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

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same time, confirm that the safety devices are functioning properly before
starting the robot.
4. If there are several operators working together in the robot application
system, make sure that all operators and their related personnel know that the
robot has been activated before they can start the robot.
5. Before turning on the power of the motor, starting teaching or automatic
operation, please confirm again that there are no workers or remaining obstacles
in the robot safety fence and around the robot.
6. When starting the robot and recovering from the fault state, after turning on
the power of the control cabinet, please put your hand on the emergency stop
switch, so that when an abnormal situation occurs, you can immediately cut off
the motor power.
7. Before activating the robot, please confirm that the following conditions have
been met.
Confirm that the installation state of the robot is correct and stable.
Make sure that the various connections of the robot control cabinet
are correct, and the power supply specifications (power supply voltage,
frequency, etc.) meet the requirements.
Confirm that the various application connections (water,
compressed air, protective gas, etc.) are correct and consistent with the
specifications and models.
Make sure the connection with the peripheral device is correct.
Please confirm that in addition to the software motion limit, a
mechanical limit stop/or limit switch has been installed to limit the
robot's motion range.
When the robot is stopped by a mechanical limit stop, make sure to
check the related parts or replace the failed mechanical limit stop (if
necessary).
Confirm that safety measures have been taken: safety fences or
alarm devices and interlocking signals have been installed and
protective devices have been installed.
Please confirm that the safety guards and interlocks are functioning
properly.
Confirm that the environmental conditions (temperature, humidity,
light, noise, dust, etc.) all meet the requirements, or that the
specifications of the system and robot are not exceeded.
.3.4 Trial run safety

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Danger
During the test run, there may be design errors, teaching errors, and work errors
in various elements such as teaching programs, fixtures, and logic controllers.
Therefore, it is necessary to further enhance safety awareness when carrying out
the commissioning operation.
Pay attention to the following points during the test run:
1. First, confirm whether the actions of the buttons, switches, and signals for
stopping the robot, such as the emergency stop button and the hold/run switch,
are normal. Once a dangerous situation occurs, if the robot cannot be stopped,
the accident cannot be prevented.
2. When the robot is tested, first set the operation speed of the robot to a low
speed (around 5% to 10%) to confirm the teaching operation. Check the
operation repeatedly for about 2 to 3 cycles. If a problem is found, stop the robot
immediately and make corrections. After making sure that there is no problem,
gradually increase the speed (50%→70%→100%), and repeat the confirmation
operation again for about 2 to 3 cycles each.
.3.5 Safety during teaching
Danger
EFORT recommends that the teaching should be completed outside the safety
fence. But if you really need to enter the safety fence, please strictly abide by the
following matters, and refer to the following 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.
Before teaching, please confirm that the emergency stop switch functions
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. Before starting the robot, please make sure that all safety protection devices
(safety fences) are working properly.
3. The teaching work should be done by two people-a teacher and an observer.
Observers also assume the responsibility of safety supervision; and confirm the
signal status of "work start" before teaching.

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4. Before entering the safety fence, the instructor must turn the teaching switch
on the teaching pendant to the manual position to prevent the control cabinet
mode switch from turning to the automatic mode and causing an accident. Once
the robot makes any abnormal movement, immediately press the emergency stop
switch, and immediately exit the robot working area from the preset withdrawal
path.
5. Outside the safety fence, where the entire robot movement can be monitored,
please install an emergency stop switch for the observer. Once the robot has
incorrect movement, the observer must be able to easily press the switch to stop
the robot immediately. In addition, if you need to restart the robot after an
emergency stop, please perform reset and restart manual operations outside the
safety fence. Demonstrators and observers must be specially trained and qualified
personnel.
6. Please clearly indicate that the teaching work is in progress, so as to prevent
anyone from operating any robot system device through the control cabinet,
operation panel, teaching pendant, etc.
7. After completing the teaching work, before confirming the teaching trajectory
and teaching data, please remove all personnel and obstacles left in the safety
fence and around the robot, and confirm that there are no personnel and
obstacles left in the safety fence. Please perform confirmation outside the safety
fence. At this time, the speed of the robot should be less than or equal to the safe
speed (250mm/s) until the movement is confirmed to be normal.
8. If you need to restart the robot after an emergency stop, please manually reset
and restart it outside the safety fence. At the same time, confirm all the safety
conditions, and make sure that there are no remnants of people and obstacles
around the robot and the safety fence.
9. During the teaching process, please confirm the range of motion of the robot,
and it is forbidden to approach under the arm of the robot. To prevent the danger
caused by accidental operation, pay special attention to when the robot grips the
workpiece, it is forbidden to approach the robot arm to prevent the danger
caused by the accidental drop of the workpiece.
10. For safety, in teaching or inspection mode, the maximum speed of the robot is
limited to 250mm/s (safe operating speed). However, immediately after the
completion of teaching or error recovery, when the operator verifies the teaching
data, please set the speed of the inspection operation as low as possible.
11. During the teaching process, both the teaching operator and the supervisor
must always monitor the robot for abnormal movements, possible collisions and
squeeze points on the robot and its surroundings. At the same time, please

