop equipment.
5. It is forbidden to use the main machine to use unsuitable materials, adjust or
modify the robot inappropriately.
6. Unauthorized personnel, or those who have not received training in the use of
robots and understand the risks, may not operate the robot. Authorized personnel
must read through this instruction manual and sign the relevant documents in the
attachment.
7. Do not use robots in the following situations:
Robot components are exposed.
Safety device is disabled
When all or part of the fuses and / or mechanical equipment are
disabled.
The processed material does not meet the requirements
More than one person is not allowed to use the machine at the same
time.
8. Any use of robots in violation of the above requirements is strictly prohibited,
especially non-original accessories shall not be used at will.
Mandatory measures
1. Before starting the machine, make sure that no one is in the danger zone.
2. All operators must receive special training on the use and maintenance of
industrial machines.
3. The person in charge shall continuously monitor and ensure that all programs
are running normally, and ensure that the application of safety protection
programs is properly in place.
4. Perform maintenance according to the requirements in Chapter 7 Maintenance
in this manual to keep the industrial robot clean and tidy.
5. A suitable tool box should be prepared to summarize cleaning tools and
maintenance tools; staff must wear personal protective equipment.
6. In addition to these instructions, the tester must also comply with current
health and safety regulations.
7. When the robot malfunctions, or is suspected of being damaged, the machine
is not running, or the machine makes abnormal noise, the machine should be
stopped.
8. Once the machine is found to have a fire (regardless of the size of the fire), it
should immediately call the police and find a professional team to fight it.
9. When the machine is in operation, the door of the electric cabinet must be
closed at all times and must not be opened. Electric cabinet keys must be kept by
electricians.
10. When operating the robot, personnel shall not enter the safety protection

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area.
11. Before starting the automatic mode, all temporarily disabled safety functions
must be restored to their normal working conditions.
WARNING
Gravity and release of the braking device may cause a fall hazard.
.3 Safety precautions in each work process
Danger
For all operations of installation and connection, please strictly observe the
following matters, and refer to the following national/international standards.
The robot complies with the safety requirements for robots used in industrial
environments (GB11291.1-2011/ISO10218-1:2006) for the design of safety
functions.
1. Before operation, please read and understand all manuals, specifications and
other relevant documents provided by EFT. In addition, fully understand the
operation, teaching, maintenance and other processes. At the same time,
confirm that all safety measures are in place and effective.
2. When transporting the robot, avoid exceeding the specified height:
Only people qualified to operate forklifts and cranes are allowed to
move/transport the robot body, control cabinet, etc.
During handling, never approach or walk under the robot body or control
cabinet.
Do not stay on the robot body or control cabinet during handling, and never
touch or support them manually.
3. Hook the wire rope to the lifting ring as described in the robot lifting icon,
and before operation, confirm that the lifting ring is not loose.
4. When using a sling transfer control cabinet, please remove the teach pendant
and its bracket to avoid hooking other equipment with cables.
5. Before transporting the robot, please remove all unnecessary objects and
clear the passage to the installation location.
6. If using a forklift, please fix the control cabinet to prevent the control cabinet
from toppling over.
7. Since the robot is composed of precise components, please protect the robot

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.3.1 Safety of robot installation and connection
.3.2 Safety before starting the robot
Danger
Before operating the robot, the following items must be strictly followed, and
please refer to the relevant national/international safety standards. The robot
complies with the safety requirements for robots used in industrial
environments (GB11291.1-2011/ISO10218-1:2006) for the design of safety
functions.
1. Before operation, please read and understand all manuals, specifications and
other relevant documents provided by EFT. In addition, fully understand the
operation, teaching, maintenance and other processes. At the same time,
confirm that all safety measures are in place and effective.
2. Be sure to install the robot's control cabinet, operation panel and all other
control devices outside the safety protection device (fence). Only in this way can
the entire robot's movement range be monitored.
3. Confirm that there are no personnel, packaging materials, fixtures or other
obstacles within the movement range of the robot arm.
4. Eliminate any areas between fixed equipment and mobile equipment that
may pinch people.
from collision and impact.
8. When the total power supply at the installation site is turned on, the power
cable of the control cabinet must not be connected. Otherwise it will be
extremely dangerous and may cause electric shock. When connecting the input
power cable, make sure that the main power supply is off. At the same time, in
order to prevent the input power supply or circuit breaker from being
mistakenly closed, please put a clear shut-off sign on all power supply units and
circuit breakers, indicating that inspection/maintenance and repair are in
progress, and lock the main power supply with a lock or place a chuck switch.
9. When the wiring work is completed, be sure to cover the cover plate of the
input power connection end. Otherwise, it will be extremely dangerous. If you
touch the terminal by mistake, it may cause electric shock.
10. Please place the motor/signal cable connected to the robot in the cable slot to
prevent damage. Also, take measures to prevent them from being stressed. Do
not connect to the power supply until all connections between the control
cabinet and the robot body are completed. Otherwise, it is very dangerous and
can cause accidents such as electric shock

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5. Before connecting the power cable, please confirm whether the voltage,
frequency and cable specifications of the power supply meet the requirements.
6. Make sure that the control cabinet and peripheral equipment are properly
grounded. The grounding wire of the robot control cabinet and the surrounding
equipment should be grounded separately and cannot be connected together. At
the same time, if electromagnetic switches, contactors and other devices are
added to the external equipment, please install the power filter or equivalent
device on the power inlet of the adjacent robot control cabinet.
7. Before turning on the "power" of the robot, please make sure that the robot
installation meets the robot installation requirements.
8. When the operator operates the robot, an observer must be configured to
monitor, and this observer must also complete the corresponding training of
EFORT.
9. For application items (water, compressed air, protective gas, etc.), the system
must be equipped with monitoring instruments to promptly and automatically
detect abnormal conditions of water supply and gas supply.
10. If the largest waste, metal dust particles, fine particles, etc. will be generated
during the robot work, please cover the robot body, robot control cabinet, and
peripheral devices with a suitable cover.
.3.3 Robot startup safety
Danger
To start the robot, first connect the power cord, then turn the power switch from
OFF to ON. For these operations, please strictly observe the following matters,
and refer to the relevant domestic/international standards.
The robot complies with the safety requirements for robots used in industrial
environments (GB11291.1-2011/ISO10218-1:2006) for the design of safety
functions.
Before starting the robot, make sure that the emergency stop switch is working
properly.
1. Before operation, please read and understand all manuals, specifications and
other relevant documents provided by EFORT. In addition, fully understand the
operation, teaching, maintenance and other processes. At the same time, confirm
that all safety measures are in place and effective.
2. Check the names and functions of all switches, displays, and signals necessary
for robot operation.
3. Do not enter the safety fence unless the robot power is disconnected. At the