EFORT ER180-4-3200 User manual

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ER180-4-3200 Mechanical Operation and
Maintenance Manual for Industrial Robot
EFORT Intelligent Equipment Co., Ltd.
Service Line（Tel）：[phone]

Mechanical Operation and Maintenance Manual for ER180-4-3200 Industrial Robot
Statement
Thank you for purchasing EFFORT ER180-4-3200 industrial robot. Please
read the instruction manual before starting to use the robot. The following
contents are directly related to your personal and property safety. Any
misconduct that does not strictly follow the instructions as stated in the manual
may result in physical damage or property loss. The statement and instruction
manual is the latest version for ER180-4-3200 series. More updates can be
found at www.efort.com.cn.
This manual only serves as the operation guide for ER180-4-3200
industrial robots. EFFORT will not be responsible for any physical damage or
property loss that is not caused by the defect of the product. It is strongly
recommended that operators should have received special training before having
access to operation, teaching, repair, maintenance and inspection of the product.
Version No：V 1.3

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Contents
Chapter One Safety.................................................................................................................. 1
1.1 Safety Instructions............................................................................................................. 1
1.1.1 Safety Precautions during Adjustment, Operation, Maintenance............................... 1
1.1.2 Safety Countermeasures of Robot Body..................................................................... 3
1.2 Shift, Transfer, and Sale of Robots....................................................................................6
1.3 Abandonment of Robots.................................................................................................... 7
Chapter Two Basic Description............................................................................................. 8
2.1 Robot System Composition............................................................................................... 8
2.2 Unpacking..........................................................................................................................8
2.3 Machine Body Nameplate............................................................................................... 10
2.4 Body Composition and Direction Identification of Each Axis........................................10
2.5 Robot Axis Range Limit and Home Position.................................................................. 11
2.6 Robot Performance Parameters....................................................................................... 12
2.7 Allowable Value of Wrist Payload...................................................................................14
2.7.1 Allowable Weight...................................................................................................... 14
2.7.2 Allowable Maximum Static Payload Torque.............................................................14
2.7.3 Allowable Maximum Moment of Inertia.................................................................. 14
2.7.4 Allowable Payload Curve..........................................................................................14
Chapter Three Handling and Installation............................................................................... 15

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3.1 Handling the Robot..........................................................................................................15
3.1.1 Precautions................................................................................................................ 15
3.1.2 Handling Method.......................................................................................................15
3.2 Installing the Robot......................................................................................................... 17
3.2.1 Setting up a Safety Fence.......................................................................................... 17
3.2.2 Installation Procedures.............................................................................................. 17
3.2.3 Ground Mounting......................................................................................................18
3.2.4 Supporter Installation................................................................................................ 20
3.2.5 Suspended Installation...............................................................................................20
3.3 Installation Environment................................................................................................. 20
3.4 Integrated Connection Interface...................................................................................... 21
Chapter Four Overhaul and Maintenance.............................................................................. 25
4.1 Preventive Maintenance.................................................................................................. 25
4.1.1 Daily Inspection........................................................................................................ 25
4.1.2 Quarterly Inspection..................................................................................................25
4.1.3 Annual Inspection......................................................................................................26
4.1.4 Inspection Every Two Years......................................................................................26
4.2 Overhaul of Main Bolts................................................................................................26
4.3 Inspection of the Lubricant..............................................................................................27
4.4 Change the Lubricant.......................................................................................................27
4.4.1 The Oil Supply Quantity of Lubricant...................................................................... 27

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4.4.2 Space Orientation of Lubrication.............................................................................. 28
4.4.3 Lubricant Replacement Steps for J1~J4 Axis Decelerator and Wrist Parts.............. 28
4.4.4 Release the Residual Pressure in Lubricating Oil Cavity......................................... 30
4.5 Robot Maintenance and Use Area................................................................................... 30
4.6 Home Position Calibration.............................................................................................. 31
4.6.1 Home Position Calibration Method...........................................................................32
4.6.2 Mechanical Home Position Calibration of Each Axis...............................................32
Appendix...................................................................................................................................33
A Table of Screw Tightening Torque..................................................................................33
B Backup List........................................................................................................................ 33

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Chapter One Safety
1.1 Safety Instructions
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
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
Warning!
It indicates a situation that will cause death or serious injury to the user if the handling is
incorrect.
Attention
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.