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confirm the safe passage of the teaching operator for retreat in case of emergency.
12. After the robot's movement teaching is completed, please set the robot's
software limit to a little bit outside the robot's teaching movement range. For how
to set the software limit, please refer to the EFORT industrial robot operation
manual。
.3.6 Safety during automatic running
Danger
Since the teaching program will be reproduced at high speed, please strictly
observe the following items, and refer to the relevant international and domestic
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.
Before automatic operation, please confirm that all switches are functioning
properly.
1. Before operation, please read and understand all manuals and other related
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. During automatic operation, never enter or part of your body enter the safety
fence. At the same time, before starting to operate the robot, make sure that there
are no remnants of people or obstacles in the safety fence.
3. During automatic operation, the robot looks like it has stopped while waiting
for the timer delay or external signal input. But don't get close to the robot at this
time, because when the timer expires or an external signal is input, the robot will
resume operation immediately.
4. In automatic operation, this situation will be extremely dangerous: if the grip
of the workpiece is not enough, the workpiece may be thrown off during the
movement of the robot. Be sure to confirm that the workpiece has been gripped
firmly. When the workpiece is gripped by pneumatic gripper, electromagnetic
method mechanism, etc., please adopt a fail-safe system to ensure that the
workpiece will not be ejected once the driving force of the mechanism is suddenly
disconnected. Even when there is an error, when the possibility of the workpiece
is minimal, please install a protective fence, such as a net cover.
5. The "automatic running" sign is displayed on the safety fence and must not
enter the work area. At the same time, please confirm the safe passage so that the
operator can evacuate in an emergency.

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6. If the stored fault causes the robot to stop in automatic operation, please check
the displayed fault message and follow the correct fault recovery sequence to
recover and restart the robot.
7. After the fault recovery sequence and before restarting the robot, confirm that
the safe working conditions are met, and confirm that there are no persons,
fixtures, peripheral devices or obstacles left in the safety guard or around the
robot。
.3.7 Safety during fixing
Danger
To perform maintenance, please strictly abide by the following clauses, and refer
to relevant international and domestic 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.
Before servicing, please confirm that all switches are functioning properly.
1. Before operation, please read and understand all manuals and other related
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. Before entering the safety fence, please confirm that all necessary safety
measures are prepared and function well.
3. Before entering the safety fence, please cut off the control power to the main
power. And put a clear signal to show that the shutdown and maintenance are in
progress, and the main power switch is locked or clamped to prevent someone
from turning on the power by mistake.
4. Maintenance work is limited to those who have completed special training for
the corresponding model of robot.
5. Before the maintenance work, confirm that there is enough space around the
robot to avoid interference with peripheral equipment. At the same time, keep the
peripheral devices in a fixed state to prevent any sudden movements.
6. Before entering the safety fence, be sure to turn off the automatic operation
function. If there is any abnormal movement of the robot, you should
immediately press the emergency stop switch and immediately withdraw from
the specified evacuation route.
7. In addition to the emergency stop switch of the teach pendant in the hands of
the operator, please install another emergency stop switch for the inspector

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outside the safety bar and in a place where it is easy to observe the entire robot
motion range. In case of abnormal movement of the robot during maintenance,
this switch must allow the inspector to press it very easily. After an emergency
stop, reset and restart the robot from outside the fence. In addition, both the
operator and the inspector must be personnel who have completed special
training courses.
8. During operation, both the operator and the supervisor must always observe
abnormal movements, possible collision points, and the surroundings of the
robot.
9. When replacing, please use only the spare parts provided by EFORT.
10. Before removing the servo motor of any joint shaft, please support the robot
arm with a suitable lifting device. Removing the motor will invalidate the brake
mechanism of the shaft, and if there is no reliable support, the arm will fall.
Please note that if you press any axis brake release switch on the control cabinet,
the same danger will occur.
11. When the drive module and power module need to be replaced, please turn off
the control power and wait at least 7 minutes. Then, please confirm that the
output voltage of the power supply is 0V before starting replacement work,
removing the connector, etc. Please also be careful not to touch any parts to
prevent electric shock or burns.
12. If compressed air or water is supplied, before servicing, please cut off the
supply source and remove any remaining pressure in the pipeline.
13. When the robot expands the additional axis, make sure that the emergency
stop signal of the additional axis should be connected in series to the emergency
stop circuit of the control cabinet.
14. When changing the robot parts, be sure to confirm the matching degree of the
parts and the original parts, and carefully check the schematic diagram to
prevent damage to the robot control cabinet components or external components
caused by miswiring.。
.3.8 Safety during inspection and maintenance
Danger
In order to prevent system failure, please strictly follow the following provisions
for robot cleaning, inspection, maintenance or replacement parts. Also refer to
relevant international and domestic safety standards.
Before inspection and maintenance, please confirm that all emergency stop
switches are functioning properly.
1. Before operation, please read and understand all manuals and other related

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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. Before inspection and maintenance work, remove unnecessary objects and
clear the passage to the installation location.
3. The inspection and maintenance work is limited to those who have completed
special training for this robot or robots of the same model.
4. Before performing inspection and maintenance work, please confirm that there
is enough space around the robot to avoid interference with peripheral
equipment. At the same time, set the peripheral equipment to a fixed state to
ensure that they will not move suddenly.
5. Before entering the safety fence, please cut off the power supply of the entire
line or the power supply of the robot as required by the work, and please cut off
the power supply until the total power supply. And put a clear signal to show that
the shutdown, inspection/maintenance is in progress, and the main power switch
is locked or locked to prevent someone from turning on the power by mistake. If
the entire line cannot be stopped, please install a temporary safety fence between
the target robot and any adjacent robots.
6. When performing the inspection and maintenance of interlocking signal lines,
please turn off the power of all signal-related equipment without fail to ensure
safety. During this work, no safety fences are allowed.
After completing the inspection and maintenance work, please confirm that the
safety devices (safety fences, safety latches, emergency stop switches, etc.),
peripheral devices, interlocking lines and other safety devices are working
properly.
7. In addition to the emergency stop switch held by the operator, please install
another emergency stop switch for the supervisor outside the safety fence. The
installation position should be selected in a place that can monitor the entire
robot motion range. If the robot moves abnormally during
maintenance/inspection, the supervisor must easily press the switch. After an
emergency stop, recovery and restart of the robot must be performed outside the
safety fence. In addition, operators and supervisors must be personnel who have
completed special training courses.
8. Before entering the safety fence, the teach instructor must switch the teaching
mode switch on the teach pendant to manual mode to prevent the control cabinet
mode switch from switching to automatic mode and cause an accident. Once the
robot makes any abnormal movement, immediately press the emergency stop
switch, and immediately exit the robot working area from the preset withdrawal