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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.

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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 mis-operation 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.
Warning
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.
Attention
When designing and manufacturing the end effector, it is controlled within the
allowable load range of the robot wrist.

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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
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.

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Attention
Industrial Robot Gesture Method
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.
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.

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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.
1.2 Shift, Transfer, and Sale of Robots
Attention
When the robot is shifted, transferred, or sold, it is necessary to ensure that the
auxiliary documents of the robot, such as the mechanical manual, electrical
maintenance manual, and robot programming manual, are transferred to the new
user.
When shifting, transferring, or selling to a foreign country, the customer must be
responsible for preparing mechanical manuals, electrical maintenance manuals,
and robot programming manuals in appropriate languages, modifying the display
language, and ensuring compliance with local laws and regulations.
The new user does not read the instruction manual and performs wrong operation
or unsafe operation, which may lead to accidents.
Attention
When the robot is shifted, transferred, or sold abroad, if there are no special
provisions in the contract terms at the time of the initial sale, the security-related
terms shall not be inherited by the new recipient.
The original customer and the new recipient must sign a new contract.

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1.3 Abandonment of Robots
Attention
Do not decompose, heat or incinerate the batteries used for the control device and
robot body. Otherwise, fire, rupture and burning accidents will occur.
Attention
Do not disassemble the board and components of the control device before
discarding it.
Sharp parts such as cracks or cuts, wires, etc. may cause injury.
Attention
After the cables and external wiring are removed from the connector and junction
box, do not disassemble them further and then discard them. Otherwise, it may
cause injury to hands or eyes due to conductors, etc.
Attention
When carrying out abandoned work, please pay full attention not to be pinched or
injured.
Attention
Waste products should be discarded in a safe state.

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Chapter Two Basic Description
2.1 Robot System Composition
The industrial robot is composed of the following components:
Robot body
Control Cabinet
Teach pendant
Connection (power supply) cables, etc.
Fig. 2-1 Industrial Robot System Composition
2.2 Unpacking
Attention
1、Please check whether the packing remains intact or not before unpacking.
2、Please check after unpacking whether all the accessories are complete and
whether they match with the model information on the order list. Contact the
supplier if the accessories are not the same as ordered.

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Table 2-1 Standard Accessories
Name
Model
Quantity
Unit
Remarks
Robot body
ER180-4-3200
1
PC
Control cabinet
10900024008
1
PC
Teach pendant
11700010510
1
PC
Teach pendant cable
10900019866
1
Control cabinet power
cable
10900016326
1
SET
Standard Length: 8 m
Customized Length: 12 m/16
m/20 m
Control cabinet encoder
cable
10900016328
1
SET
Standard Length: 8 m
Customized Length: 12 m/16
m/20 m
Control cabinet brake
cable
10900016327
1
SET
Standard Length: 8 m
Customized Length: 12 m/16
m/20 m
Control cabinet circular
socket
10900001221
1
PC
Already installed on the control
cabinet
10900001227
1
PC
10900001196
2
PC
Circular socket shield
10900002138
1
PC
Already installed on the control
cabinet and the robot body
10900001113
1
PC
10900001122
1
Accessories(bracket and
pins)
\
1
SET
Already installed on the control
cabinet
Document DVD
\
1
PC

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2.3 Machine Body Nameplate
The robot machine nameplate can be seen on the robot body, which contains the corresponding model
type, weight, voltage, production number,manufacturing date and other information as shown in Figure 2-2.
Fig. 2-2 Robot Machine Body Nameplate
2.4 Body Composition and Direction Identification of Each Axis
The robot mechanical body is mainly composed of the base part, the rotating part, the big arm part, the
small arm part, the wrist body part and the wrist part. The four joints of the machine body are driven by
four servo motors, and the joints cooperate with each other to realize the adjustment of the position and
posture of the robot end in space. Please refer to figure 2-3 for the detailed illustration of the body
composition and direction identification of each axis.