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path.
9. During the inspection/maintenance process, both the operator and the
supervisor must always monitor the robot for abnormal movements, possible
collisions and squeezes on the robot and its surroundings. At the same time,
please confirm the safe passage of the operator for emergency evacuation.
10. If it is inevitable to remove the safety fence during the inspection/maintenance
process, please provide sufficient safety measures:
Stop the robot and peripheral equipment in a suitable place.
To lock/calibrate the power supply and switch, it is necessary to prevent
anyone from turning on the power by mistake or turning the switch to
automatic mode by mistake.
After completing the inspection/maintenance, reinstall the safety fence
and confirm that all safety measures and safety functions are the same
as the original ones.
11. Please use only the parts approved by EFORT to replace. Also, during
inspection/maintenance, be sure to use the teaching mode and move the robot at
the lowest possible speed.
12. When the drive module and power module need to be replaced, please turn off
the control power and wait at least 7 minutes. Then, please confirm that the
output voltage of the power supply is 0V. After confirming that the output of the
DC power supply is becoming 0V, start replacing or unplugging the connector. In
addition, if the robot has just stopped running, the heat sink or regenerative
absorption resistor may still be hot. Therefore, be careful not to touch any hot
parts.
13. Before removing the servo motor from the rotating shaft, please use a suitable
lifting device to firmly support the robot arm. Removing the motor outside the
shaft will invalidate the shaft's braking system and the arm will fall. In addition,
pressing any brake release button on the control panel will also cause the same
danger.
14. If the robot must maintain the same posture before and after maintenance,
please record the posture data of the robot before replacing parts.
15. At the beginning of the replacement process, when removing printed circuit
boards or cables, check and record their location, connector number, installation
method, setting data, etc., so that they can be restored as they are. After the
connector is inserted, its locking mechanism must be firmly locked. Also, never
touch the pins of the connector.
16. When the application device (water, compressed air, protective gas, etc.) is

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used, please turn off their supply source and clear the residual pressure in the
pipeline before performing inspection/maintenance.
17. After overhaul/maintenance, please confirm that all safety protection
equipment should function normally.
18. Do not change or modify the robot without the permission of the company. In
the event of unauthorized modification, EFORT will not be held responsible.
19. A variety of data backup batteries are built into the robot arm and control
cabinet. If the wrong battery is used, it will cause burning, overheating, explosion,
corrosion, liquid leakage, etc. Therefore, the following requirements must be
strictly followed.
Only use the batteries specified by EFORT;
Do not recharge, disassemble, change and heat the battery;
Do not discard the battery in water or fire;
Batteries with damaged surfaces may have been short-circuited inside
and must never be used again;
Do not use metals, such as wires, to short the positive and negative poles
of the battery. Do not dispose of used batteries in garbage that is
incinerated, landfilled, or dumped on the ground. When discarding
batteries, please wrap them in bags to prevent them from contacting
other metals, and please dispose of them in accordance with local
regulations.
20. When the robot expands the additional axis, make sure that the emergency
stop signal of the additional axis should be connected in series to the emergency
stop link of the control cabinet. After connecting to the extension axis, the safety
function of the emergency stop link needs to be tested to ensure compliance with
the safety control logic. After changing the safety-related components, the safety
function of the emergency stop link needs to be tested to ensure compliance with
the safety control logic.
21. When changing the robot parts, be sure to confirm the matching degree of the
parts and the original parts, and carefully check the schematic diagram to
prevent the damage to the robot control cabinet components or external
components caused by miswiring.

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Chapter 2 Installation and Commissioning
.1 Overview
This chapter contains assembly instructions and information on installing the ER15-4-1600 robot on
the job site.
Before starting any installation work, it is very important to check all the safety information. Please be
sure to carefully read the "EFORT Robot Safety Manual" and Chapter 1 of this manual. There are several
general safety aspects that must be paid attention to. More specific safety information for hazards and
safety risk avoidance when performing operating procedures
.2 Unpack
.2.1 Preparation before installation
This section is intended for use when unpacking and installing the robot for the first time. It
also contains useful information needed in the process of reinstalling the robot in the future.
Before installing the robot, check the following items:
Table 2-1 Robot storage environment
1
Visually inspect the robot to ensure that it is not damaged.
2
Make sure that the lifting device used is suitable for carrying the
specified robot weight.
3
If the robot is not installed directly, it must be stored according to the
robot storage environment requirements.
4
Ensure that the expected operating environment of the robot meets the
requirements of the robot's operating environment.
5
Before transporting the robot to its installation site, make sure that the
site meets the ground installation requirements.
6
Before moving the robot, please check the stability of the robot.
7
Once these prerequisites are met, the robot can be transported to its
installation site as described in the following section.
The following table shows the allowed robot storage conditions：
Table 2-2 Robot storage environment
parameter
Value
Minimum ambient temperature
-25℃
Maximum ambient temperature
+55℃
Maximum ambient humidity
+70℃
parameter
40%-90%（40℃）
The following table shows the allowed robot operating conditions：
Table 2-3 Robot operating environment
parameter
Value