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Fig. 2-3 Body Composition and Axis Direction of ER180-4-3200 Industrial Robot
2.5 Robot Axis Range Limit and Home Position
Each axis of the robot body has a home position and range limit. When the robot system is running
normally, each axis of the robot is controlled to move within the allowable range. In addition, in order to
ensure further safety, mechanical end stops are provided on some axes to prevent the robot from operating
beyond the allowable range when the robot (control) system is abnormal.
Mechanical end
stop of J1
Home position
of axis J1
Home position
of axis J2
Mechanical end
stop of J3
Mechanical end
stop of J2

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Fig. 2-4 Robot Axis Range Limit and Home Position
2.6 Robot Performance Parameters
Table 2-2 Robot Performance Parameters
Model
ER180-4-3200
Motion Type
Joint
Control Axes
4 Axis
Maximum
Motion Speed
Axis J1
104°/sec
Axis J2
104°/sec
Axis J3
104°/sec
Axis J4
210°/sec
Maximum
Motion Rage
Axis J1
±175°
Axis J2
+40°/-86°
Axis J3
+60°/-52°
Axis J4
±360°
Maximum Operation Radius
3150mm
Maximum Wrist Load
180 kg
Installation
Ground mounting or suspended installation
Prevention Rate
Robot body:IP65 Electric Cabinet:IP43
Repeat Precision
±0.2mm
Robot Body Weight
1500kg
Mechanical end stop of J4
Mechanical end stop of J3

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Figure 2-5 Motion Space of ER180-4-3200

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2.7 Allowable Value of Wrist Payload
Attention
The installation payload at the front end of the robot wrist is affected by the allowable
weight of the wrist, the allowable payload torque value, and the allowable moment of
inertia. The allowable payload torque value changes according to the actual payload
moment of inertia. The wrist payload should be strictly controlled within each
allowable value. When using the robot with a wrist payload other than the allowable
value, normal operation cannot be guaranteed.
2.7.1 Allowable Weight
Robot Model
Maximum Allowable Weight
ER180-4-3200
180kg
2.7.2 Allowable Maximum Static Payload Torque
Robot Model
Allowable static payload torque
Rotation of axis J4
ER180-4-3200
506.5 Nm
2.7.3 Allowable Maximum Moment of Inertia
Robot Model
Allowable Maximum Moment of Inertia
Rotation of axis J4
ER180-4-3200
32kgm2
2.7.4 Allowable Payload Curve
Fig. 2-6 Wrist Axis Torque Diagram of ER180-4-3200

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Chapter Three Handling and Installation
3.1 Handling the Robot
3.1.1 Precautions
Please read the following precautions carefully before handling the robot
Attention
The handling must be performed by a professional with lifting and forklifting work
qualifications. Unprofessional performance might lead to flipping or falling
accidents.
Attention
Please follow the procedures described in the manual and check whether the weight
of the robot and the control cabinet exceeds the maximum lifting load before
handling the robot. Operations that do not follow these procedures might lead to
flipping or falling accidents.
Attention
Please protect the cables when handling the robot and the control cabinet. Besides,
the cables should be covered by a shield to prevent from accidental damage.
3.1.2 Handling Method
Position the robot as shown in figure 3-1. Lift the robot body from its previous carrier (the total
allowable weight is greater than the weight of the robot body). Rubber hoses should be placed on the cables
to prevent from direct contact with the robot body. During hoisting, the angle of each axis should be
adjusted to the value given in the table below, so as to ensure that the center of gravity is in the middle,
which is convenient for hoisting. When lifting, please hold the robot upright to avoid tilting.
Note: Neither the end effector nor the robot arm has any tool. Caution is advised if a tool is installed to
the end effector or robot arm. Adjust the robot position with the parameters shown in the following table.